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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

Section Topic

A. Physical constants, first aid and safety

B. General Process description

C. Plant start procedure

D. Plant shut-down procedure

E. Plant operation check list

F. Maintenance

G. Operation trouble shooting

H. Chemical specifications and control of solutions

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

SECTION : A

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

Physical Constants for CO2

TO BE DEFINED AT LATER STAGE

Note: All pressures are absolute pressures.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

FIRST AID

When Carbon Dioxide takes the place of oxygen in inhaled air, insufficient oxygen will reach the
lungs and asphyxia will result.

Excess CO2 in air will also increase the rate of breathing as indicated in the following table:

Carbon Dioxide Increased Lung


in Air Ventilation
(Vol. Percent)

0.1-1.0 Slight and unnoticeable increase


2.0 50% increase
3.0 100% increase
5.0 300% increase,
breathing becomes laborious

The (Threshold Limit Value) T.L.V. limit for which all workers may be continuously exposed is
5000 ppm or 0.5%.

1. SYMPTOMS

Initially there may be an increased ventilation rate with an increased pulse rate. Then with the
onset of asphyxia there is muscular incoordination, faulty judgement, emotional instability,
fatigue, fainting, vomiting, gasping for breath and unconsciousness.
Note: This can happen very quickly.

Breathing then becomes shallow and the skin and mucous membranes take on the dark blue
appearance of cyanosis.

Skin contact with liquid CO2 causes cold burns.

2. INHALATION

Minimizing personal risk, immediately remove the victim to an uncontaminated area. Make
sure there is no obstruction to the airway. Administer pure oxygen. If breathing is weak or stop-
ped, apply artificial respiration with simultaneous administration of oxygen preferably using an
oxygen resuscitator. Summon an ambulance and keep the victim warm and rested.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

3. SKIN CONTACT BY LIQUID OR DRY ICE

Flush with water for at least 5 minutes then treat as thermal burns. Seek medical advice as soon
as possible.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

SAFETY

WARNING:
The product gas produced by this NGCU system may contain carbon monoxide which if inhaled
can cause illness or death. The gas produced by the NGCU does not contain oxygen in quantities
sufficent to support life.

SAFETY PRECAUTIONS:
Due to the possible presence of carbon monoxide gas in the combustion chamber, reciever
tank, or other vessels used in connection with this NGCU, it is important that the following
procedure be followed before any of the equipment is opened and entered for any reason:

1. Shut down NGCU before entering any vessels.

2. Before entering, open all access doors and hatches of vessel and ventilate by means of
an atmospheric air or exhaust fan until the oxygen content is the normal level of 21%.

3. Wear a life support system while inside the vessel.

4. At all times, have another employee stand by immediately outside the vessel to render
assistance if needed.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013
Safety Instructions

WARNING: HIGH PRESSURE

All piping and vessels should be treated as though they are pressurized. Before maintenance,
always slowly depressurize any device containing a liquid or gas after the device has been
isolated (valved off) from the rest of the system. Personnel should wear protective clothing and
eye protection.

Opening devices under pressure can cause contents (liquid and / or gas) to spray out with
possible injury to personnel. Device components which can be removed such as lids, covers,
and plugs can be forced out of the operator’s hands and become a dangerous projectile.

WARNING: HIGH PRESSURE

Some devices operate at very high temperatures while others at low temperatures. Protective
clothing should be worn when working in the proximity of these devices (piping, vessels, etc.).
Before maintenance, these components that operate at temperatures above or below ambient
temperature should be allowed to cool / warm to ambient conditions. Low temperature liquid
CO2 lines should never be valved off without safety relief valve protection.

WARNING: ASPHYXIANT

Carbon dioxide is an asphyxiant and, when in confirned areas, suffocating concentrations may
develop. Maintain proper ventilation to prevent asphyxiation due to possible CO2 release.
Never enter any equipment:

1. Prior to vessel being purged of gases and replaced with air and

2. Without additional safety procedures in place; e.g. the use of breathing apparatus and
the “buddy” system.

WARNNG: CHEMICALS

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013
Review Material Safety Data Sheets (MSDS) enclosed under Section ”H” of this manual prior to
handling and chemicals. Contact LEW company if MSDS are missing from the equipment
manual.

WARNING: ELECTRICITY

Before working any electrical device, the power should be disconnected, locked and tagged out.
Even control voltage contains a risk for injury. All maintenance should be performed by
authorized and qualified personnel.

