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  • Handbook 11º Parte

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    Planta de acido

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    72 vistas20 páginas

    Handbook 11º Parte

    Cargado por

    Robert
    Planta de acido

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    © All Rights Reserved
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    418 HANDBOOK OF SULPHURIC ACID MANUFACTURING temperature. The optimum operating conditions can be determined by measuring the amount of $03/H;SO, leaving the tower or in the case of a final absorber, observing the opacity of the stack. The quslity of the stack emissions are observed as the operating conditions are varied. Operating conditions must reach steady state and be held for a Period of time before the affects of the new operating conditions are recorded. A systematic progiam of varyi ‘operating conditions and observation will allow the optimum operating conditions to be determined, Stripping ‘Stripping is the opposite of absorption and involves the removal of dissolved gases in the liquid by an inert gas. Ina sulphuric acid plant, the primary stripping process is the removal of dissolved SO; from weak and concentrated sulphuric acid streams In these stripping operations, the process is liquid pase controlled rather than gas-phase controlled, as is the case with the absorption of SOs into H,S0,. This mears thatthe rate of SO, stripping depends on how fast the SO; is able co diffuse through the bulk liquid 10 the liquid surface. Once the SO» reaches the surface, it is quickly strinped from the liquid and moves away from the liquid surface Equipment Details The basic components ofa tower are: Shell Packing support Packing Distributor Mist eliminator ons Paci fou ‘TYPICAL DRYING TYPICAL ABSORBING TOWER TOWER Figure 4-15 - Typical Drying and Absorbing Towers eTReNeAcDeveTeM 440 Venturi Absorber Towers ‘Venturi absorber towers were designed and introduced to the industry by Outokumpu (formerly Lurgi) in the caily 1970's. The venturi absorber tower operates co-currently rater than counter-currently as in # packed tower Hot gases enter the top of the venturi and flow down through the fixed throzt section of the venturi, Acid is sprayes into the gas ebove the venturi throst where it mixes intensely with the gas. The high degree of mixing and surface renewal provides for very favourable conditions for mass and heat transfer. ‘The venturi is followed by a conventional packed tower that serves to capture and remove the entrained acid droplets. The packing can be irrigated with uncooled aci¢ or with cold acid that has been cooled in an exchanger. The total pressure drop 2cross the venturi and packed tower is normally about 150 to 200 mm WC (6 to & in WC) which similar to the pressure drop across a conventional pecked tower Operating the absorber co-currently allows the gas to exit the tower at a higher temperature typically in the range of 120 to 140°C (246 t0 284°F). The higher the gas temperature leaving the absorber the less the gos needs to be reheated as it returns to the converter for the final conversion stages in a double absorption plant. ‘This also allows plats to operete at lower $0; concentrations. The higher operating temperature can also be used to edvan generation of low pressure steam. for the purpose of energy recovery and —— sureoRt Figure 4-16 — Venturi Absorber Tower 420. HAROBOOK OF SULPHURIC ACID MANUFACTURING Packing, Packing in an acid plant tower serves to bring into intimate contact gas and acid to promote more efficient mass and heat transfer. To achieve this requirement, the following properties are desired: igh surface to volume ratio Ability of high liguic Low cost, Low weight to volume (i.e. bulk density) Resistance to sulphuric acid in all concentrations and at high temperatures High mechanical strength and crush resistance Packing surface should be easily wetted surface renewal Early pecking was simply randomly shaped ceramic pieces dumped in a tower. Pressure drops were high and sass transfer efficiency relatively low. Early plants were small so these drawbacks were not criticel. As plant size increased, the deficiencies of the early packings became more noticeable. The design and operation of towers was revolutionized by the introduction of the Raschig ring. The rings were uniform in shape so tower performance was prediciable and consistent Figure 4-17 - Ceramic Raschig Ring The next advancement in tower packings was the introduction of the saddle. The saddle offered further improvements in mass transfer efficiency and lower pressure drop. Today, saddles are still the standard for acid plant towers. The term ‘ntalow’ is often used to refereace saddles in general but the term ‘ntalox’is actually a trade ame originally belonging to Norton which subsequently became Saint-Gobain Norpro. In October 2002, the Intalox® trademark transferred to Koch-Glitsch for use with the metal aad plastic packing only. The use of Intalox® for ceramic saddles by both companies was discontinued as of this date. Ceramic saddles produced by NorPro are now called Norton® Saddles. Other equivalent names are Novalox® (VFF) and Flexisaddle™ (Koch), ‘There are also generic type saddles available from various manufacturers. Different saddles may appear similar but cate should be taken to ensure the product will perform as anticipated. The basie characteristics of the packing (ie. picces/volume, specific surface arca, bulk