maintenance procedure- hcl synthesizer furnace overhaul

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MAINTENANCE PROCEDURE MUHAMMAD REHAN KHAN MAINTENANCE ENGINEER HCL synthesizer Furnace Overhaul R-1660 A/B

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this presentation is the maintenance procedure of HCl synthesizer furnace overhaul

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Page 1: Maintenance procedure- HCl synthesizer furnace overhaul

   

 

MAINTENANCE PROCEDURE

MUHAMMAD REHAN KHANMAINTENANCE ENGINEER

HCL synthesizer Furnace Overhaul

R-1660 A/B

Page 2: Maintenance procedure- HCl synthesizer furnace overhaul

HCl Synthesizer Furnace (R-1660a/B)Process Description: Straight Through Synthesis

Maximum feed temperature for H2 and Cl2 is 700C

The burner consists of two concentric tubes, with Cl2 flow through the inner tube and H2 through the outer annulus.

Above the burner, the gases are ignited and burn to produce hydrogen chloride gas. The H2 flow is always greater than the Cl2 flow by at least 5%.

The Hydrogen chloride gas at a temperature of 2000-25000C flows from the combustion chamber into an integral isothermal falling film absorber

The heat of combustion is 0.7 KWh per Kg of HCl and the heat of absorption in water is 0.5 KWh per Kg of HCl. The combustion chamber cooling system and the absorber cooling system each removes about half of the heat generated.

The vent gases contain less than 0.5 ppm HCl.

Vendor: Nantong Long-Trust Graphite Science & Technology Development Co., Ltd.

Page 3: Maintenance procedure- HCl synthesizer furnace overhaul
Page 4: Maintenance procedure- HCl synthesizer furnace overhaul

HCl Synthesizer Furnace (R-1660a/B)Furnace Assembly:   

Capacity : 90 tons/day of 31% HClMaterial: GraphiteDesign Pressure: 0.10 MPaG (-500 mmH2O)Design Temperature: 200COperation: 8000 hr/year

Tail Tower:Material: GraphiteDesign Pressure: 0.06 MPaGDesign Temperature: 50C

Fan:Type: CentrifugeMaterial: FRPCapacity: 300 m3/hrInlet Pressure: -200 mmH2ODesign Pressure: 0.06 MPaGKw – 2900 rpm

Synthesis

Receiver

Cooling

Absorption

Denso Meter

RD

Burner Housing

Page 5: Maintenance procedure- HCl synthesizer furnace overhaul

HCl Synthesizer Furnace (R-1660a/B)

Synthesis

Receiver

Cooling

Absorption

Denso Meter

RD

Burner Hosing

RD

1.2bar Bursting pressure Denso meter

Absorption blocks (6)

Cooling blocks (10)

WeirBlocks are made of graphite with addition Bakelite (Phenol-formaldehyde resin) which is no more than 12 percent

Page 6: Maintenance procedure- HCl synthesizer furnace overhaul

HCl Synthesizer Furnace (R-1660a/B)

Synthesis

Receiver

Cooling

Absorption

Denso Meter

RD

Burner Hosing

Tail gas towerBurner assembly

H2 tube Cl2 tube

Burner arrangement

Page 7: Maintenance procedure- HCl synthesizer furnace overhaul

HCl Synthesizer Furnace (R-1660A/B)

Furnace Part Item Code Description

Burner Assembly

4705.1660.0001 Chlorine Burner- highly pure quartz

4705.1660.0002 Hydrogen Burner- highly pure quartz

4705.1660.0003 Burner support for Cl2 impregnated graphite

4705.1660.0004 Burner support for H2 impregnated graphite

4705.1660.0005 Connector tube -impregnated graphite (Nozzle)

Sight glass assembly

4705.1660.0006 Compressed plate for sight glass

4705.1660.0007 Compression board for sight glass

4705.1660.0008 Sight glass

4705.1660.0009 Sight glass

RD / access.