WARNING: MOVING HAZARDS

Certain equipment (blowers, pumps, motors, etc.) can present moving hazards. Always keep
clear of moving equipment while in operation. Before maintenance, the power source for these
devices must be disconnected, locked and tagged out.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013
OSHA:

We believe that our equipment is in compliance with the normal safety standards but
compliance may require additional items for which we cannot be held responsible. The items
supplied by us are based on our interpretations of the standard available normally, but the
responsibility for adherence to the provisions of the safety standards / safety rests with the end
user.

We believe that our equipment requires the use of certain substances in compliance with the
normal safety standards but compliance may require your developing written hazard
communication programs, label certain in-plant containers, make material safety data sheets
available to employees, and conduct employee training. Material Safety Data Sheets (MSDS) are
enclosed for your reference and should be referred to when scheduling maintenance or repair
procedures during which your employees may come in contact with one or more of the
substances listed. The information supplied is based on our interpretations of the standard, but
the responsibility for adherence to the provisions of any safety act rests with the user.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

OXYGEN DEFICENT ATMOSPHERES

The normal oxygen content of air is approximately 21%. Depletion of oxygen content in air,
either by combustion or by displacement with inert gas, is a potential hazard to personnel
throughout industry.

A poorly recognized aspect of this hazards is the response to humans when exposed to an
atmosphere as low in oxygen as 8 to 12%. In this case, unconsciousness can be immediate and
without warning.

When the oxygen content of air is reduced to about 15 or 16%, the flame of ordinary
combustible materials, including those commonly used as a fuel for heat or light, will be
extinguished. Somewhat below this concentration, an individual breathing the air is mentally
incapable of diagnosing the situation as the symptoms of sleepiness, fatigue, lassitude, loss of
coordination, errors in judgments, and confusion will be masked by a state of “euphoria” giving
the victim a false sense of security and well being.

Human exposure to atmospheres containing 12% or less oxygen will bring about
unconsciousness without warning and so quickly that the individual cannot help himself. This is
true if the condition is reached either by immediate change of environment or by gradual
depletion of oxygen.

Most personnel working in or around oxygen deficient atmospheres rely on the buddy system
for protection, but the buddy is equally liable to asphyxiation if he enters the area to rescue his
unconscious partner unless he is equipped with a portable air supply. The best protection is
obtained by providing both the worker and his buddy with a portable supply of respirable air.
Life lines are acceptable only if the area is free of obstructions and the buddy is capable of
lifting his partner’s weight rapidly and without straining himself. In practice, this has seldom
been possible.

RECOMMENDATION

If any oxygen deficient atmosphere is known to exist (as can be determined by analysis) or is
suspected:

1. Use the buddy system. Use more than one buddy if required to remove a worker in an
emergency.
2. Provide both the worker and his buddy with self-contained or air line breathing
equipment.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013
CAUTION – CARBON DIOXIDE GAS

CO2 is colorless, odorless gas. Heavier than air. It is not poisonous although it does not support
respiration and relatively low concentration in air can produce symptoms of asphyxiation of
inhaled for long periods.

The maximum permitted level of CO2 in air for continuous working is 0.5%.

NOTE: Appropriate warning signs should be affixed in those areas where high concentrations of
CO2 gas may accumulate.

Example:

CAUTION – CARBON DIOXIDE GAS

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

SECTION : B

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

CO2 Production Process Description

The Process for CO2 production/generation to liquefaction system can be defined in following
steps:
 Combustion
 Scrubbing
 Absorption
 CO2 Gas Cooling

Combustion:

The CO2 is produced from the complete combustion of a gas fuel.


Fuel and Air supply components as well as controls are built into the burner. The fuel/air
mixture is carefully controlled to obtain maximum CO2 in the flue gas without a trace of smoke.
Flue gas passes through the reboiler firebox and tubes, transferring heat to the absorption
solution. The fuel gas then passes to the scrubber tower.

Scrubbing:

The stainless steel scrubber tower has packings and countercurrent flow to ensure maximum
flue gas cooling and impurities removal.
A scrubber water recirculation and treatment system is included, to handle the gas scrubbing
water from the CO2 gas generator. This in-line system significantly reduces the volume of water
discharged to drain, providing an economical and environmentally friendly water system.

Absorption:

The absorption solution is a low concentration aqueous solution made up of


monoethanolamine (MEA), copper carbonate, sodium vennadate and water. This solution has
an affinity for, and will absorb CO2. The operation of the CO2 generator consists of the
continuous circulation of absorption solution which is cooled and subsequently absorbs the CO2
in the absorber tower. The rich solution is then heated, releasing its CO 2 content in the stripper
tower to become lean solution.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

Clean cool flue gas enters the absorber tower, flowing through absorber towers. Lean solution
is pumped from the reboiler via the heat exchanger and solution cooler to be distributed from
the top of the absorber tower and mix with the flue gas among the polypropylene packings
within the tower. The CO2 in the flue gas is selectively absorbed into the solution on the way
through, and the solution, charged with CO2, collects at the base of the tower as rich solution
and other gases vented out from the top of the absorber column.