density, etc. should be examined and checked against the parameters assumed in the design of the tower. As well, the mechanical properties and dimensions of the saddles should be checked against the standard. Wall thickness may vary considerably resulting in saddles thet may appear similar 10 ‘another manufacturer's saddle but are not as robust and may be subject to chipping and breakage. Figure 4-18 - Ceramic Saddle Small improvements and variations have been mede to the basic seddle shape to further enhance the packing performance. Nor‘on developed Super Intalox saddles which incorporated seallops or ridges along the curved edge Of the saddle. As wel, small holes were introduced in the body of the saddle. These modifications were intended 10 improve mass transfer efficiency and reduce pressure drop. The scallops create poiats at which liquid droplets ca ‘form and fall to next piece of packing, exposing new liquid surface for mass transfer. The holes allow ges to flow “mare easily through the packing resulting in less pressure drop. The packing has not been widely used in the “industry even though the performance data shows an improvement over regular saddles. Figure 4-19 - Ceramic Super Intelox Saddle __Anotler variation of the basic sadile shape is the CECEBE HP™ packing. The packing is characterized by is “larger size, lange rectangular holes aad scalloped edges. Those features axe similar 1o the Super Intalox saddles but ae magnified in tems of size. Figure 4-20 - CECEBE HP™ fer A complete departure ftom random packing is structured packing. ‘The packing comes in | cubic foot blocks td is stacked in the tower so that each layer is oriented 90 degrees to the layer above or below it. At the edge of the ‘pieveat gas bypassing. Structured packing exhibits extremely low pressure deops. Liquid and gas are divided and $22 HANDBOOK OF SULPHURIC ACID MANUFACTURING. recombined by the packing thus providing the high mass transfer rates by continuously renewing the liquid surface. The packing has not caught on for new tower incallations because ofits high cost but has found a niche in the plant upgrade market. Installing structured packing can allow a tower to handle a higher gas flow without the need to completely replace the tower. in these cases, the packing cost is small compared tothe cost of a new tower designed fora higher capacity Figure 4.21 - Structured Packing Another relatively new packing is WavePak™ developed by Saint-Gobsin NorPro and marketed exclusively by Monsanto Enviro-Chem Systems for all sulphuric acid applications. The packing gets its name from the unique shape of the packing which is a complete departure from the traditional saddle shape. ure 4-22 - WavePAK™ (Courtesy of Monsanto Enviro-Chem Systems (MECS)) One of the newest packings to hit the market is fom Koch Knight LLC which slready market a line of packing under the tradename Flexisaddle™. The newest packing is Flexisaddle™ LPD (low pressure drop) (patent applied for) which is basically a saddle shaped random packing with holes in the surface of the saddle. A significant difference is a rib in the middie of the saddle which appears to eatend the surface area available for each piece of packing. The added surface area combined with the numerous holes appears to give the packing the low pressure crop and high performance (i.e. high mass transfer rates) claimed by Koch Knight LLC. The rib in the middle of the packing also prevents the pieces from nestng together. ‘This keeps the bed voidage constant and minimizes setting of the packing over time Figure 4-23 -Flexisaddle™ LPD. STRONGACD SYSTEM 423 Ceramic packings for sulphurie acid service have traditionally been manufactured from fireclay or porcelain However, the latest packing to hit the market is manufactured fiom red shale, The packing has the same shape and features as CECEBE HP™ packing but is much larger in size having a nominal size of 120 mm (4.7 in) compared to 76 mm G in.), The most notable feature of the packing is its red colour which is characteristic of the red shale ‘material. The larger packing size results in lower number of pieces per unit volume and a lower pressure drop. Figure 4-24 — HP+ Saddle ‘Table 4-1 — Characteristics for Random Packing sie | Pie fea cane You. | oaee perfe | perme | white | gin | eve | mm | | we | tm | s_ | too | 3s | oo | 2 | 2 | = | a | 7 2 | 2 | soo | 375 | oo | 36 | | «| 130 000 | 3 | G0 | 9 ™ [| 2 | 17 woo [359 | 575 | 28 Th a[roaten | ae =| 26 | 900 | 368 | 589 | 37 nm [| # | ne | 70s | 2500 | 403 | of | ot 700 uuiseea | ETL BE 5 7 | 93 | in| fa Ove was] a a E _ [2 |e | 6 | us | » | » | © ail ~ [2 | os |» | im | ~% | 2 | 2 ar | a | 6 | 7 3 S00 | IT | asa] aT | eae LOO ao | 2 | os | = | 3 | 38 424 aNoBooK OF suLPHUE (CD WANURACTURING z Bulk ] Surface Packing Packing a Density | area Vola | Factor ‘Type 5 ; pert | perm | wee | kgm | mim | % Ve _| im Not z ei E ae spas cascade [No.3 | Ee = z z = = me Mini-Ring [No E aoe 18 se No.7 : = : | 8 Gros ] Paitin | orxer | 8 | 203 | sai | aso | - a ene Rings Characteristics for Structured Packing te Balk Density Surface Area Void Packing Type Sie - [eves aeimy | ete) | Gm) & ra 3 ry a Flexeremie® Typed | 513 8 7 [_iype2s a8 18 86 2 Registered Trademarks Novalox® Vereinigte Fullkirper-Fabriken, GmbH & Co. (VFF) Raschig AG Saint-Gobain NetPro Koch Engineering Inc. Flexcranie® Koch Engincering ine. Installation Installation of random pscking is important in order to prevent gas ot liquid high preseure drops and broken or chipped pecking. To ensure # uniform