Urea Preconc. New2
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Transcript of Urea Preconc. New2
VACUUM PRE-CONCENTRATOR
PRESENTED BY:-
JAGDISH PRASAD JAT (GET)
SHUVAJIT DEB (GET)
SAROJ DEY (DET) JOYDEB MAITY (DET)
WHAT IS VACUUM PRE-CONCENTRATOR???...
Vacuum pre-concentrator is a process equipment which increases
the concentration of the urea solution by the evaporation of water,
prior to the vacuum concentrators.
FUNCTION OF VACUUM PRE-CONCENTRATOR
It allows a considerable saving of LP steam in the vacuum concentrator stages.
It reduces the load of E-106.
The heat of absorption of the leaving gases from V-102 , in aqueous carbonate solution , is utilized in E-104.
Parts Of Vacuum Pre-Concentrator
The item is mainly divided in three part :-
1.Top Separator(V-104)Where the released flash gases are removed before the solution enters the tube bundle. Vapors are extracted by 1st vacuum system, PK-101. It is a vacuum section equipment.
2.Intake Falling Film Type Evaporator(E-104)Where the low residual carbonate is decomposed and water is evaporated.The required heat is supplied by means of partial condensation (in the shell side) of overhead gas coming from the MP Decomposer. It is a medium pressure section equipment.
3.Bottom Liquid Holder(L104)Where the urea solution at 84 to 87% wt. is collected.The urea solution leaving the vacuum pre-concentrator holder, L-104, is sent by urea solution pump, P-106 A/B to the bottom of 1st vacuum concentrator , E -114. Again it is a vacuum section equipment.
FEED TO VACUUM PRE-CONCENTRATOR From the L-103 of LP Decomposer ,70.65% urea solution is fed to
V-104 top where the pressure is reduced to 0.34 ata through LV-
1022 .
Vapors coming from top of V-102 are absorbed by aqueous
solution of carbonate from P-103 in a full-cone sprayer(ΔP =22
kg/cm2 & 51.35 m3/hr ) and this solution is fed to the shell side of
E-104.
PRE-CONCENTRATOR FEED DETAILS
Hydrolyzer feed contains following component of different concentrations namely:-
COMPONENT CONCENTRATION(wt.%) MASS FLOW RATE (kg/hr)
Urea 70.65 161026
NH3 2.12 4831CO2 0.42 966WATER 26.81 61096TOTAL MASS FLOW RATE 227919
VACUUM PRE-CONCENTRATOR
10-V-104
10-E-104
10-L-104Sight Glass
87°C 0.34 kg/cm2(abs)
102°C 0.34 kg/cm2(abs)
FROM P-103
FROM V-102 TO E-106
TO T-101
FROM P-109
FROM L-103
TO E-114
TO PK-101
PROCESS PARAMETERS
FLUID CIRCULATED
OPERATING PRESSURE(Kg/cm2g)
DESIGNPRESSURE(Kg/cm2g)
OPERATING TEMPERATURE(°C)
DESIGN TEMPERATURE(°C)
MASSFLOWRATE(Kg/hr)
SHELL SIDE (INLET)
NH3-CO2-H2O(MIXED PHASE)
18.3 24 130 165 173588
SHELL SIDE (OUTLET)
NH3-CO2-H2O(MIXED PHASE)
18.3 24 115 165 173588
TUBE SIDE (INLET)
UREA SOLUTION 0.34(abs) 1.8 & F.V 86 132 208049
TUBE SIDE VAPORS (OUTLET)
NH3-CO2-H2O(VAPORS)
0.34(abs) 1.8 & F.V 86 132 17432
TUBE SIDE LIQUID (OUTLET)
UREA SOLUTION 0.34(abs) 1.8 & F.V 102 132 190617
VACUUM PRE-CONCENTRATOR OUTLET(BOTTOM)
COMPONENT CONCENTRATION(wt.%) MASS FLOW RATE (kg/hr)
Urea 84.48 161026
NH3 0.40 757
CO2 0.10 188
WATER 15.03 28646
TOTAL MASS FLOW RATE
190617
VACUUM PRE-CONCENTRATOR OUTLET (TOP)
COMPONENT CONCENTRATION(wt.%) MASS FLOW RATE (kg/hr)
Urea - -
NH3 10.92 4074
CO2 2.09 778
WATER 86.99 32450
TOTAL MASS FLOW RATE
37302
Vacuum Pre-concentrator Pressure at 0.34ata??...