Stripping:

As mentioned, the rich solution will release its CO2 content when heated to a predetermined
temperature. This is accomplished by firstly exchanging heat with the lean solution in the heat
exchanger, then utilizing the heat from combustion in the reboiler unit.
Rich solution from the base of the absorber tower is transferred by the rich solution pump,
through the heat exchanger to the top of the stripper tower.
The rich solution extracts heat from the lean solution in the heat exchanger and is further
heated by CO2 gas and steam rising through the packings in the stripper tower.
Complete stripping of the solution takes place in the stripper tower, the CO 2 gas rising to the
top of the tower and the solution, now “lean”, is pumped backed to the reboiler awaiting
transfer to recommence the cooling and absorption cycle.

CO2 Gas Cooling:

CO2 gas and steam pass through a gas cooler where the CO2 is cooled and the steam is released
through a condensate separator float valve for return to the absorption solution via the base of
the absorber tower.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

Technical Description

Our 1000kg/hr CO2 production system, operating from Natural Gas having, to produce pure
liquid CO2 of food and beverage quality suitable for feeding into bulk storage. The total system
essentially comprises:

 Reboiler
o Double safety protection. (low & high level, high pressure and vacuum breaker
control)
o Constructed of certified boiler plate and boiler tubes.
o Double pass vessel; unit is supplied fully assembled with no onsite insulation
required.
o Inspection openings allow convenient access for maintenance;
o Incorporates fully automatic natural gas fired burner, gas train and integral fan,
as well as controls all built in to the burner;
o Easy access for servicing fuel filter;
o Fuel meter indicator, indicates fuel consumption accurately;
 Stripper tower (carbon steel) with superior, custom–made ceramic packings for high
efficiency operation.
 Stainless Steel scrubber tower with packings and countercurrent flow for maximum flue
gas cooling and impurities removal.
 Scrubber water recirculation and treatment system, to handle the gas scrubbing water
from the CO2 gas generator. This in-line system includes heat exchanger for scrubber water
cooling, stainless steel recirculation pump, control system and associated valves and fittings, all
compactly mounted on the process unit base frame.
 Single countercurrent flow carbon steel absorber tower with polypropylene packings.
 Heat exchanger units for lean to rich transfer, solution cooling and gas cooling.
(Shell & Tube type; Tubes bundle of SS and Shell of CS)
 Stainless steel condensate separator for return of liquid to the process from gas cooling.
 Rich and lean solution pumps (both with stainless steel impeller and shaft).
 Bypass solution filter in rich solution circuit with easily maintained filtration element.
 Stainless Steel & Carbon Steel piping.
 Smaller components are pre-piped, pre-wired and mounted to a steel base frame. The
major vessels are installed separately, either indoor or outdoor, allowing optimum layout
flexibility.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

SECTION : C

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

Plant Start-up procedure

Procedures before Initial Start-Up:

FLUSHING:

The reboiler and absorber should first be filled to the proper level with fresh, clean water and
then flushed to remove any dirt or foreign material accumulated during installation and packing
of the towers. It is recommended that this procedure be performed twice.

Before refilling with fresh, clean water, the inspection port in the reboiler and at the base of the
absorber tower should be opened and an internal inspection be made. Any dirt or packing chips
not removed by the flushing procedure should be cleaned out at this time. When inspection and
cleaning have been completed and inspection ports closed, the reboiler and absorber should be
filled to the proper levels with fresh, clean water only in preparation for curing the refractory of
the combustion chamber and the boil-out.

CURING THE REFRACTORY:

The refractory (firebrick lining) in the combustion chamber and rear door must be "cured"
before attempting full capacity operation.

