8

Attachment F.1

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a

0 dynea m e a Ireland T E C H E I O I ~ Y CENIWE Inquiry Document Replacement Catalytic Oxidkr Unit

Page I of 10

Dynea Ireland

TECHNICAL SPECIFICATIONS

for

Replacement of Catalytic Oxidizer Unit

TABLE OF CONTENT

1 INTRODUCIION .........--....,,*....,-... Ill.l............ .....-...m......t....r.....r...... ....... ......... ..... . .............. 2

2

3 PERFORMANCE GUARANTEE ._.... ........... 4

SCOPE OF SUPPLY -.... .. ..... .....-..... .....- .... ....-..... .. .......... -..I...+.....-..n...- .... I...C. ..... -....U ..... .. 2

.... ,. ..... .... - .... ..... ..... ..- ..... -.. .... .....-.....- ..... .... 3

TECHNICAL SPECIFICATlONS ..+......... ..- ..-._...-........... ...--... ...+ .... -...-. .... .... +. ..... -...- ........ -3

DE~CRIITON .................................................................... ....... .........................~-.... . .... .-..... ...,... ...... 3 CAPACrTY ...._.... ._. .......................... _.........._.... ......_l....f......ff.....tt...... . ................. ......... ......-.. .... ........3 WASTE GAS WECIFICATIONS ............................................................................................................ 4

4.1 4.2 4.3 4.4 P ~ ~ ~ c E .................................................................................................................................. 4.5 R E Q U ~ OPERATIONAL .................................................................................................... 4.6 DEFlMTION OF SUPPLIER'S SCOPE ..................................,........-.............................,,...-...*.......-........ 6

TENDER SuhQMARy,..., -..,.. .......... .. .....-..... .+ ....-....-... .. ..... .. ....-....-..... .... .*. .....-....... ..... .......-- 8 4.7 DSSIGN REQUIREMENTS ....__. . . . . . . . . . . __. . . . .. . . . . __. . . . . . . . . . .._- .........__.. . . . . . . . ... .. . . . . . . . . . . . . . . . . . . ---.... .. . . , . . _. . . . .. .. . ..- 7

5

5.1 5.2

CASE A) WASTE GAS FROM m PROCESSES .................................................................................. 8 CASE B) WASTE GAS FROM FORMOX PROCESS ............................................................................. 9

File: Atntchment F. l crcatedon 31.01 02

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I 0 dynea Dynea Ireland Page 2 of 10 TECWNOWGY L M R E Inquiry Document Replacement Catalytic Oxidizer Unit

INTRODUCTION

Dynea Iteland, located in Cork, Inlarrd, is producing urea- and formaldehyde based resins. Aqueous hrmaldehyde is p d u c e d in the continuos FORMOX process, and the resins are produced from formaldehyde and other raw materials in three batch reactom.

The waste gases b r n the FORMOX process are at present cleaned in a cstalytic oxidizer unit, which is designed fbt smaller loads thm the waste gases from today’s FORMOX process. The waste gases from the resin production is cleaned in a scrubber system.

For htum cleaning of the waste gas from the FORMOX and resin pnxlucthn, two different cases will be evaluated:

A) production p-.

Installation of a Catalytic oxidizer designed to clean the waste gases from b t h

B) FORMOX process only. The existing scnrbber will cuntinue to clean the waste gas from the resin production.

Installation of a catalytic oxidizet designed to clean the waste gases from the

In both m s the catalytic oxidizer unit will mn 24 hlday, 7 daysheck and 48-t weekslyear.

SCOPE OF SUPPLY

Design, delivery of materiels, fabncatbn, and testing of one catalytic oxidizer system as

Erection, eommissbning and start-up of the catalytic oxidizer una.

Training of operators and maintenance personnel.

All documentatbn including all certificates and design calculations as required by the bcal and international authorities. It will be the responsibiiii of the supplier that the vessels meet all statutory requirements. Dynea reserves the right to use an independent inspection agency approved by the local authoriies

specified in the technical specifications.

Crtetedon 31.01.02 File: Amhment F.1

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~~ ~

Normal off-gas flow me: Maxhurn off-gas flow rate: Minimum off-gas flow rate, desired; Minimum off-gas flow ai, required:

~-

0 dynea

Case A Case 3 8 000 Nm3h

1 OOONm3h 3 300 Nm3/h

8 WO Nrn’/h 9 000 Nm3h

5 000 Nrn’lh-

I 1 h0 Nm’h . .

