Eastman Chemical Company · Reliability What makes Eastman Gasification so reliable? • Operations...

EASTMANThe Chemistry of New Ideas 1983 - 20011983 - 2001

Eastman Chemical CompanyFine Tuning to Improve Availability and

Reliability of Coal Based Gasification

Gasification Technologies 2001

San Francisco, California

October 7-10, 2001

Written By

Steve Hrivnak, Principal Mechanical Engineer

Presented By

Nathan Moock, Senior Chemical Engineer

EASTMANBackground

hApproximately $5 B in sales annually

hOver 400 Chemicals, Fibers andPlastics

hHeadquarters - Kingsport, TN

hManufacturing sites around theworld

Gas Production and Rectisol Area

Simplified Flow Diagram - Gasification Plant

Water Clarification/Soot Removal

Soot

Grey waterRecycle togasifiers

Quench blowdownSlag

Coal Slurry

Oxygen

Slag

Quench blowdown

No.1Scrubber

No.2Scrubber

Gasifier

No.2

Gasifier

No.1

CoalSlurry

Oxygen

Wet

Syngas

Process Gas Cooling Train

Shift Gas Cooling Train

Dry shifted gas

Dry process gas

ShiftReactor

Coal &Water

Rod Mill A

Pump A

Coal &Water

Rod Mill B

Pump B

Hg removal

Hg removal

Yearly Gasifier Production Rate

1516171819202122232425262728

1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001**

Mill

ion

KSC

F

** 2001 data is based on annualized production through week 39

Gasification Complex Shutdown occurs on odd number years with 7-10 days of production downtime

Gasifier On-Stream Time% Uptime, without bi-annual shutdown and power failures

* 2001 is thru 9/17

* 2001 is YTD 9/17

Average Gasifier Run Length(Time between switches or shutdowns)

Top 10 Shutdown Causes1983 – 2000

Rank Shutdown Cause % of total

1 Feed Injector Failure 18.5%

2 Slurry Feed Pump 15.2%

3 Planned Switch 10.7%

4 Low Quench H2O Flow 6.7%

5 Low Slurry Flow 5.7%

6 Low level in Gasifier 4.7%

7 O2 Leak 4.0%

8 PSV failure 2.5%

9 Dip/Draft Tube 2.0%

10 DCS - PLC failure 2.0%

Description Count

Feed injector failure (prior to new design) 2Low quench flow (pump failure; hole in valve) 2Plant wide power failure 1Black Water exchanger fouling 1Oxygen Plant Shutdown (Lightning) 1PSV Relieved prematurely 1Modicon (programmable logic controller) 1Dip Tube Failure (coal contamination) 1

Shutdown Causes2000

Description Count

Feed Injector failure (Test Injector) 1Power failure 1Planned - for Complex Shut Down (bi-annual) 1Geho inverter shutdown, G-8B ($0.52 fuse) 1

Shutdown Causes2001

Reliability

What makes Eastman Gasification so reliable?

• Run Reviews

• Feed Injectors• Maintenance

• Coal Supply• Refractory• Fabrication Shop

• Operations

• Equipment

• Engineering

Reliability


• Operations

•Operators - 1/2 work force has more than 10 years experience ingasification.

• 3 year total training program

• 25% with 18 years gasification experience.•Technical Staff - has an average of 12.5 years experience ingasification.•Process Improvement Staff - has an average of 2.5 years experience ingasification with an average of 13 years engineering experience.

•• Experience - Experience - Experience Experience - Experience - Experience

Reliability


• Operations• Engineering

• Materials Engineer has 19 years experience with gasification.

• Plant Engineering staff has an electrical and mechanical engineerwith 9 years experience with gasification.

• Pressure vessel engineers and inspectors on site and available forimmediate use. We are the only builder and user in the state ofTennessee.

•Advanced process controls group

• Also have such services as video inspection, x-ray inspection, andinfrared photography, etc.

Reliability


• Run Reviews


•Operations and Maintenance discuss successes and failures.

