improved valve maintenance and quality for delayed...
TRANSCRIPT
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Slide 0
Improved Valve Maintenance and Quality for Delayed Coking
Experience from related industries
Dr. Martin FrankCEO
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Slide 1
SchuF was founded by Ludwig Schwärzel und (and) Josef Frank . Their initials were used to form the company name…
Sch
SchuF HQ Frankfurt, Germany - 1911 and 2003
uF
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Slide 2
SchuF Company Information
• SchuF today operates across the globe and is represented in over 75 countries
• SchuF has designed and delivered over 1 million valves – mostly highly customised and engineered for specific processes
• The key areas of industry focus for SchuF are the Chemical, Petrochemical, Pharmaceutical, Oil, Gas & Refining, and Plastics and Polymer industries
• SchuF is the inventor of many valve types (Bottom Outlet, Lift Plug, Tank Emergency Shut-off etc.), but is best known for designing special valves for severe media, difficult operating environments or new processes
• SchuF valves are characterised by:
Unique designs
High performance and longevity
Use of high quality materials
German precision engineering
Unique designs
High performance and longevity
Use of high quality materials
German precision engineering
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Slide 3
• Today SchuF has five full scale manufacturing plants in Germany, Ireland, USA, Brazil and India with 300 employees of which over 50 are design engineers.
Skippack, PA, USA 1967 Indaiatuba, SP, Brazil 2006
Coimbatore, India, 2007Cork, Ireland 1991
…Worldwide
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Slide 4
Industrial Processes to be Reviewed
• Polymers & PTA
• Gasification
• Heavy Oil Upgrading
• Coal Liquefaction
• Mining
• Coking
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Slide 5
High flow rates
Pressure drops of up to 160 bar
Slurries with 50% + solids content
Flashing
Corrosion & erosion
Vibrations
Non standard valve alignment
Crystals in process
Severe Operating Conditions
SchuF designs valves for industries that operate under severe conditions. Our valves typically have to counter the effects of two or more of the following factors:
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Slide 6
Polymers andPTA (Purified Terephtalicacid)
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Slide 7
PTA Crystalliser Arrangement
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Slide 8
SchuF designTypical design
Main Differences
● Body geometry constant acceleration
● Flow to Open i.e. flashing takes place outside and no direct stream
● material and surface treatment selection
Designed to Meet Process Requirements
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Slide 9
• Spindle protector to improve particle size distribution
• SchuF x³ bell curve to enhance controllability between optimum and max
• 3 Phase flow calculation
Unlike commonly used ISA formulas
SchuF's Cv calculation is a true 3 phase programme
SchuF Proprietary Features
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Slide 10
Polymer Filter Switching Valves
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Slide 11
Multiport Switching Valves
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Slide 12
Mining – Alumina, Copper& Nickel
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Slide 13
Alumina Production Challenges
Alumina is produced by refining hydrate or trihydrate bauxite:
•Bauxite is an extremely dirty, and erosive substance
•The process results in the build up of a hard abrasive scale
•Valves must be able to handle high solid contents
•It subjects machinery to thermal and mechanical shock
•Operator abuse is common
•The Alumina production process destroys valves rapidly
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Slide 14
SchuF Alumina Approach
Through a combination of design, process knowhow and materials used, valve life and efficiency can be improved. Some examples include:
• Disk grinding mechanism
• Integral body and bonnet
• Renewable seat with hardened facing
• Graphite packing and spring washers
• Reinforced graphite or spiral wound gaskets
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Slide 15
Oxidative Leaching Mining Processes
Process Name Developed by Temperature Particle size Pressure Used forTotal pressure oxidation Placer Dome 225°C n/a 3400 kPa Copper, NickelChlorine enhanced pressure leeching (CSEL) Cominco 150°C 40 microns 1100 kPa Copper, GoldDynatec Dynatec 150°C 30-40 microns NickelAAC/UBC Anglo American 150°C 10-20 microns 700 kPa Zinc, CopperActivox Western Minerals 100-110°C 10-15 microns 1000 kPa Copper, NickelAlbion Mount Isa Mines 85-90°C 5-15 microns CopperNSC (Nitrogen Species Catalyised) Sunshine 125°C 400 kPaAmonia Leech Processes Arbiter, Coloso CopperAcid Leech Process Sherrit 120° - 225°C Nickel, PlatinumPlatsol Platsol 220°C 3200 kPa Cooper, GoldIntec Intec 85°C atmp. Cooper, Gold
• Autoclave isolation Models 71KS and 50• Autoclave vent valve Model 74CS• Flash Cooling letdown Model 74CS• Autoclave discharge letdown Model 74CS
• Flash Cooling letdown Model 74CS• Autoclave discharge letdown Model 74CS• Autoclave Feed Model 28KS• Drain Valves Ram Seal
Valves provided by SchuF
Valves provided by SchuF
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Slide 16
Angle Control Valves for Activox Process
Control valve for autoclave let down
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Slide 17
Autoclave Isolation for Copper & Nickel Mining
Y Globe Control ValveAngle Control Valve
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Slide 18
GasificationClean Coal Technology
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Slide 19
Gasification – Clean Coal Technology
Gasification Process