Dynea Ireland Page 3 of 10 CENTRE Inquiry Wument Replacement Catalytic Oxidizer Unit

Complete sets of fabrication drawings to be approved by Dynea. The fabrication drawings must as a minimum, but not limited to, contain the following: - All applicable specifkatms for the medmn*kal equipment - All Electrical 8 Instrument specifications and diagrams for the unit - One P&ID, with the interface points for all process connections and utility systems

indicated - Functional design specification (FDS) for the total oxidizer system, including the

interlock system showing all signals to the Dynea phnt - General Arrangement drawings for the unit - All drawings and specifications needed for civil wrks and installation

Complete sets of final fabrication drawings (A8 Built drawings).

PERFORMANCE GUARANTEE

The supplier is required to give perfbrmance guarantees on the premise that the unit will be used to clean the waste gases b m the FORMOX process using the molybdenum and iron oxide catalyst. and the resin production process.

TECHNICAL SPECIFICATIONS

Description

The waste gases h m one formaldehyde plant of the FORMOX process type and three batch reactors for production of formaldehyde based resins shall be transporkd to the catalytic oxidim.

The FORMOX process is continuous, but the resin production is batch-wise, so the total flow rate and composition of the waste gas sb-eam will vary. Process flow diagrams for the plant waste gas system is attached showing three different operating conditions.

It is desirable to clean the waste gases from the resin reactors also when the FORMOX plant is shut down. The vendor must in his offer specify the best possible turn down of the unit as described in the next section.

Capacity

The design flow rate fur the new oxidizer unit is:

Pile: AtteEhmnt F.l c‘reaterl on 3 1 . f lI -05

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0 dynea Dynea Ireland TEcHNo1rnqy CENTRE Inquiry k m e n t Replacement Catalytic Oxidizer Unit

Page 4 of 10

Waste gas specifications

Case A: Waste gas from b t b FORMOX process and min production

- -. Temperature

Pressure

COMPOSmlON

Metbannl

-~ - .-

. -

CHJOH -- - -. -

Oxygen 0,

Nz Nitrogen

C a r h Monoxide CO

Carbon Dioxidc CO2

. -

. - -

--

. -- Formaldehyde C11,O - . -

Dimethyl Ether CH3WH3

Methylformiate HCOOCH3

Formic Acid HCOOH

Water HZO

.. - - ~

UNIT MIN NORMAL MAX

IO 30

To be spcc. -.. .-

“C

Barg Tu be spec.

. ..

332 1.- 3000 - 69 m m m 3 .-. . -

rng/~m’ 75 000 122 500 125 000

.- Balance

3p3 13 391

556

87 m m m 3

mg/Nm‘ 2 319 6 738

--- rnglNm’ . --

m w m ’ --

. -

. - - 0 465

Traces Ttaces -- .

Sat. ai 10°C Sat. at 30°C

File- Attachment F.l Created on 3 1.01.02

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0 dynea

‘Temperature

PWSUre

COMPOSITION

Methanol

~.

. - . -

-- -.

CHqOH -. - .-

- Oxygen -“I___- 02 NZ Nitrogen

Carbon Monoxide CO

Carbon Dioxide COz

Formaldehyde CHZO

..

. -

- -

-. Dimethyl - Ether CH3WH3

Methylformiate -. - HCOOCH,

Formic Acid HCmH

Water H20 .-

Dynea Ireland

UNIT MIN NORMAL 1 MAX

50

To be spec. -. -

QC 10 30

Bug To be spec. To be spw.

rnflrnj 80 200 ’ 3000

mgtNm’ -

m m m ’ .. .

m m m 3

m m m ’ 100 3 500

r n g ~ ~ r n ’ . ..

74 500

Balance Halmcc

97 100 t 100000

3 740 I5 420 23 100

- .-

- 7532- 1 8520 . - 2 670

Q 535 535 __I_ .. - . - rng/Nm3 - ..

Traces Traces

Sat. at 30°C ~ ~~

sat. at 10°C

TECHNOLWY CIWTRE inquiry Document Replwment Catalytic Oxidizer Unit Page 5 of 10

Case B: Waste gas from FORMOX process only

Performance

The priorities in terms of efficiencies are firstly efficient contaminant removal followed by minimisation of fuel usage and operational msts.