•Running action items list. i.e.: procedures; projects; investigations

Reliability


• Run Reviews• Maintenance


• Highly trained

• 25% with 18 years gasification experience

• PM schedules and procedures for important equipment

• Shift crew to handle emergency work

• Specialized tools and jigs to cut down maintenance times

Hoist allows for easy bolt removal

Maintenance Costs Normalized To 1996 Costs

0

20

40

60

80

100

120

1996 1997 1998 1999 2000 2001

Perc

ent

Without CSD*2001 data is projected

Complex Shutdown

•Happens once every two years for vesselinspection

•World Class Planning Process

•Includes Operations and Maintenance

2001 shutdown

•Production Suspended for 8 1/2 days

•520 Work orders completed

•22,000 man hours

Reliability


• Run Reviews



Feed Injector Team organized in 1985.

Awarded 6 Patents Dealing with Injector Improvements.

Better materials, finite element stress analysis, and shieldedtechnology have yielded a feed injector that has 5 x life increase andis reusable.

Elimination of Injector Failure as Shutdown Cause

37 Day Run 54 Day Run

Reliability


• Run Reviews


• Operations

• Equipment

• Engineering

• Rod Mills

• Slurry Pumps

• Lock Hopper Valves

• Quench Water Pumps

Rod Mill Pinion Failure History•“A” mill – Pinion Failure on 8/18/95, 12/5/97, 3/10/98,7/15/98

•“B” mill – Pinion Failure on 3/28/98, 5/5/98

A pinion should last 5 to 7 years and then be replacedfor wear, not breakage!

Each failure cost $20,000 to repair and we lost 15% ratefor 24 hours.

Root Cause Failure Analysis identified whatRoot Cause Failure Analysis identified whatcould be attributed to shorter pinion lifecould be attributed to shorter pinion life

••Is current rod charge level too high?Is current rod charge level too high?

••When should we add rods?When should we add rods?

••Are we floating the mill before startup?Are we floating the mill before startup?

••How do we “jog” the mill for maintenance?How do we “jog” the mill for maintenance?

••Is clutch engagement too fast?Is clutch engagement too fast?

••Can poor pinion to bull gear alignment overCan poor pinion to bull gear alignment overstress the shaft?stress the shaft?

Rod mill - Discharge End

Trommel

BearingBull Gear

Bearings

Clutch

Pinion Shaft

Clutch Engagement Time - Before

Clutch Engagement Time - After

Poorly Aligned Pinion

Bull GearPinion

Where thegearsmesh

Lubricator

Excellent Alignment

Excellent Alignment

Ends of pinion within 15 F of each other.

Slurry Pump

PistonDiaphragms

InletCheckValves

OutletCheckValves

Reliability


• Run Reviews


• Coal Supply

• Operations

• Equipment

• Engineering Slag Viscosity

01200

Temperature, C

Viscos

ity,cP

Reliability


• Run Reviews


• Coal Supply• Refractory

• Operations

• Equipment

• Engineering

hOn-site expertise onrefractory inspection

and changeoutsComplete “hot face”

changeout in 22-26days

Eastman employs 12in-house brick masons;Each with an average10 years experiencechanging out gasifierrefractories.

Brick inspectiontechniques, at factoryand in gasifier

Wear measurementcharting

Hot Face

New

Reliability


• Run Reviews


• Coal Supply• Refractory• Fabrication Shop

• Operations

• Equipment

• Engineering

On site fabrication and engineering services!

We fabricate and repair anything from feedinjectors, Quench rings/Dip Tubes, slag crushers,pressure vessels, to valve bodies and small parts.Whatever it takes to keep the plant running.

Eastman’s’ expertise, experience, supporttechnologies, and reliability focus in

Gasification technology will enable us totake advantage of the future of coal as themajor source of energy and feedstock for

the chemical and other industries.

Conclusion

EASTMANThe Chemistry of New Ideas

Eastman Chemical Company · Reliability What makes Eastman Gasification so reliable? • Operations...

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