VACUUM PRE-CONCENTRATOR

PRESENTED BY:-

JAGDISH PRASAD JAT (GET)

SHUVAJIT DEB (GET)

SAROJ DEY (DET) JOYDEB MAITY (DET)

WHAT IS VACUUM PRE-CONCENTRATOR???...

Vacuum pre-concentrator is a process equipment which increases

the concentration of the urea solution by the evaporation of water,

prior to the vacuum concentrators.

FUNCTION OF VACUUM PRE-CONCENTRATOR

It allows a considerable saving of LP steam in the vacuum concentrator stages.

It reduces the load of E-106.

The heat of absorption of the leaving gases from V-102 , in aqueous carbonate solution , is utilized in E-104.

Parts Of Vacuum Pre-Concentrator 

The item is mainly divided in three part :-

1.Top Separator(V-104)Where the released flash gases are removed before the solution enters the tube bundle. Vapors are extracted by 1st vacuum system, PK-101. It is a vacuum section equipment. 

2.Intake Falling Film Type Evaporator(E-104)Where the low residual carbonate is decomposed and water is evaporated.The required heat is supplied by means of partial condensation (in the shell side) of overhead gas coming from the MP Decomposer. It is a medium pressure section equipment.

3.Bottom Liquid Holder(L104)Where the urea solution at 84 to 87% wt. is collected.The urea solution leaving the vacuum pre-concentrator holder, L-104, is sent by urea solution pump, P-106 A/B to the bottom of 1st vacuum concentrator , E -114. Again it is a vacuum section equipment.

FEED TO VACUUM PRE-CONCENTRATOR From the L-103 of LP Decomposer ,70.65% urea solution is fed to

V-104 top where the pressure is reduced to 0.34 ata through LV-

1022 .

Vapors coming from top of V-102 are absorbed by aqueous

solution of carbonate from P-103 in a full-cone sprayer(ΔP =22

kg/cm2 & 51.35 m3/hr ) and this solution is fed to the shell side of

E-104.

PRE-CONCENTRATOR FEED DETAILS

Hydrolyzer feed contains following component of different concentrations namely:-

COMPONENT CONCENTRATION(wt.%) MASS FLOW RATE (kg/hr)

Urea 70.65 161026

NH3 2.12 4831CO2 0.42 966WATER 26.81 61096TOTAL MASS FLOW RATE 227919

VACUUM PRE-CONCENTRATOR

 

10-V-104

10-E-104

10-L-104Sight Glass

87°C 0.34 kg/cm2(abs)

102°C 0.34 kg/cm2(abs)

FROM P-103

FROM V-102 TO E-106

TO T-101

FROM P-109

FROM L-103

TO E-114

TO PK-101

PROCESS PARAMETERS

FLUID CIRCULATED

OPERATING PRESSURE(Kg/cm2g)

DESIGNPRESSURE(Kg/cm2g)

OPERATING TEMPERATURE(°C)

DESIGN TEMPERATURE(°C)

MASSFLOWRATE(Kg/hr)

SHELL SIDE (INLET)

NH3-CO2-H2O(MIXED PHASE)

18.3 24 130 165 173588

SHELL SIDE (OUTLET)

NH3-CO2-H2O(MIXED PHASE)

18.3 24 115 165 173588

TUBE SIDE (INLET)

UREA SOLUTION 0.34(abs) 1.8 & F.V 86 132 208049

TUBE SIDE VAPORS (OUTLET)

NH3-CO2-H2O(VAPORS)

0.34(abs) 1.8 & F.V 86 132 17432

TUBE SIDE LIQUID (OUTLET)

UREA SOLUTION 0.34(abs) 1.8 & F.V 102 132 190617

VACUUM PRE-CONCENTRATOR OUTLET(BOTTOM)

COMPONENT CONCENTRATION(wt.%) MASS FLOW RATE (kg/hr)

Urea 84.48 161026

NH3 0.40 757

CO2 0.10 188

WATER 15.03 28646

TOTAL MASS FLOW RATE

190617

VACUUM PRE-CONCENTRATOR OUTLET (TOP)

COMPONENT CONCENTRATION(wt.%) MASS FLOW RATE (kg/hr)

Urea - -

NH3 10.92 4074

CO2 2.09 778

WATER 86.99 32450

TOTAL MASS FLOW RATE

37302

Vacuum Pre-concentrator Pressure at 0.34ata??...