This is accomplished by lighting the burner pilot only as follows:


1. Start cooling water flow.
2. Close main disconnect of reboiler control panel.
3. Gas Fired Unit: Open blower disconnect. NOTE: The blower is not required during curing
process.
4. Adjust pilot gas pressure reducing valve.
5. Gas Fired Unit: Close manual valve in main fuel (gas) line.
6. Set burner control to “Pilot Test”. Start reboiler.
7. Fully open pilot fuel gas valve and air valves.
8. Adjust pilot flame with needle valve under valve cap.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

BOIL OUT:

After the combustion chamber has been ”cured”, the unit can be started and brought upto
temperature. The following temperatures are recommended during boil-out:
1. Lean MEA to absorber (43C)
2. Absorber gas inlet (40C to 43C)
3. All water valves open
Add a water solution of sodium carbonate (soda ash) to the absorber at this time. Use five (5)
pounds of sodium carbonate per 100 poounds of CO2 capacity, e.g. 110lb; sodium carbonate for a
1000kg/hr re-boiler. Do not use sodium hydroxide (caustic soda) in place of soda ash.
When boil-out is completed, drain and flush unit. Flush with clean water twice.
Change dirty filter during boil-out as required.
NOTE: Use only sodium carbonate as specified for boi-out agent. Other agents may cause damage
to equipment internals and result in premature failure of components.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

Before Start Check:

 That all pumps are filled with liquid


 That all pump inlet valves are completely open
 That all pumps discharge valves are slightly open

NEVER OPERATE THE PUMPS WITHOUT LIQUID

 That liquid level in re-boiler is correct


 That liquid level in MEA tank and absorber tank is correct
 That liquid level in water scrubber is correct
 That liquid level in permanganate scrubber is correct
 That gas inlet valve on gas cooler is open to normal position
 That blow off valve after gas cooler is open

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

MEA Installation (AMINE SOLUTION)

It is very important that the correct MEA concentration be maintained during operations. This
concentration is generally 15% MEA in water. Review the MEA material safety data sheet prior to
use. For intial charging of system use two (2) parts MEA for every ten (10) parts water. This will result
in a 15% solution concentration.

When approximately 85% of the water liquid levels are obtained, the solution should be circulated
for a minimum of one (1) hour. The concentration should then be checked by titration method.

Adjust as required to obtain 15% solution when adding remaining liquid.

NOTE:

The total amount of MEA used for intial charge should be logged in a data book at this time. This will
be a valuable reference for recharging the system after major maintenance is performed.

Corrosion inhibitor to be added at this time. This procedure is described in next pages.

NOTE:

It is very important that MEA charged in to the plant be of high purity and be iron and chloride free.

High purity water should also be used when charging the plant with MEA. The water should contain
less than 100ppm total dissolved solids, 51ppm total hardness, 2ppm chlorides, 3ppm sodium, 3ppm
potassium and 10ppm iron.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

DETERMINATION OF MEA CONCENTRATION

The normal operating concentration of the MEA solution is 15%. Due to minor differences in design,
operation, and age, units may require slight adjustments to this value.

The re-boiler has been designed to operate at a concentration range of 12% to 16%.

An MEA concentration check should be made and recorded daily using the following procedure and
apparatus.

METHOD: A cool, lean MEA sample is titrated with 0.1N sulfuric acid using
bromothymol blue indicator.

REAGENTS: 0.1N Sulfuric Acid


0.04% Bromothymol blue solution
Distilled Water

APPARATUS: 25ml Burette with reagent storage jar


1ml Ostwald folin pipette
250ml Erlenmeyer flask or beaker
Dropping bottle
Funnel

PROCEDURE: 1) Collect a sample of cool lean MEA solution from the sample valve located
in the piping between the lean MEA pump and the solution inlet to the
absorber.
2) Place approximately 100ml of neutral water in a 250ml erlenmeyer flask or
beaker.
3) Measure exactly 1ml of amine solution in the ostwald folin pipette and
transfer the solution in to the water.
4) Add 10 drops of 0.04% bromothymol blue indicator solution.
5) Titrate to a yellow end point with 0.1N sulfuric acid. Note that the blue
color of the solution fades to a green tint and with several more drops of
acid, the yellow end point appears. The addition of more acid does not effect
a change in color.
6) Record the volume of acid added in the titration step.

0.1% Methyl red indicator solution may be used, should the bromothymol
blue solution not be available. The above procedure and following
calaculations are the same for each solution. The end point with methyl red is
the first indication of a definite pink color.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

CALCULATIONS: The weight percent monoethanolamine in solution is calculated from the


formula:

Mol. Wt. Monoethanolamine = 61.08


Density Monoethanolamine = 1.01 g/ml at 25C
Percent MEA = ml. Acid X 0.1N acid X 6.11
1.01 X Volume of sample

To further simplify this calculation, the following method can be used:

The value read on the 50ml burette after complete titration is accomplished
when multiplied by .611 will result in the percentage (%) of MEA in solution.
Percent MEA=burette reading X .611

NOTE: Solution sample should be taken from only sample valve located in the cool,
lean piping between the lean pump and solution inlet to the absorber.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

CORROSION INHIBITOR USAGE

When using MEA to absorb CO2, the solution can become corrosive. For this reason, it is necessary
to add corrosion inhibitor each time the plant is completely charged with fresh solvent.

