This document summarizes safety issues related to ethoxylation reactions involving ethylene oxide (EO). It discusses the hazards of EO including gas phase explosions, liquid phase decomposition, runaway reactions, and toxicity. It reviews case histories of accidents in EO production and ethoxylation plants caused by factors like backflows, leaks into insulation, and impurities initiating decomposition. The document also examines how vessel material, impurities, and insulation can impact the thermal stability of EO and discusses the importance of process design and material selection to safely produce ethoxylates.
In this article includes many studies and investigation reporting on the effect of various parameters to the prills quality like crushing strength, size distribution, abrasion and impact resistance, humidity factors urea moisture absorption, vacuum studies etc. The Nitrogen, moisture, Prill strength &Biuret contents and the size distribution of prilled urea are important factors of determining urea quality. High temperature of prilled product is a common in most of urea plant in India. In some plants in India the temperature of prills as high 80oC in hot summer days at high load. Our plant temperature of prills is also 65-700C.This result in poor strength dust formation, increase in caking tendency. Granulated urea has definite advantage over prilled urea but expensive to produce till recently. We have installed BFC for line-1 & 2.A modification also done in Urea line –I plant in month of March 2018 to solve foaming problem in waste water section (distillation tower) and this modification proven and beneficial.
The explosion hazard in urea process (1)Prem Baboo
In Urea plant passivation air is used in reactor, stripper and downstream of the all equipments. The reactor liner material used Titanium, Zirconium, SS 316L (urea grade), 2RE-69 and duplex material .except Titanium and Zirconium all stainless steel required more passivation air. In CO2 some quantity of Hydrogen is present about 0.14% to 0.2% . The passivation oxygen and Hydrogen makes explosive mixture. To avoid a fire or explosion in a process vessel is to introduce inert (noncombustible) gases in such a way that there is never a mixture with a combustible concentration in exit of MP vent. Mixtures of fuel, oxygen, and inert gases are not combustible over the entire range of composition. In CO2 stripping process the HP scrubber is the risky vessel and this vessel consisting blanketing sphere, Heat exchanger part and a scrubbing part. With help of triangular diagram that shows the shape of the combustible/noncombustible regions for a typical gaseous mixture of fuel, oxygen, and inert at specified temperature and pressure. Present article how to avoid that combustible rang and how to tackle that gases in CO2 & ammonia stripping process.
Experience of material in fertilizers industriesPrem Baboo
Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty 2 RE-69 materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.
In this article includes many studies and investigation reporting on the effect of various parameters to the prills quality like crushing strength, size distribution, abrasion and impact resistance, humidity factors urea moisture absorption, vacuum studies etc. The Nitrogen, moisture, Prill strength &Biuret contents and the size distribution of prilled urea are important factors of determining urea quality. High temperature of prilled product is a common in most of urea plant in India. In some plants in India the temperature of prills as high 80oC in hot summer days at high load. Our plant temperature of prills is also 65-700C.This result in poor strength dust formation, increase in caking tendency. Granulated urea has definite advantage over prilled urea but expensive to produce till recently. We have installed BFC for line-1 & 2.A modification also done in Urea line –I plant in month of March 2018 to solve foaming problem in waste water section (distillation tower) and this modification proven and beneficial.
The explosion hazard in urea process (1)Prem Baboo
In Urea plant passivation air is used in reactor, stripper and downstream of the all equipments. The reactor liner material used Titanium, Zirconium, SS 316L (urea grade), 2RE-69 and duplex material .except Titanium and Zirconium all stainless steel required more passivation air. In CO2 some quantity of Hydrogen is present about 0.14% to 0.2% . The passivation oxygen and Hydrogen makes explosive mixture. To avoid a fire or explosion in a process vessel is to introduce inert (noncombustible) gases in such a way that there is never a mixture with a combustible concentration in exit of MP vent. Mixtures of fuel, oxygen, and inert gases are not combustible over the entire range of composition. In CO2 stripping process the HP scrubber is the risky vessel and this vessel consisting blanketing sphere, Heat exchanger part and a scrubbing part. With help of triangular diagram that shows the shape of the combustible/noncombustible regions for a typical gaseous mixture of fuel, oxygen, and inert at specified temperature and pressure. Present article how to avoid that combustible rang and how to tackle that gases in CO2 & ammonia stripping process.
Experience of material in fertilizers industriesPrem Baboo
Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty 2 RE-69 materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.
Ureap lant energy improved with operation philosophyand reactor internalsPrem Baboo
The energy of H.P. loop directly proportional to the pressure of h.p loop. The H.P loop is the heart of urea plants. Conversion of urea depends upon N/C & H/C ratio, reactor internal construction, i.e. configuration of trays, reactants mixing phenomenon, flow pattern etc. other than pressure. In conventional plants there was too much pressure of the reactors for higher urea conversion. Now philosophy has been changed our mind concentrated on flow pattern of the fluid dynamics and internals of the reactors. The performances of Urea Reactors can be improved by the application of the latest generation of internals like HET, Vortex mixture and conversion booster. As a consequence, the HET & Vortex mixture can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a retrofit design. The increase in the efficiency has permitted direct benefits to the overall day-by-day performances of the units, thus allowing lower energy consumption and a reduced environmental impact. The present paper based on these facts and how to improve energy by changing internals, operational parameters like molar ratio, recycling of water in the system, pressure & temperature of the system to improve energy and equipment’s life. The most important of these consists of a sharp reduction in specific steam consumption. The fluid-dynamics of a urea reactor can be significantly improved by the introduction of the latest generation of internals. e.g. Super cup trays, Vortex mixture, NIIK internals, siphon jet trays etc. No pressure drop observed because the gas phase directly converted to liquid phase the driving force compensates the pressure drop and No load limitation.
