Gord Montgomery’s Post

Notes on primary reformer catalyst reduction * primary reformer temperature 680-700oC ( kbr design ) , HTS inlet 280 - 320oC , HDS above 330 and less than 0.1ppmv sulfur * introduce gas , S/C = 16 ( 4 hr ) , rise to S\C = 8 ( 20 hr ) * Take samples every 6 hr from primary, secondary and HTS to confirm that the primary reformer methane slip has reached a stable low value, If not extends time 6 hr more *introduce gas , S/C = 4.5 , take 3 sample with in one hour ,confirm methane slip at good low value * Reduction will start from down to up l, as it is an endothermic reaction and the tube inside will be higher in temperature in down. Decreasing H2O/ H2 ratio , S/C (4) increasing flow / plant load 40 and Co & H2 partial pressure helping too much in reduction complete on tube top if it take a time why flame is yellow, long in video ? This is normal at low loads. It will stabilize as the plant load increases after the reduction process, plant load at this step 14% , It is normal that there is more air to control the temperature and because the amount of fuel is less vacuum is high and flames length is longer than normal to ensure heat distribution and reduce thermal stress on the top due to very low load , as it is the lowest load the plant can operate at is 40 - 50%

❌COMBUSTION ASSUMPTIONS REJECTED❌: Flue gas recirculation is accomplished by extracting gases from the exhaust stack using a blower to inject it into the combustion air. Flue gas recirculation is a process in which flue or exhaust gases are reintroduced into the combustion zone. This is typically achieved by connecting a blower to the exhaust stack, which then directs the exhaust gases into the combustion air of the burner. The quantity of recirculated flue gas must be precisely adjusted to match the air and fuel flow across the burner's operating range. ✅The Rogue Combustion Burner System with #ClearSign Core Technology™ employs a proprietary mechanism known as Internal FGR. This system utilizes the velocity of the combustion air to draw flue gas from the burner flame into the fuel and air mixing zone. Before entering the mixing zone, the flue gas is directed along the walls of the furnace, where heat is exchanged with a secondary fluid (such as water, oil, or glycol). This process enhances the furnace's heat exchange efficiency and cools the flue gas, improving heat absorption in the flame zone. The design of the Internal FGR system inherently adjusts the amount of flue gas in proportion to the combustion air, thereby eliminating the need for manual tuning of this parameter during burner operation. #GoRogue 🔥 ClearSign Technologies

Scaling up flow reactors can several challenges, including: 1. Heat transfer: As the size of the reactor increases, it becomes more difficult to efficiently transfer heat throughout the system. This can lead to temperature gradients, which can affect reaction kinetics and product quality. 2. Mixing: Achieving proper mixing at larger scales can be challenging, leading to uneven distribution of reactants and products. This can impact reaction efficiency and product quality and yield. 3. Pressure management: Managing high pressures in larger flow reactors can be challenging and may require specialized equipment to ensure safety and optimal performance. 4. Residence time distribution: Ensuring consistent residence times for all reactants in a large-scale flow reactor can be difficult, leading to variations in reaction rates and product quality. 5. Scale-up costs: Scaling up flow reactors can be costly, as it may require larger equipment, increased energy consumption, and more complex control systems. 6. Process control: Maintaining precise control over reaction parameters such as temperature, pressure, and flow rates becomes more challenging at larger scales, requiring sophisticated control systems and monitoring tools. Scaling up flow reactors requires careful consideration of these and others challenges to ensure successful and efficient operation at larger scales. #Flowchemistry

Scaling up flow reactors can several challenges, including: 1. Heat transfer: As the size of the reactor increases, it becomes more difficult to efficiently transfer heat throughout the system. This can lead to temperature gradients, which can affect reaction kinetics and product quality. 2. Mixing: Achieving proper mixing at larger scales can be challenging, leading to uneven distribution of reactants and products. This can impact reaction efficiency and product quality and yield. 3. Pressure management: Managing high pressures in larger flow reactors can be challenging and may require specialized equipment to ensure safety and optimal performance. 4. Residence time distribution: Ensuring consistent residence times for all reactants in a large-scale flow reactor can be difficult, leading to variations in reaction rates and product quality. 5. Scale-up costs: Scaling up flow reactors can be costly, as it may require larger equipment, increased energy consumption, and more complex control systems. 6. Process control: Maintaining precise control over reaction parameters such as temperature, pressure, and flow rates becomes more challenging at larger scales, requiring sophisticated control systems and monitoring tools. Scaling up flow reactors requires careful consideration of these and others challenges to ensure successful and efficient operation at larger scales.