Dimensions of vacuum pre-concentrator
DIMENSIONAL PARAMETERS OF V-104
TAG NO – 10-V-104Manufacturer – SUNGJIN GEOTEC CO. LTDCapacity – 85.5 m3 Length - 5139 mmWeight – 29600 kg (Empty) & 29600 kg (operating weight)
Internal Diameter – 4700 mmShell Thickness – 13mm2:1 Elliptical Head Thickness – 16mm(normal), 13.6mm(min.)Insulation – ROCKWOOLINSULATION THICKNESS- 70mm
DIMENSIONAL PARAMETERS OF E-104
TAG NO – 10-E-104Manufacturer – SUNGJIN GEOTEC CO. LTDCapacity – 16.7m3 (shell side) 25.8m3 (tube side)Length - 4270 mmWeight – 55160 kg (Empty) & 90060 kg (operating weight)
Internal Diameter – 3302 mmShell Thickness – 36mmTUBESNumber- 2162O.D- 2”Thickness- 2.1082mmLength- 4293mmPitch- 63.5mm(triangular)
DIMENSIONAL PARAMETERS OF E-104FERRULESNumber- 2162O.D- 2”Thickness- 3.5mmLength- 400mmBAFFLES(25% H CUT)Number-4Baffle Space- 700mmImpinging Baffle-1Tie Rods- 22 (ø16)Insulation – ROCKWOOLINSULATION THICKNESS- 70mm
DIMENSIONAL PARAMETERS OF L-104
TAG NO – 10-L-104Manufacturer – SUNGJIN GEOTEC CO. LTDCapacity – 17m3 Length - 3587mmWeight – 3900Kg (Empty) & 7310Kg (operating weight)
Internal Diameter – 1550mmShell Thickness – 8mm2:1 Elliptical Head Thickness – 8mm(normal), 6.8mm(min.)Insulation – ROCKWOOLINSULATION THICKNESS- 70mm
GAD
GAD
NOZZLES & CONNECTION DETAILS
NOZZLE NO. NOMINAL SIZE SERVICEN1 46” VAPORS OUTLETN2 16” UREA SOLUTION INLETN3 12” UREA SOLUTION OUTLETN4 16” NH3 – CO2 – H2O INLET
N5 16” NH3 – CO2 – H2O OUTLET
CN1 2” LEVEL CONNECTION CN2 2” THERMOCOUPLE CONNECTIONCN3 2” PRESSURE INDICATOR CONNECTIONM1 24” MANHOLE AND DAVITSG1 14x600 SIGHT GLASSSG2 14x600 SIGHT GLASSD 3/8” DRAINV 3/8” VENTPG1,2 3/4” PRESSURE GAUGETW1,2 1” THERMOWELL
MATERIAL SPECIFICATION (V-104 & L-104 )SHELL PADS SA240-316L
SHELL FLANGE SA266-2 + 316L
NOZZLE CHECK SA312-TP316L/SA240-316L
NOZZLE FLANGE SA182-F316L
SKIRT SA240-316L/SA516-70
STUD BOLTS AND NUTS
NOZZLE -
MANHOLE SA193-B8/SA194-8
GASKETS -
GIRTH FLANGE AISI JACKETED ASBESTOS FREE NOZZLE -
MANHOLE SPIRAL WOUND (14.5)
INTERNAL 316L S.S
SETTING BOLTS/NUTS IS 1367 PART 1 & 3 IS 3757 CLASS 8.8GALVANIZED HIGH STRENGTH BOLT
MATERIAL SPECIFICATION (E-104)SHELL PADS SA240-316L
TUBE SHEET SA965-316L
TUBES SA213-TP316L
BAFFLES OR SUPPORT SA240-316L
TIE ROD 316LS.S
SPACER SA213-TP316L
IMPINGMENT BAFFLE SA240-316L
SHELL NOZZLE NECK SA240-316L
SHELL NOZZLE FLANGE SA182-F316L
STUD BOLTS AND NUTS STATIONARY SA193-B7/SA194-2H
MANHOLE SA193-B8/SA194-8
GASKET
SHELL CHANNEL END 316L SS JACKETED ASBESTOS FREE
NOZZLE SPIRAL WOUND (t4.5)
FERRULES SA213-TP316L
EXTERNAL INSPECTION OF VACUUM PRE-CONCENTRATOR
S.N. Description of Activity for External Inspection of Vacuum Pre-concentrator
YES NO
1. Check the conformity of the gaskets between the separator , the exchangers and holders to the mechanical drawings and if the relevant flanges are tightened .
2. Check that two sight glasses have been provided at holder and they are easily accessible to see the level.
3. Verify that all instrument tapings are as per P&ID and GAD of equipment.
INTERNAL INSPECTION
Preparation for Internal Inspection:-1. Open the man holes of the top and bottom.
S.N. Description of Activity for Internal
Inspection of Vacuum Pre-concentrator YES NO
1. Check the planarity of liquid distributor.
2. Perform the water test of liquid bell distributor in order to check if its holes are free.
3. Moving the ferrules by hands , check if all are well fixed into the tubes.
4. Perform spot check of ferrules holes (by using metal wire of appropriate diameter) in order to detect if some metal shaving is present due to manufacture in workshop.
INTERNAL INSPECTION
S.N. Description of Activity for Internal Inspection of Vacuum Pre-concentrator
YES NO
5. Verify that the inlet pipe is tangential and stiffener rings has been provided.
6. Verify that vortex breaker has been provided in holder.
7. Box up the man hole by putting a new gasket.
THANK YOU
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