A green building in a grey cement plant – Transforming bypass dust into indus...A TEC Group
In the Rohoznik plant a “bypass dust washing installation” has been installed to enable full incorporation of the bypass in cements and production of chloride salts that can be commercialized. This ReduDust process transforms the problem of a “bypass dust excess” into an opportunity for supplementary sales.
Cause and prevention for steam turbine blade scaling & fouling Prem Baboo
The paper intended to deposition of Wang scaling/deposition & corrosion on turbine blades. How to deposit these scales? Prevention and control the deposits. Major steam turbine problems causes and effects. Practical examples of our shut down experience of 40 ata & 100 ata steam turbines. Lab analysis detail report of wet steam cleaning and sand blasting cleaning of the blades.
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
2018 11 baboo the analysis and prevention of safety hazards in nfl complexPrem Baboo
The success of any industries lies its efficient working which in turn depends not only on equally and quantity of the service or product but also much on safe working. NFL is totally committed to conduct all its activities in harmony with society and nature without compromising on the health and safety of the employees as well as the people living around the complex. A full-fledged safety and environment protection department has been set up in the unit to achieve fulfillment of its statutory obligations concerning prevention of personal injuries, maintaining safe working conditions and protection of environment. For effective implementation of Safety, Health & Environment (SHE) policy, Each and every employee shall observe the safe system of work and follow proper safety work permit system while carrying out maintenance job inside the factory. This paper provides the detailed analysis of these hazards: In which plant sections and during which project phase do these safety hazards occur, which safety hazards occur most frequent and which hazards has the highest risk factor and troubleshooting case study and further improvement to learn these incidents
High pressure vessel_leakage_in_urea_plants (1)Prem Baboo
In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.
Ureap lant energy improved with operation philosophyand reactor internalsPrem Baboo
The energy of H.P. loop directly proportional to the pressure of h.p loop. The H.P loop is the heart of urea plants. Conversion of urea depends upon N/C & H/C ratio, reactor internal construction, i.e. configuration of trays, reactants mixing phenomenon, flow pattern etc. other than pressure. In conventional plants there was too much pressure of the reactors for higher urea conversion. Now philosophy has been changed our mind concentrated on flow pattern of the fluid dynamics and internals of the reactors. The performances of Urea Reactors can be improved by the application of the latest generation of internals like HET, Vortex mixture and conversion booster. As a consequence, the HET & Vortex mixture can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a retrofit design. The increase in the efficiency has permitted direct benefits to the overall day-by-day performances of the units, thus allowing lower energy consumption and a reduced environmental impact. The present paper based on these facts and how to improve energy by changing internals, operational parameters like molar ratio, recycling of water in the system, pressure & temperature of the system to improve energy and equipment’s life. The most important of these consists of a sharp reduction in specific steam consumption. The fluid-dynamics of a urea reactor can be significantly improved by the introduction of the latest generation of internals. e.g. Super cup trays, Vortex mixture, NIIK internals, siphon jet trays etc. No pressure drop observed because the gas phase directly converted to liquid phase the driving force compensates the pressure drop and No load limitation.
A green building in a grey cement plant – Transforming bypass dust into indus...A TEC Group
In the Rohoznik plant a “bypass dust washing installation” has been installed to enable full incorporation of the bypass in cements and production of chloride salts that can be commercialized. This ReduDust process transforms the problem of a “bypass dust excess” into an opportunity for supplementary sales.
Cause and prevention for steam turbine blade scaling & fouling Prem Baboo
The paper intended to deposition of Wang scaling/deposition & corrosion on turbine blades. How to deposit these scales? Prevention and control the deposits. Major steam turbine problems causes and effects. Practical examples of our shut down experience of 40 ata & 100 ata steam turbines. Lab analysis detail report of wet steam cleaning and sand blasting cleaning of the blades.
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
2018 11 baboo the analysis and prevention of safety hazards in nfl complexPrem Baboo
The success of any industries lies its efficient working which in turn depends not only on equally and quantity of the service or product but also much on safe working. NFL is totally committed to conduct all its activities in harmony with society and nature without compromising on the health and safety of the employees as well as the people living around the complex. A full-fledged safety and environment protection department has been set up in the unit to achieve fulfillment of its statutory obligations concerning prevention of personal injuries, maintaining safe working conditions and protection of environment. For effective implementation of Safety, Health & Environment (SHE) policy, Each and every employee shall observe the safe system of work and follow proper safety work permit system while carrying out maintenance job inside the factory. This paper provides the detailed analysis of these hazards: In which plant sections and during which project phase do these safety hazards occur, which safety hazards occur most frequent and which hazards has the highest risk factor and troubleshooting case study and further improvement to learn these incidents
High pressure vessel_leakage_in_urea_plants (1)Prem Baboo
In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.
Removal of Coke during Steam Reforming of Ethanol over La-CoOx Catalystinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
Effect of Hindered Phenol Stabilizers on the Oxygen Induction Time (OIT) Test...Philip Jacoby
This paper examines the use of the OIT test in predicting the stability of polyolefins and adhesives to thermal oxidative degradation, and the effect of antioxidant type and concentration on the OIT results
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.