Insertion Vortex Flow Meter | LUGB-Insertion- Royce Water Systems - Measurement Instrumentation https://lnkd.in/dsbumM5U Insertion Vortex Flow Meter - Overview This insertion vortex flow meter measures the volume flow of non-conductive liquids, gases, and saturated and superheated steam. It has no moving parts, eliminating abrasion and wear. It is in a fully welded SS304 body (SS316 selectable). It has a patented sensor and flow sensor body and eliminates drift and vibration influence. It is highly accurate, especially for gas flow. It has a variety of signal outputs and selections such as 4-20mA, pulse with HART or pulse with RS485. When the temperature and pressure change significantly in gas flow measurement the vortex flow meter could add temperature and pressure compensation. The vortex flow meter could also work as a BTU meter and measure steam or hot water energy.  Applications include the chemicals and petrochemical industries. Suitable for use with light oil or any purified water, such as thermal oils, desalinated water, demineralised water, RO water, boiler feed water, condensate water etc. Insertion Vortex Flow Meter - Features Measured Medium: Liquid, Gas, Steam Accuracy: 1.0% (Flange), 1.5% ... #RoyceWater

In a Sulfur Recovery Unit (SRU), the thermal reactor is a critical component of the Claus process, responsible for converting hydrogen sulfide (H₂S) into elemental sulfur. The main components of a thermal reactor include: 1. Burner The burner introduces and mixes acid gas (rich in H₂S) with combustion air or oxygen. Its design ensures proper mixing and turbulence to initiate the exothermic reactions. It typically operates at high temperatures (~1000-1500°C) to sustain the Claus reaction. 2. Reaction Chamber This is the primary section where combustion and thermal reactions occur. Combustion of one-third of the H₂S in the presence of air forms sulfur dioxide (SO₂) and releases heat. H2S + 3/2 O2 ➡️ SO2 + H2O 2 H2S + SO2 ➡️ 3/x Sx + 2 H2O 3. Refractory Lining Protects the thermal reactor shell from extreme heat and corrosion. The refractory must be resistant to high temperatures, sulfur compounds, and thermal cycling. 4. Inlet Nozzle(s) Introduces acid gas, air, or oxygen into the reactor through the burner. Ensures proper flow and mixing of reactants. 5. Outlet Nozzle Guides the hot gas stream (containing sulfur vapors, SO₂, H₂S, and H₂O) to the waste heat boiler (WHB) or subsequent processing units. 6. Instrumentation and Controls Includes temperature sensors, pressure gauges, and flow meters to monitor and control the reaction conditions. Automated controls ensure the correct H₂S-to-air ratio for efficient sulfur recovery. 7. Quench Zone (if applicable) In some designs, a quench zone or cooling mechanism might be integrated to lower the temperature before the gases exit to the next stage. For example waste heat boiler WHB which will be talked about further more in separate post. 8. Safety Devices Includes pressure relief systems and explosion-proofing measures due to the flammable and toxic nature of H₂S. These components work together to ensure efficient conversion of H₂S into sulfur, optimizing recovery rates while maintaining safe operation. ✳️✳️ Stay tuned, we are not finished yet ✳️✳️

HCl Gas Flow Measurement Using Thermal Insertion Mass Flow Meters (Part-1) Gas flow measurement is crucial in various industrial processes, and different technologies are available for this purpose. Among these are Thermal Mass Flow Meters, Coriolis Mass Flow Meters, Differential Pressure (DP) Flow Meters, Ultrasonic Flow Meters, Vortex Shedding Flow Meters, and Rotameters. HCl gas measurement presents unique challenges, especially when the flow rate is low, such as below 30 kg/hr, and there are material compatibility issues. Additionally, Coriolis Flow Meters require a minimum pressure of around 10 bar for accurate measurements. In this blog, we explore the use of Thermal Insertion Mass Flow Meters for low-pressure and low-flow gas measurements. Thermal mass flow meters operate on the principle of convective heat transfer to measure mass flow rate. They consist of a reference heated element and a temperature sensor. The reference element is heated to a constant temperature above the gas temperature, and the temperature sensor measures the gas temperature. To maintain a constant temperature difference (ΔT) between the reference element and the gas, a certain amount of heat must be provided to the reference element. The heat required to maintain this temperature difference is directly proportional to the mass flow rate of the gas. By measuring the amount of heat (power) needed to maintain ΔT, the flow meter can determine the mass flow rate of the gas. .....contd gsn@atrasahi.com www.atrasahi.com