Gasification Process
o Coal
o Lignite
o Petcoke
o Gas
o Oil Residue
o Biomass
o Orimulsion
SynGas
(CO+H2)
o Electricity
o Steam
• Ammonia
• Methanol
• Hydrogen
• Other chemicals
oTown Gas
oTransportation Fuel
IGCCCombined
Cycle Power Generation
Chemicalfeedstock
Condition/Distribution
Liquefaction
• Gasification transforms feedstocks and residues to higher valve energy sources
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Slide 20
Lurgi/Sasol Gasifier
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Slide 21
Shell Gasification Process – Feed Control Valve
• Application: Coal gasification dry feed
• Medium: Pulverised coal with nitrogen
• Valve design: incorporates many features including:
special trim design
unique disk contour
only special hard metal materials are used
yoke bellows construction
easy to replace trim parts
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Slide 22
Black Water/Gas Control Valves
• Application: Coal gasification dry feed
• Medium: Inert gas and gas particles
• The design incorporates many special features including:
special trim design
unique control contour
only special hard metal materials are used
energy dissipation mechanism
easy to replace trim parts
• Application: Black Water Gasification
• Medium: Black water
• The design incorporates many special features including:
the medium is injected into the flash drum below water level
design funnel to reduce pressure
continuous accelerating design of body and funnel
special hard metal materials are used
design leads to lower wear and tear
Siemens Gasification Process – Feed Control Texaco (GE) Gasification Process –Control Let Down
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Slide 23
Other Gasification Valves
• Application: Feed Start-up Diverter Valve
• Medium: Coal dust and particles• The Diverter valve design features :
No dead space Intrinsic regulation mechanism Integral flushing ports
• Application: Black Water Diverter Valve
• Medium: 70% solids coal slurry• The Diverter valve design features :
No dead space Hard faced sealing surfaces Integral flushing ports
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Slide 24
Heavy Oil Upgrading & Coal Liquefaction
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Slide 25
Severe conditions3 phase flow,Large pressure differences with P1=Pv i.e. extreme flashingHigh temperatures (material stress)Difficult media (coal, vacuum bottoms, PTA etc.)
SchuF Experience:• Valve design and construction (e.g. opening out or in control valve, diverter, angleor wedge plug instead of ball valves)•Material selection (Tungsten Carbide, Ceramics, Titanium Grade 5, C12, Hastelloy, TiN coating etc.)•Best 3 phase sizing programme•CFD simulations•Collaboration with KAB engineers for heavy oil upgrading and coal liquefaction
Liquefaction and Heavy Oil Upgrading
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Slide 26
5-way diverter valve
Blocking valve
Control valve
HPHS
to MPHS
Flushing valve
Let Down Service
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Slide 27
Heavy Oil Upgrading Switching Valve ++
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Slide 28
Vacuum Residue Switching
Kohle Öl Anlage Bottrop
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Slide 29
Hydrocracker Let Down
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Slide 30
Delayed Coking
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Slide 31
Bringing It all Together
• Custom design• Material choice• Process adjustment
• Process Knowledge• Special valve design• Special materials• Process adjustment
• Custom design• Material choice• Process adjustment
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Slide 32
Gate Valve for Coking (Petrobras)
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Slide 33
Coker Portfolio I
IsoPlug SwitchPlug
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Slide 34
Coking Defence System (CDS)
Flushing ports Purge to Drain Valve Retractable Bottom
Common in Polymer, and slurry type industries
Common in the chemical and pharmaceutical industry
Common in Mining industry
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Slide 35
Coker Valves II - Injection & Quench Valves
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Slide 36
III - High Pressure Decoking Control Valve
• Operating Position Features:
guarantees minimum flow to pump in the closedposition
Equal % flow control of water to pump and some minimum recirculation in partially open position
No piston in flow path. Absolutely minimum pressure loss (₯). No wear on seat or contour in open position
• Operating conditions: 3000 PSI, 85°C
• Typical sizes: 2” to 6” (or higher upon request) ASME2500
• Body Material: Carbon Steel WC6 or C12
• Superior design – few moving parts
• Low maintenance valve due to reduced wear and tear
• Available with electric, pneumatic or hydraulic actuators
• Can be modified according to customer wishes
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Slide 37
IV - New Coker Valve Assembly
Conventional Coker Set Up for isolation, steam, quench, condensate, and drain
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Slide 38
Steam, Quench, Isolate Multi-Valve Assembly
The new SchuF assembly replaces valves, multiple functions and all unnecessary piping minimising dead space
This slide is to be presented during the conference
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Slide 39
Valve Assembly Comparison to Traditional Layout
The drawings below illustrate the space saving of the valve assembly compared to the traditional piping and multiple valves approach. In additional the valve assembly minimises dead-space and number of potential leak points.
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Slide 40
SchuF Valve Portfolio
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Slide 41
Thank You!