The unit shall reduce the levels of methanol, formaldehyde, dimethyl ether and carbon monoxide to meet the h i t s stated by the German rules, which art defined in the “TA-Lull” (Technische Anleitung mr Reinhaltung der Luft). The unit must also meet the requirements given by the Irish authorities and defined i0 the safety report for the sh. According to these requirements, we have to meet the following d m u m levels:

Formaldehyde: 5 Methanol: Dimethyl ether: 150 CarbDn monoxide: SO2 NO, Solids / dust

m m m 3 150 mg/Nm3 rngt~rn~ 100 mglNrn3 500 m m m 3 500 m@m:

50 m m m

The sum of methanol + formaldehyde + dimethyl ether must not exceed I50 mg/Nm3

File: A t t w h i F.1 crested on 3 1.01.02

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0 dynea Dynea Ireland Page 6 of 10 - ~ ? ~ D W L O G Y L’ENCRE

Requid opentianal information

Inquiry Document Replacement Catalfic OKjdi7m Unit

The following operatknal information must be supplied with the offer and the technical documentation:

Catalyst costs for 5 years of operation.

Catalyst replacement frequency and cost. Energy (fuel) consumption fmures must be supplied and documented.

All utility consumption ftgum must be supplied and documented.

Definition of supplier’s scope

The oxidizer system will be designed and supplied by a system vendor. Suppliers scope:

Catalytic oxidizer unit incl. heat exchangers. Material selection: SS.

Catalyst.

Start-up burner or heater.

Fan(s).

All valves and piping excluding the main pipelines from the plant. Standards and materials to be approved by Dynea.

Instrumentation and control system for automatic operation incl. control panel and proper housing.

Required safety interlocks and automatic shut down system. The vendor must specify the required unit shut down time and the response time of the interlock system.

Required sampling points with manually operated leak proof valves according to specifications approved by Dynea.

A demister tank designed to dry the oxidizer feed gas stream shall be included in the scope of supply. All waste gases will normally be saturated with water at the given tempsrature. The demister tank shall have connectbns for a pump and level switches for disehzarge of effluent liquid. The pump and the instrumentation of the tank is not part of the supply.

specified prOt0t;ol is required. Interface to the plant DCS, signals to ba specifted. Full cmmunimtion based on a

Online exhaust gas monitoring system for CO and total hydrocarbons will be required.

Insulation and cladding. The insulation should be divided into sections and must be

Prices to be specified separately.

detachable for maintenance.

All necessary supports (preferably skid mounted). Weather prding, must be approved by Dynea.

The vendor must supply dust and partick specifidions fur the oxidiier feed gas.

Erection incl. electrical and instrument installation, supptiers scope.

CreatFd on 3 1.01.02 File: A W h t F.!

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0 dynea Dynea Ireland Page 7 of 10 T F C H N ~ Y C m Inquiry Document 0 Replacement Catalytic Oxidizer Unit

Commissioning and start-up.

Training of operators and maintenance personnel. Transportation. The ddivery is CIP (Incotems l S 0 ) on the specified site.

All necessary padring (sea worthy) required for the safe transport to the site.

Painting of any external c a h n steel parts. Paint specification to be approved by Dynea.

Supplied by Dynea:

Start-up fuel supply.

Foundation I civil works according to vendor's specification.

Illumination.

Earthing.

All utility connections from the plant incl. power supply and cable connections to the plant

Instrumentation and discharge pump for the demister tank.

DCS.

Design requirements

The catalytic oxidiser sy-stem will not be provided with a secondary heat exchanger for

The energy supply for start-up is natural gas, which is available on site (and used for the

steam production.

existing unit).

It is assumed that the exhaust streams (now and in the future) ore free from known catalyst poisons including, but not limited to, halogens, lead, phosphorous compounds, arsenic, silicones, heavy metals, silica compounds, sulphur compounds, etc. Vendor to specify known catalysl pokons.

The oxidizer shell replace the existing unit, and will therefore be placed on the same area. The available area have the following dimensions: L= 11 m, W=6rn.

File. AWhnmt F.l Creakdon 31.01.02

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dynea Dynea Ireland Page 8 of 10

~ H N O L O G Y ~ N T R E inquiry Document Replacement Catalytic Oxidizer Unit

TENDER SUMMARY

Case A) Waste gas from both processes

The undersigned of€ers to deliver the in this inquiry specified work to the following fixed prices:

1

5

6

7

Delivery:

catalytic oxidizer

Instrumentation, control panel

Communication protowl to DCS

System for on-line measurements of exhaust gas

Transport and installation (CP Dynen Ireland)

Commissioning and training (excl. hotel, -sport etc.)

