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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Unique Solutions for Reliability and Process Improvements
Presented by:
Randeep Malhan – Project Manager, DuPont Sustainable Solu:ons
Kirk Bailey – Business Development Manager, DuPont Sustainable Solu:ons
April 9, 2013
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Typical challenges in a sulfuric acid plant PFD of Sulfur Burning Plant
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
! Solution - MECS® Process Gas Slide Gate Valves
• New double block & bleed design • Design certified for isolation of gases for confined space entry • Two flexible sealing plates • Two stage seating wedge mechanism • Metal seat with machined radius profile • Purge air/vent line for annular space
Challenge: Tight shut-off requirement at the main blower discharge
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Air
To Waste-Heat Boiler
3
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
MECS® Process Gas Gate Valves
Secondary Seat
Primary Seat
Secondary Gate
Primary Gate Primary Gate Seat
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Rollers
Guide Rail Guide Guide
Body Wedges Wedges
Wedge Bar
MECS® Process Gas Gate Valves
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Carriage Assembly
Rollers
Wedge Bar
Gate
Seat
6
MECS® Process Gas Gate Valves
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
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Typical challenges in a sulfuric acid plant PFD of Sulfur Burning Plant
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
! Over time the sulfate build-up causes the packing to solidify and freeze
the shaft
• “It took two days to get them out of the stuffing box, even taking the shaft loose from the bearings.”- Anonymous plant engineer
! Solution • Air purge • MECS® Shaft Packing with corrosion inhibitors • Remove and replace packing without shutting the plant down
“It took two days to get them out of the stuffing box, even taking “It took two days to get them out of the stuffing box, even taking “It took two days to get them out of the stuffing box, even taking
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Challenge: Damper shafts freeze up over time
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
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Typical challenges in a sulfuric acid plant PFD of Sulfuric Acid Regeneration Plant
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
! Challenge • Use radiation recuperator if
steam is not desired • Foul quickly • Commonly used solutions
» Clean with a wire brush » Add a fired preheater » Use a more expensive
catalyst in 1st bed
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! Solution: MECS® Radiation Recuperator Lancing System • Developed in-house developed • Lancing performed while plant is running • 5 minute operation that effectively cleans the
recuperator – “30ºC improvement in converter 1st pass inlet
temperature...”
• Safe • Cost effective
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Spent Acid
To PRJS
To Converter 1st Pass
From Drying Tower
Challenge: Radiation recuperator fouling
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
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Typical challenges in a sulfuric acid plant PFD of Sulfuric Acid Regeneration Plant
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. 12
Challenge: Baffle wall failures and costly turnaround repairs
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
! Challenge • Furnace baffle walls can fail
through a variety of mechanisms » Thermal cycling » Pressure pulses
• Costly maintenance turnaround expenditures
• Less than optimal furnace combustion
! Solution - MECS® HexWall™ Baffle • Large inherently stable hexagonal
blocks provide long term robust design • Can replace existing baffle walls or
failed baffle walls • Easy to install • Avoid repeat costly “discovery” work
during maintenance outages • Better operational stability
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Challenge: Baffle wall failures and costly turnaround repairs
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
! Traditional Designs ! MECS® HexWall™ Baffle
Brick Baffles ! Constructed from standard 9” refractory brick,
often two layers thick ! Bricks are mortared together ! Thermal cycling can cause mortar to crack
and fail over time ! Design is not inherently stable. Wall is not
tied in around the entire circumference.
Conventional Baffle Walls
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Traditional Baffle Designs
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Traditional Baffle Designs
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
! Traditional Designs ! MECS® HexWall™ Baffle
• Large hexagonal blocks inherently stable
• Design ensures that all blocks are fully supported
• Tongue & groove interlocking joints • can be rocked to and fro unsupported • can withstand thermal expansion
MECS® HexWall™ Baffle
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Sulfur Burning Experience
First wall 8’ 5” from burner
Blocks 9” wide
2007
First wall 8’ 5” from burner
Blocks 9” wide
2012
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Second wall 21’ 5” from burner
Blocks 9” wide
2007
Sulfur Burning Experience
Second wall 21’ 5” from burner
Blocks 9” wide
2012
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Decomposition Experience
First underflow wall 17’ 0” from burner
Blocks 9” wide
2009
First underflow wall 17’ 0” from burner
Blocks 9” wide
2012
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
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21
Typical challenges in a sulfuric acid plant PFD of Sulfuric Acid Regeneration Plant
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. 22
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. 23
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
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24
Typical challenges in a sulfuric acid plant PFD of Sulfuric Acid Regeneration Plant
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Comparison of Furnace Types Sulfur Burner Decomposi:on Furnace
Primary Input Sulfur (S) Spent Acid (H2SO4)
Secondary Inputs Acid Gas (H2S), Sulfur (S), Sour Water Stripper (SWS) Output (H2S, NH3, H2O)
Ter:ary Inputs Air Air, Fuel Gas
Form of Reactants Atomized Liquid Atomized Liquid primarily, but can have Gaseous Components
Composi:on Homogeneous Heterogeneous
Primary Reac:on Strongly Exothermic Endothermic, but depends on secondary inputs
Predominant Flow Model Plug Flow Reactor (PFR) Con:nuously S:rred Tank Reactor (CSTR)
Typical Internals Baffles Baffles
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Type I Mixing Design
! Single vortex configuration
! Very tight Residence Time Distribution (RTD)
! Long path length
! Plug Flow (PF) characteristics – turns flow over quite effectively, but creates minimal axial mixing. Better suited for less complex input situations.
MECS® VectorWallTM Mixing Checkerwall
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Type II Mixing Design
! Back mixing configuration
! Broader Residence Time Distribution (RTD)
! Variable path length
! Continuously Stirred Tank Reactor (CSTR) characteristics – Stronger axial mixing. Better suited for more complex input situations where plugs would have too much variation.
MECS® VectorWallTM Mixing Checkerwall
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. 28
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates. 29
Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
No. B304 SRU, Kansas Refinery
“The Blasch VectorWall checker wall replacement has worked beyond our expectation. Improved combustion gas mixing has eliminated un-oxidized gas component carryover at reduced excess O2 (excess combustion air) and allowed a 50% increase in plant capacity. Thank you and Blasch for your efforts to make this work for our application. I know our engineers will be looking for Blasch VectorWalls in new installations and may also be looking to retrofitting some existing operations if the installation continues to show good structural stability and service life.”
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Copyright © 2013. MECS, Inc. All rights reserved. The DuPont Oval Logo, DuPontTM, The Miracles of ScienceTM and all products denoted with a ® or TM are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.
Thank You!
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