Sodium metavanadate is used as the corrosion inhibitor with the MEA solution. The inhibitor is used
with the initial MEA charge and subsequent complete system recharging of fresh solvent. Excessive
use of inhibitor has an undesireable reaction with the MEA solution. Review the sodium
metavanadate material safety data sheet prior to use.

The quantity of inhibitor used is per the following example:

One tenth (0.1) pound (0.045kg) for each gallon (or 0.012kg/liter) of pure MEA used.

Example for 200 gallons of MEA:


200 x 0.1 = 20 pounds of sodium metavanadate required.

As sodium metavanadate is somewhat difficult to dissolve, we suggest that it be dissolved in hot


water as handling of a hot MEA/water solution can be dangerous to personnel.

Add the sodium metavanadate to the water and continue mixing until the solution is clear and free
of vanadate particles. This solution may now be added through the MEA charging connection.

The MEA filters should be by-passed for approximately one (1) hour when adding and circulating the
vanadate.

Record sodium metavanadate addition on log sheet.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

ANTI-FOAM ADDITION

MEA type absorption systems can periodically have a tendancy to foam. Periodic occurences of
foaming can be effectively controlled with the addition of anti-foam agents.

Foaming typically occurs in the reboiler or stripper tower. However, it should be noted that this
foaming condition can also exist in the absorption tower and can be noted by observing pressure
build-ups in the respective towers pr erratic MEA flows coupled with extremely high system liquid
loss. The re-boiler’s capacity will also be affected as the foaming inhibits the abaility of the MEA to
absorb carbon dioxide.

Mix 20ml SAG anti-foam in water and add through the top of the re-boiler or the MEA charging
connection. Allow the anti-foam to recirculate through the plant for 45minutes. If foaming
continues, add additional charges of anti-foam.

Continuous (as opposed to periodic) foaming is typically caused by foreign components entering the
amine system via the flue gas make-up water, or other sources. If not controllable by anti-foam the
addition of an optional solvent activated carbon tower is recomended.

Do not exceed addution of more than 500ml of SAG during any 24hour period.

Record amount of SAG addition on log sheet.

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

INITIAL START-UP

1. The combustion chamber and rear door have refractory lining and must be “cured”
before attempting full capacity operations.
2. The following sequences should be followed :
a. Check that all manual valves in the system have been closed and all selector
switches are in the “OFF” position.
b. Fully open the amine cooling water valves located in the customer water supply
lines.
c. Open valves (cooling water) to 50%. Further adjustment of these valves will be
necessary when system reached normal operating temperature.
d. Fully close valves (used for fresh water and MEA addition to system only).
e. Fully open gas valves.
f. Adjust scrubbing water flow to normal.
g. Fully open lean MEA valves. Partially open lean MEA valve to approximately 25%
h. Fully open rich MEA valves. Partially open valve to approximately 25%.
i. Vent filter and pumps using connections provided.
j. Set MEA
k. Adjust lean MEA valve to obtain required flowrate.
l. Adjust rich MEA valve to obtain required flowrate.
m. Open pilot valves.
n. Start MEA re-boiler.
o. Check combustion air flow quantity and adjust valve as required to obtain the
proper rate.
p. The unit will now be absorbing CO2. Adjustment to MEA valves and may be
required as additional back pressure will be placed on the MEA solution
entering the stripper tower as CO2 is released. Check combustion gas for proper
analysis.
q. Valve located in CO2 vent line, should be open allowing the impure CO2 to vent
to atmosphere. As the purity of CO2 improves, slowly close vent valve. As the
pressure rises, adjust PCV to open at 9PSIG (0.63kg/cm2)

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Natural Gas Cracking Unit for CO2 – Plant Manual 2013

SPECIAL COMBUSTION NOTE:

Adjustment of combustion air valves is the basic menthod of air flow setup. This may require slight
variation once system is in operation and is accomplished as follows:

 When main flame is established, view flame through peep sight on re-boiler and analyze flue
gas for CO2, oxygen and smoke.
 If flame is stable and analysis is good, no further adjustment is required.
 If flame is not stable, uniform and clean, slowly open 1st valve while closing 2nd valve to
maintain the desired air flow.

NOTE: To avoid liquid shock in heat exchangers pumps should be started with discharge
valves slightly open.

Check that pressure in re-boiler rises to normal operating pressure (0.1 – 0.5 bar),
and if necessary adjust with inlet valve to gas cooler.

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