SUM TOTAL

...................................

.........................

.........................

.........................

.........................

.........................

.........................

We hereby ensure to start the work immediately after reception of a purchase order and to follow and report progress to the agreed time schedule.

5

..................................... Date

TENDER SUMMARY

.................................................................... Vendors signature

Clearedon31.01.02 File: Attachment F.1

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e 0 dynea Dynea Ireland Page 9 of I O TECHNOLOGY &me Tnquiry Document Replacement Catalytic Oxidizer Unit

Case B) Waste gas from FORMOX promss

h e undersigned offers to deliver the in this inquiry specified work to the fdIowing fixed prices:

POS DescriDtion Casf (Ewo}

I Catalytic oxidizer .........................

Instrumentation, control panel .........................

Communi&ion protocol to DCS

4 System for on-line measurements of exhaust gas

Transport and installation (CP m e a Ireland)

Commissioning and irahing (excl. hotel, hnsport etc.)

SUM TOTAL

DeIivery:

e

.........................

.........................

.........................

.......................

We hereby ensure to start the work immediately after reception of a purchase order and to follow and report

progress to the agreed time schedule.

..................................... Date

FIle: AUachment F. I

.................................................................... Vendors signature

Cres(ed on 3 1-01 .M

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Design Basis

Application

a

e

Membrane aeration system for the eficient oxygen supply in the biological wastewater treatment step. The aeration system can be applied in continuous as well as intermittent processes.

Wastewater Properties

Origin of wastewater: municipal/hMal Medium: Activated Sludge

9 MLSS: Sludge Voiume Index (SVI): Temperature: Total Dissolved SaIts (TDS): pH-value:

Plant Data

Number of basins: Basin shape: Length: Width:

9 Water depth: Freeboard:

8 Basin volume: Plant altitude:

Oxygen Requiremenls (per basin)

AOR. 10 kg 02/h SOTR: 18 kg 02h

Remarks The aerators are operated together with v d c a l mixers.

Aeration System Layout Number of basins: Number of modules per basin: Total number of modules:

Model: INVENT E-FLEX@ SMB30 Dimensions of one modde: Number of membrane t u b 5 per module: Membrane inner diameter: Wall thickness: Active membrane surface per module:

Process wnditions: *Fmcsstempemtm:

Dissolved oxygen level under process conditions:

AOWSOTR-ratio Site ambient pressure at m a.s.1.

System design: DitTuser density in the basin:

9 Aeration depth: - Design air flow per module under standard wnditions:

5 kglrn3 80 vkg 20°C 2,000 ppm 6 - 8

2 round 5.95 m 5.95 m 3.25 m 0.50 m 90 m3 2m above sea level

2 2 4

3.000 x I .530 mm 18 30 mm 1.7 mm 5 m2

20 O C 2.0 m@ 1013 mbar 0-55

32 Ya 3.05 m 178 mN3h

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e Minimum air flow per module: Maximum air flow per module: Total ah flow per bash Total air flow for a11 basins: p up to battery limit (incl. hydr. pressure):

4 Standard Oxygen Ttansfer Efficiency (SOTE): Standard Oxygen Transfer Rate (SOTR20):

Ref: 731 figureslMMeCl07-05

a I /- I

- hose Nipple

50 mN3h 215 mN3h 357 mN3h 714 mN3h 430 mbar 17.1 % 18 kg OWh

Page 1 of 2

mst Watw

{by C l i n t )

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1494

I

Ref: 731 figureslMMcC107-05 Page 2 of 2

Nutrisolv Ireland Ltd. Business Innovation Centre, Ballinode Sligo Tal: 1850 266266 lnt: +353 71 914 6355 Fax: 071 974 9872 V.A.T. Reg. No.: lE8234324D

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0

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FA- - MO T r-- --

Nutrisolv Ireland Ltd. Business Innovation Centre, Ballinode Sligo Tel: 1850 266266 Int: +353 71 914 6355 Fax: 071 914 9872 V.A.T. Reg. No.: lE82343240

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0

I I I A---- IAeroMcLone I

--- V

F d C L v l R m p - MMng 4 Sludge Sump Tank

T 0 y y I y B I I 2

0 Nutrisolv Ireland Ltd. Business Innovation Centre, Ballincde Sligo

Tel: 1850 266266 Int: +353 71 914 6355 Fax: 071 914 9872 V.A.T. Reg. No.: tE8234324D

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