4705.1660.0010 Safety Disc

4705.1660.0011 Spacer of Safety disc

4705.1660.0012 Board of safety Disc

SPARES IN WAREHOUSE

Page 8: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

A. DISMANTLING OF ABSORPTION SECTION1. Remove RD cover

2. Remove Rupture Disc

3. Remove Pressure equalizer ring

RD

Pressure Equalizer ring

RD Cover

Page 9: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

A. DISMANTLING OF ABSORPTION SECTION4. Remove associated piping

5. Mark and remove all graphite nozzles

6. Removed furnace top shell

Page 10: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

A. DISMANTLING OF ABSORPTION SECTION7. Mark orientation of Denso meter

8. Install clamp on Denso meter and  rigged down it to ground

Page 11: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

A. DISMANTLING OF ABSORPTION SECTION9. Remove shell of Absorption section

10. Mark block number and orientation on all 6 blocks

11. Remove and shift all blocks to ground shell was removed and placed to ground for cleaning and painting

Page 12: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

B. DISMANTLING OF COOLING SECTION12. Remove second shell of cooling water. 

13. Mark & remove cooling section blocks using a clamp of different diameter

14. Place all blocks one by one on soft rubber sheet (Total 10 blocks)

Clamp for removal Marking

Page 13: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

B. DISMANTLING OF COOLING SECTION15. Remove Weir shell and then weir block

Weir block shell

Page 14: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

C. TAIL GAS SCRUBBER REMOVAL16. Remove and rigged down the tail gas scrubber to ground

17. Dismantle tower on ground

18. Replace packing of tower 

Rigging arrangement

Tail gas tower

Tail gas tower

Packing

Page 15: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

RepairsRepairs that can be done are:

• Broken collar of absorption block• Repair of down comers of 

absorption block• Cracks on weir block• Repair of tail gas scrubber nozzle• Replacement of Tail gas scrubber 

packing• Power brushing & painting of shells

Repair kit

Page 16: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYLEAK TEST OF BLOCKS

Page 17: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

D. BOX UP OF FURNACE19. Install Tail gas tower

20. Install weir block and cover

21. Install Cooling section

Page 18: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

Page 19: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

Page 20: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYQUALITY HOLD POINTS

Mark clearly number and orientation of all blocks 

All graphite nozzle to be removed before removal of shells

All blocks to be placed on soft ground.

Top of blocks to be covered all the time 

During installation of cooling blocks, nozzles of all blocks should be aligned. Long stick/rod can be used after every block installation to check alignment.

All blocks should be balanced and leveled. Bubble level can be used to check for any inclination.

Cleaning of clamp/ring after every block rigging in order to remove dust/rust.

There is only 3 mm clearance between shell and graphite blocks.  

All blocks are inserted into each other making a male/female combination. 

Page 21: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

Outer H2 Tube

Inner Cl2 Tube

E. REPLACEMENT OF BURNER

H2 tube Cl2 tube

Burner arrangement Burner Housing

Page 22: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

E. REPLACEMENT OF BURNER1. Remove associated piping of burner assembly

2. Remove Hydrogen and Chlorine tube support plates and tube holders

3. Clean tube holders

H2 tube holder

Cl2 tube holder

H2 tube holder Cl2 tube holder

Cleaning of tube holders after removal

Page 23: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

E. REPLACEMENT OF BURNER4. Assemble the burner as per the following arrangement:

From top to bottom: a. H2 tube holderb. Cl2 tube  holderc. H2 tube support plated. Cl2 tube support plate

Page 24: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

E. REPLACEMENT OF BURNER4. Insert H2 and CL2 burner tubes into the assembly

5. Align tubes with holders and supports

Insertion

Alignment

Page 25: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

E. REPLACEMENT OF BURNER6. PTFE tape is compact inserted between the H2 tube and tube holder

7. With the help of hydrogen tube support plate, hydrogen tube assembly is inserted into the furnace very precisely through tie-screws

Use wood for compacting PTFE tape

Page 26: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

E. REPLACEMENT OF BURNER8. Similar PTFE tape packing is done between Cl2 tube and tube holder

9. Now Cl2 tube is installed with the help of tube holder and support plate

Page 27: Maintenance procedure- HCl synthesizer furnace overhaul

MAINTENANCE ACTIVITYJOB METHOD STATEMENT

E. REPLACEMENT OF BURNER10. Install back the piping 11. Check burner tubes assembly from sight 

glass nozzle

Page 28: Maintenance procedure- HCl synthesizer furnace overhaul

THANK YOU

MUHAMMAD REHAN KHANMAINTENANCE ENGINEER