Froth flush process
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The document discusses the FrothFlushTM process for cleaning combined cycle plant components such as condensate lines, HRSG watersides, superheaters, reheaters, and condensers. It explains that FrothFlushTM uses high velocity slugs of compressed air and water to generate full turbulence that scrubs surfaces, removing particles and salts. Test results show FrothFlushTM achieves much cleaner results than other methods, with conductivity below 50 uS/cm and solids below 0.05 mg/L. FrothFlushTM is also effective for cleaning preheat and economizer coils in HRSGs.
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Fired heaters are used for heating hydrocarbons fluids in the refineries and petrochemical plants. They are used for high temperature heat transfer. In most fired heaters, we are burning fuel gas as source of heat . There are many heaters in the world where liquid fuel is also burnt in the fired heaters to provide the energy, but their number is decreasing due to tighter pollution laws. Heaters that are processing hydrocarbons services are prone to coking and cracking depending upon the nature of the hydrocarbons being processed. Typically heaters may run length of anywhere from 3 months for coking service to 6 years for different services. Heater designers and operators are always faced with the challenge of providing uniform heat transfer to all the tubes. Engineers use equations that assume uniform heat transfer to heater tubes When designing fired heaters. However, in reality, most fired heaters do not experience uniform heat transfer, and as a result, hot spots develop on the tubes. These hot spots cause coking inside the tubes which requires the heater be shutdown periodically to remove the coke and clean the tubes. Any shutdown to clean the tubes in a fired heater causes a substantial production loss. The owners want to extend the run length of fired heaters. Furnace Improvements has developed a new patented firing technology that provides uniform heat transfer to heater tubes. This technology can be applied to most fired heaters. Our patented technology reorients the burners at a slight angle away from the tubes. We are able to direct the hottest part of the flames and flue gases away from the tubes without affecting the heat transfer in any way. FIS has installed this in 5 heaters ranging from 14 MMBtu/hr. to 280 MMBtu/hr. The clients are experiencing significant reduction in tube metal temperatures. This is translating into lower coking rates and higher tube life. We have been able to increase the capacity of the heaters in most of the cases. In one of the case study that has been presented in this heater, the heater duty was increased from 14 MMBtu/hr. to 21 MMBtu/hr. Inclined firing improves the heat transfer to the tubes and makes in uniform.
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2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation
Technical Review and Commentary on Proposed Design
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A. Operating / Mechanical Data
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The primary reformer at Agrium's Fort Saskatchewan Nitrogen Operations experienced a massive failure following a routine startup. Almost all 260 catalyst tubes in the radiant section failed, and the air-steam preheat coil was damaged, resulting in lost production. An investigation found that additional burners were lit without checks of flame impingement or tube temperature, causing the flue gas temperature to reach over 1,000°C and melt the tubes. Over 50% of tubes failed, with molten metal solidifying in the catalyst. Kellogg Brown and Root were contracted to replace all failed components and repair the furnace to restore production as soon as possible.
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The document discusses steam turbine losses and how to identify them. It outlines several types of losses including mechanical damages, flow area decreases or increases, and flow area bypasses. Specific examples of each type of loss are provided along with their symptoms and causes. These losses can lead to reduced turbine efficiency. The document also discusses the impact of deviations from design parameters on heat rate and gives an example analysis of efficiency losses for a KWU turbine.
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Examination of some of the common problems that occur on steam reformers
Analyze problems associated with
Catalyst
Tubes
Reformer Design
Common Problems
- Poisoning
- Carbon formation
- Tunnel problems
- Air leaks
- Tube failures
Less common ones include
- Tunnel Port Effect
- Flue gas Mal-distribution
CATALYST PROBLEMS
- Poisoning
- Hot Bands
- Carbon Formation
- Hot Banding & Tube Appearances
- Nipped Tubes - The Domino Effect
- Catalyst Loading
- Affect of Delta P Variation
- Catalyst Settling
- Catalyst Breakage
HARDWARE PROBLEMS
- Foster Wheeler Terraced Wall
- Mal distribution
- Collapsed Tunnels
- Effect of Removing Coffins
- Undersized Fans
- Other Hardware Problems
OPERATIONAL PROBLEMS
- Flame Impingement
- After Burning
- Catalyst Milling
- Catalyst Breakage
- Catalyst Color Variation
- Bowed Tubes
- Refractory Problems
- Other Operational Problems
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Contents
Haldor Topsøe Conventional Reforming
Haldor Topsøe Combined Reforming
Synetix LCM
Lurgi Combined Reforming
MGC Conventional Reforming
MGC Combined Reforming
MW Kellogg Conventional Reforming
Uhde Conventional Reforming
Uhde Combined Reforming
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This document discusses the use of propane (R290) as a refrigerant and variable speed scroll compressors. It notes that R290 has a very low GWP and is more efficient than other refrigerants, though it poses flammability risks. Variable speed compressors can improve efficiency with R290 over a wide operating range. The document reviews relevant regulations and standards for R290 charge limits. It presents performance data on an R290 scroll compressor and concludes that R290 is a future-proof option for refrigeration and heat pump systems if used with a dedicated compressor design that ensures safety and reliability.