density throughout the bed, the packing should be installed evenly ‘across the entire cross-section of the tower. Large piles or mounds of packing should be avoided. If the density of the bed is different in one area, gas or liquid channeling may occur. Packing should be carefully laid or poured out from the box or bag onto the surface of the packing already in the rower. The packing should never be dumped from any greet height. Small chips crested from improper handling have been known to plug pump strainers, acid coolers and avid distributors. Installers should not stand directly on the packing but on plywood boards laid on top of the packing surface ‘The plywood serves to spread out the Weight which will avoid further chipping and breakage of the packing. Al boxes and bags should be removed from the tower as soon as they ars empty. Installers should ensure that xno plywood, rope, or other construction material gets buried in the packing and all debris is removed from the tower The tower should always be packed up to the required level as shown on the drawings. Usually extra packing is ordered to allow for settling and breakage, The volume of the packaging will not equal the volume of the tower. ‘The wall effects of the smaller packaging resulss in a different volume when the packing is installed in the tower. STRONGACIDSYSTEM 425 oop eles . 0 > 0 oO 0 oO mM © alo Colum CianeterPeching Se (Be) Figure 4-25 — Correction Factor for Random Packed Towers Of the key charecterisics of packing are its mechanical properties, chemical resistance and surface ‘The mechanical properties are important since the packing is subject tb high loads from the weight of z above it including the liguid load. The packing must be able to withstand this load without breaking. tains a liquid surface for absorption. All of these characteristics are a function of the material used to e packing method also influences the final packing characteristics (Table 4-3), stoneware is composed mainly of silica end alumina derived from natural clay, usually fine texture ing point fire clay, which provides good general corrosion resistance, Packing made from stoneware has a h texture and porous appearance. Sioneware’s chemical resistance is result ofits uniform chemically resistant “Chemical porcelain is mechanically stronger, less porous and considerably moce chemical resistant than al stoneware. Like stoneware, porcelain is composed maialy of silica and alumina that bas been derived from NR 426 HANDBOOK OF SULPHURIC ACID MANUFACTURING refined rather than netural clays, The process of making potselain is more tightly contoled resting ina smoother, finer gain and more vineous prodvet thin stoneware. Porcelain generally hat less icon content than stoneware | Chemical porcelain resists al alas, solvens and acs, with the exception of hydrofuoric aid. } Porcelain can withstand service in solutions of 10% sodium hydroxide up to SOC (122°F) and 1% sodium hydroxide 10 93.9°C (200°F). They ate also generally more expensive to produce because of higher fring temperatures Patented Aludur® 11 ceramic was developed to provide the added strength necessary for large bodies such as grid blocks. The material is approximately 2.5 times stronger than chemical porcelain, and it provides equal or teiter corrosion resistance, Aludur® 11 ceramic is also highly resistant to thermal shock, which is an important characteristic inthe manufueur of large product. In addition, the ceramic may be supplied giazed or unglazed. Glazed ceramics are less easly atacked by concentrated sulphuric acid Ceranics with low absorption rates. are particularly suited for spplications involving high operating terperatures andthe possibilty of thermal shock, Ceramics that are fired at high temperatures (ie. 1200°C (2192"F)) will resist breakage and thermal shock. Thorough vitiication crates « song material, maximizing chemical resistance end ineriness. Resistance to abrasion and erosion ae slso maximized ‘Metals There are a number of alloys that exhibit low enough corrosion rates in sulphuric acid that they could be used 10 ‘manufacture metal packing for use in absorption towers. Metal packing has several advantages over ceramic packing. Metal can be formed into more shapes than ceramic, giving rise to more efficient shapes. Metal is much. lighter than ceramic so mechanically the tower can be designed for smaller loads thus reducing costs. The disadvantage of using alloys for packing is their high cost. Using thinner material for the packing can reduce costs but then corrosion rates become a problem. Corrosion rates of 0.127 muva (5 mpy) are less significant when metal thickness are 6 to 10 mum but become significant when packing is made from material that is less than 0.5 mm (19.7 mils) in thickness. At this “low” corrosion rate, the packing life would be less than S years. A metal pecking was developed and designed but it failed to gain acceptance in the industry Packing Quantity The amount of packing required to fill a tower is not simply the volume of the packed section in the tower. The effvcts of packing nesting together and setling must be considsred. The wall area to volume ratio of a 2 cubic foot tox of packing is totaly different to the corresponding ratio in the actual tower which affects the amount of packing required. Finally, breakage must be taken into consideration. To determine the actual amount of packing, the tower diameter to packing size rato is wsed. For a 4000 mm

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