Dimensions of vacuum pre-concentrator

 

DIMENSIONAL PARAMETERS OF V-104

TAG NO – 10-V-104Manufacturer – SUNGJIN GEOTEC CO. LTDCapacity – 85.5 m3 Length - 5139 mmWeight – 29600 kg (Empty) & 29600 kg (operating weight)

Internal Diameter – 4700 mmShell Thickness – 13mm2:1 Elliptical Head Thickness – 16mm(normal), 13.6mm(min.)Insulation – ROCKWOOLINSULATION THICKNESS- 70mm

 

DIMENSIONAL PARAMETERS OF E-104

TAG NO – 10-E-104Manufacturer – SUNGJIN GEOTEC CO. LTDCapacity – 16.7m3 (shell side) 25.8m3 (tube side)Length - 4270 mmWeight – 55160 kg (Empty) & 90060 kg (operating weight)

Internal Diameter – 3302 mmShell Thickness – 36mmTUBESNumber- 2162O.D- 2”Thickness- 2.1082mmLength- 4293mmPitch- 63.5mm(triangular)

  

DIMENSIONAL PARAMETERS OF E-104FERRULESNumber- 2162O.D- 2”Thickness- 3.5mmLength- 400mmBAFFLES(25% H CUT)Number-4Baffle Space- 700mmImpinging Baffle-1Tie Rods- 22 (ø16)Insulation – ROCKWOOLINSULATION THICKNESS- 70mm

  

DIMENSIONAL PARAMETERS OF L-104

TAG NO – 10-L-104Manufacturer – SUNGJIN GEOTEC CO. LTDCapacity – 17m3 Length - 3587mmWeight – 3900Kg (Empty) & 7310Kg (operating weight)

Internal Diameter – 1550mmShell Thickness – 8mm2:1 Elliptical Head Thickness – 8mm(normal), 6.8mm(min.)Insulation – ROCKWOOLINSULATION THICKNESS- 70mm

 

GAD

 

GAD

 

NOZZLES & CONNECTION DETAILS

 

NOZZLE NO. NOMINAL SIZE SERVICEN1 46” VAPORS OUTLETN2 16” UREA SOLUTION INLETN3 12” UREA SOLUTION OUTLETN4 16” NH3 – CO2 – H2O INLET

N5 16” NH3 – CO2 – H2O OUTLET

CN1 2” LEVEL CONNECTION CN2 2” THERMOCOUPLE CONNECTIONCN3 2” PRESSURE INDICATOR CONNECTIONM1 24” MANHOLE AND DAVITSG1 14x600 SIGHT GLASSSG2 14x600 SIGHT GLASSD 3/8” DRAINV 3/8” VENTPG1,2 3/4” PRESSURE GAUGETW1,2 1” THERMOWELL

MATERIAL SPECIFICATION (V-104 & L-104 )SHELL PADS SA240-316L

SHELL FLANGE SA266-2 + 316L

NOZZLE CHECK SA312-TP316L/SA240-316L

NOZZLE FLANGE SA182-F316L

SKIRT SA240-316L/SA516-70

STUD BOLTS AND NUTS

NOZZLE -

MANHOLE SA193-B8/SA194-8

GASKETS -

GIRTH FLANGE AISI JACKETED ASBESTOS FREE NOZZLE -

MANHOLE SPIRAL WOUND (14.5)

INTERNAL 316L S.S

SETTING BOLTS/NUTS IS 1367 PART 1 & 3 IS 3757 CLASS 8.8GALVANIZED HIGH STRENGTH BOLT

MATERIAL SPECIFICATION (E-104)SHELL PADS SA240-316L

TUBE SHEET SA965-316L

TUBES SA213-TP316L

BAFFLES OR SUPPORT SA240-316L

TIE ROD 316LS.S

SPACER SA213-TP316L

IMPINGMENT BAFFLE SA240-316L

SHELL NOZZLE NECK SA240-316L

SHELL NOZZLE FLANGE SA182-F316L

STUD BOLTS AND NUTS STATIONARY SA193-B7/SA194-2H

MANHOLE SA193-B8/SA194-8

GASKET

SHELL CHANNEL END 316L SS JACKETED ASBESTOS FREE

NOZZLE SPIRAL WOUND (t4.5)

FERRULES SA213-TP316L

EXTERNAL INSPECTION OF VACUUM PRE-CONCENTRATOR

  S.N. Description of Activity for External Inspection of Vacuum Pre-concentrator

YES NO

1. Check the conformity of the gaskets between the separator , the exchangers and holders to the mechanical drawings and if the relevant flanges are tightened .

2. Check that two sight glasses have been provided at holder and they are easily accessible to see the level.

3. Verify that all instrument tapings are as per P&ID and GAD of equipment.

INTERNAL INSPECTION

Preparation for Internal Inspection:-1. Open the man holes of the top and bottom.

 S.N. Description of Activity for Internal

Inspection of Vacuum Pre-concentrator YES NO

1. Check the planarity of liquid distributor.

2. Perform the water test of liquid bell distributor in order to check if its holes are free.

3. Moving the ferrules by hands , check if all are well fixed into the tubes.

4. Perform spot check of ferrules holes (by using metal wire of appropriate diameter) in order to detect if some metal shaving is present due to manufacture in workshop.

INTERNAL INSPECTION

 

S.N. Description of Activity for Internal Inspection of Vacuum Pre-concentrator

YES NO

5. Verify that the inlet pipe is tangential and stiffener rings has been provided.

6. Verify that vortex breaker has been provided in holder.

7. Box up the man hole by putting a new gasket.

THANK YOU  

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