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The document discusses various aspects of ammonia production processes including:
1) Simplified block diagrams of typical ammonia, methanol, and hydrogen production plants showing the main process units.
2) Modern conventional ammonia plant flowsheets have the same main process steps but differ in equipment designs between vendors.
3) Other flowsheet options for ammonia production including the Braun Purifier process, ICI AMV, ICI LCA, dual pressure Uhde process, and Linde LAC process.
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Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
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- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
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- 1. Combined Cycle Plant Applications FrothFlush™ Condensate and Feedwater Results: •Targets SigmaClean™ HRSG Watersides •Steam Chemistry •Water Cycle Chemistry •Stabile Operation Superheaters/Reheaters/MS piping, SigmaBlow™ Condenser
- 3. Why FrothFlush TM? • Very high Reynolds numbers and complete turbulence using small quantities of water return the fastest, highest quality and most consistent flushing of pipe circuits • Cleaning to this level prevents contaminates from entering the steam generation equipment. • Improves water chemistry in the HRSG which in turn improves the ability to achieve steam purity. • Current cleaning requirements result in minimal feedwater and condensate suction strainer fouling.
- 5. FrothFlush™ 6 inch pipe, 1,000 feet in length 40 feet per second “Froth” (compressible) Air / Water “slug” The FrothFlush™ process utilizes short two phase (air/water) frothed slugs displaced at velocities of 15 20 meters/sec generating Reynolds numbers of 4 5 million to remove both particulate and non particulate contamination from the metal surfaces.
- 6. FrothFlush™ Full Turbulence Effectiveness of FrothFlush™ is due to generation of full turbulence that scrubs particles and salts from pipe & tube surfaces
- 7. Improved Cleanliness • The FrothFlush™ effectiveness in removal of particulate contamination is monitored by means of Millipore filters. Samples of the flush effluent water are taken and filters using fine Millipore filters. • Millipore filters are so fine that the water sample will not flow through the filter without the aid of a vacuum to draw the sample water through the filter. • • The effectiveness of the FrothFlush™ process in removal of salts from the metal surfaces is monitored by measurement of the conductivity of the effluent flush water. • VGB Guideline for acceptable solids in flush water is < 5 mg/l. FrothFlush™ will typically achieve cleanliness of < 0.05 mg/l. • The VGB Guideline for acceptable flush water conductivity is < 1,000 S/cm. The FrothFlush™ process typically achieves flush water effluent < 50 S/cm. VGB(ISO-3166-1, British Virgin Islands)
- 8. Typical FrothFlush™ Results First FrothFlush™ 11th Froth FrothFlush™ Final Effluent on 20th FrothFlush™ The above sequence of photographs show the typical results of a FrothFlush™ of a piping system
- 9. Millipore® 0.45 Micron Patch Test First FrothFlush™ (500ML) 11th FrothFlush™ (500ml) Final Acceptable at 20th Pass 600 S/cm 60 S/cm FrothFlush™ (500ml) 15 S/cm System cleanliness far exceeds criteria specified in VGB BES&T Millipore™ Test Apparatus Guideline and all other water flush methods.
- 10. FrothFlush™ Preheat & Economizer Coil Flushing • Contamination is proportional to system metal surface area. • Contamination is proportional to amount fabrication to build a HRSG coils. Cutting, grinding, welding and PWHT generates more contamination. • Piping typically contributes less contamination than HRSG coils to the steam cycle as piping has less metal surface and less fabrication. • The FrothFlush™ process effectively flushes contamination from HRSG preheat and economizer coil sections at high velocity and high turbulence. • Effective removal of particulate and non-particulate contamination prior to gas turbine first fire minimizes fouling of BFW pump and attemperator strainers and sensitive control valve trim. • Removal of imbedded salts from metal surfaces of the pre-boiler piping and coils reduces the tine required to achieve steam cycle purity.