HCl Gas Flow Measurement Using Thermal Insertion Mass Flow Meters (Part-1) Gas flow measurement is crucial in various industrial processes, and different technologies are available for this purpose. Among these are Thermal Mass Flow Meters, Coriolis Mass Flow Meters, Differential Pressure (DP) Flow Meters, Ultrasonic Flow Meters, Vortex Shedding Flow Meters, and Rotameters. HCl gas measurement presents unique challenges, especially when the flow rate is low, such as below 30 kg/hr, and there are material compatibility issues. Additionally, Coriolis Flow Meters require a minimum pressure of around 10 bar for accurate measurements. In this blog, we explore the use of Thermal Insertion Mass Flow Meters for low-pressure and low-flow gas measurements. Thermal mass flow meters operate on the principle of convective heat transfer to measure mass flow rate. They consist of a reference heated element and a temperature sensor. The reference element is heated to a constant temperature above the gas temperature, and the temperature sensor measures the gas temperature. To maintain a constant temperature difference (ΔT) between the reference element and the gas, a certain amount of heat must be provided to the reference element. The heat required to maintain this temperature difference is directly proportional to the mass flow rate of the gas. By measuring the amount of heat (power) needed to maintain ΔT, the flow meter can determine the mass flow rate of the gas. ....contd. gsn@atrasahi.com www.atrasahi.com

What is Heat duty and it's Application Heat duty refers to the amount of heat energy transferred in a heat exchanger or any thermal process. It is typically measured in units like watts (W), kilowatts (kW), or British thermal units per hour (BTU/hr). Steps to Calculate Heat Duty 1. Identify the type of heat transfer (sensible, latent, or combined). 2. Determine the required parameters (mass flow rate, specific heat, temperature change, heat transfer coefficients, etc.). 3. Apply the appropriate formula based on the scenario. 4. Perform unit conversions if necessary to match the desired output. Formula for Heat Duty Calculation 1. For Sensible Heat Transfer Q = m.Cp. ∆T Q : Heat duty m : Mass flow rate Cp : Specific heat capacity ∆T : Temperature change 2. For Latent Heat Transfer (Phase Change) Q = m λ λ: Latent heat of vaporization or fusion (kJ/kg or BTU/Ib) 3. For Heat Transfer in Heat Exchangers Q = U A. LMTD U : Overall heat transfer coefficient A : Heat transfer area LMTD: Logarithmic mean temperature difference Example If 2 kg/s of water is heated from 30°C to 80°C, and the specific heat capacity of water (Cp) is 4.18 kJ/kg-K, the heat duty is: Q = m. Cp ∆T = 2 ×4.18 × (80 - 30) = 418 kW Applications of Heat Duty 1. Heat Exchangers: For heating, cooling, condensing, or vaporizing fluids. Example: Preheating process streams. 2. Reactors: To maintain reaction temperature in exothermic or endothermic processes. Example: Cooling a polymerization reactor. 3. Boilers and Condensers: Generating steam or condensing it back into liquid. Example: Steam generation in power plants. 4. Cooling Towers: Removing excess heat from water using air. Example: Cooling water in industrial processes. 5. HVAC Systems: For heating or cooling spaces. Example: Air conditioning in buildings. 6. Energy Recovery: Reusing waste heat to improve efficiency. Example: Heat recovery from flue gases. #process_engineer #chemical #heat #heatduty #heatexchanger

Cover Gas in Secondary Aluminum Melting - Benefits of an Inert Atmosphere https://lnkd.in/gBvJ7_hi "In the realm of secondary aluminum melting, refining, and recycling, the utilization of cover gas stands as a pivotal technique for enhancing process efficiency and product quality. Cover gas, essentially an inert gas blanket, serves to shield molten aluminum from the detrimental effects of atmospheric oxygen interaction, mitigating oxidation and dross formation. This technical overview aims to provide melt supervisors and technicians with a comprehensive understanding of cover gas applications, encompassing gas selection, volume, flow rates, furnace equipping, as well as the associated benefits and hazards. A particular emphasis will be placed on integrating cover gas capabilities into circulation and transfer pumps, simplifying the cover gas delivery system." #pumpingupsustainability #moltenmetalpump #liquidmetalpump #covergas