Ceramic Packing and Internals. for Acidic Applications

Transcription

1 Ceramic Packing and Internals for Acidic Applications

2 Advanced Ceramic Technology Saint-Gobain NorPro is a global leader in the production of ceramic products for mass transfer and heat transfer applications. Our technical accomplishments in developing materials and products for improved performance have mirrored the industry s most important advances for more than 40 years. Saint-Gobain NorPro continues to lead the industry in delivering standard and custom materials and shapes for acidic applications. Saint-Gobain NorPro s advanced ceramic technology is the result of decades of experience developing products and materials, combined with our access to the vast resources of our parent company, Compagnie de Saint-Gobain. This level of expertise makes us uniquely qualified to provide quality standard products as well as custom products for particularly difficult or unusual applications. Ask us about product development partnerships and custom-engineered solutions. No matter what your application or where you are located, you will find us an exceptional resource. WavePak ceramic packing is an example of Saint-Gobain NorPro s ability to engineer new products for specific acidic processing applications. WavePak packing was developed and patented by Saint-Gobain NorPro and is marketed exclusively by Monsanto Enviro-Chem Systems.

3 Typical Materials Comparison PHYSICAL DATA Material Chemical Resistance (% weight loss) NorPro ASTM C-279 (mod.) Water Absorption (weight % open porosity) NorPro ASTM 373 Leachable Iron (weight % iron) NorPro Two Basic Formulations In addition to custom-formulating material compositions to meet specific process requirements, Saint-Gobain NorPro offers two standard materials for optimum durability and chemical resistance in most corrosive applications. Proware Chemical Ceramic <4.0% <0.4% <0.01% Proware Chemical Ceramic Saint-Gobain NorPro s Proware chemical ceramic material is mechanically stronger, less porous and considerably more chemical resistant than the typical chemical stoneware on the market. A silicaalumina body derived from refined clays and other minerals, this tightly controlled material is much smoother, more finely-grained and vitreous than typical stoneware and is virtually iron-free. Proware chemical ceramic resists all alkalis, solvents and acids, with the exception of hydrofluoric acid. It maintains its integrity in solutions of 10% sodium hydroxide up to (50 c) and 1% sodium hydroxide up to (93 c). Proware chemical ceramic is the standard material for all of NorPro packing products for acidic applications. Aludur 11 Ceramic <3.0% <0.4% <0.005% Aludur 11 Ceramic Saint-Gobain NorPro developed its Aludur 11 ceramic material to provide the added strength necessary for large shapes, such as grid bars and support plates. This material is approximately three times stronger than Proware chemical ceramic, and it provides equal or better corrosion resistance. Like our Proware material, Aludur 11 ceramic resists all alkalis, solvents and acids, except hydrofluoric acid. It maintains its integrity in solutions of 10% sodium hydroxide up to (50 c) and 1% sodium hydroxide up to (93 c). Aludur 11 ceramic is highly resistant to thermal shock, which is an important characteristic of large, monouthic ceramic parts, such as support plates. Other Available Materials Carbon For processes where ceramic packing is not viable, Saint-Gobain NorPro offers carbon Raschig rings.

4 Support Plates The beam construction of the Model 4808 and Model 4908 gas-injection support plates delivers the ultimate ceramic plate performance. The continuous beam-type risers increase gas and liquid handling capacity while providing more than four times greater load-bearing capacity than ceramic plates with cylindrical gas risers. In addition, the uniform wall thickness and sectional design provide exceptional thermal shock resistance. Standard support plates can be used with liquid rates up to 50 gpm/ft 2. Model 4808 Aludur 11 Multi-beam Support Plate For towers 6 in. 48 in. ID (152mm mm) Saint-Gobain NorPro supplies the Model 4808 support plate for towers up to 48 inches (1219mm) in diameter. For greater tower diameters, Saint- Gobain NorPro offers the Model 4908 support plate with beams up to 72 inches (1829mm). The modular design of the Model 4908 is ideal for towers with cross sections greater than 72 in. (1829 mm), which require the use of mid-span supports. Model 4908 Aludur 11 Multi-beam Support Plate For towers 48 in. ID and greater (1219mm and greater)

5 NorPro Aludur 11 grid bars are ideal for use as primary supports in sulfuric acid absorbers, driers, coolers and other highly corrosive applications in large-diameter towers. The Aludur 11 ceramic offers excellent chemical resistance at temperatures well beyond the limits of high-quality Proware chemical ceramic. However, Aludur 11 grid bars should not be used in systems where they will be exposed to superheated steam for an extended period of time. Saint-Gobain NorPro generally designs its grid bar supports for installation on 6 in. (150mm) centers for use with 6 in. rings or on 8 in. (200mm) centers for use with 8 in. grid block. Saint-Gobain NorPro also custom-designs systems to meet specific centerto-center spacing requirements. Individual grid bars are provided up to 84 in. (2134mm) in length. Towers with diameters greater than 84 in. (2134mm) are accommodated through the use of midspan supports. Grid bars work equally well with stacked or dumped packing. When used with dumped packing, Saint- Gobain NorPro recommends a secondary layer of grid blocks or cross partition rings on top of the primary grid bar supports. Model 4817 Grid Bar Supports for Stacked and Dumped Packings Open Area Comparison Model 4817 grid bars Model 4817 grid bars on 8-in.(200mm) on 6-in.(150mm) Competitor Dome spacing spacing % open area of support 83% 77% 58-62% Type of stacked 8 in. Saint-Gobain elements on support NorPro grid block 6 in. cross partition rings 6 in. cross partition rings % open at support/stack element interface % open area at element that supports random 59% 72% 48% 62% <37% (1) <62% (1) packing Minimum size packing retained 2 in.(50mm) saddles 3 in.(75mm) saddles 3 in.(75mm) saddles Potential capacity increase vs. dome 60% 30% Higher open area means lower pressure drop or greater hydraulic capacity. The square stacking pattern provides 62% open area. Secondary support elements that are not stacked in a square pattern have less than 62% open area. 8 in. high bars at 6 in. centers 26.6 lbs/ft kg/m 2 8 in. high bars at 8 in. centers 20.0 lbs/ft 2 98 kg/m 2 10 in. high bars at 6 in. centers 33.2 lbs/ft kg/m 2 10 in. high bars at 8 in. centers 25.0 lbs/ft kg/m 2 NorPro Aludur 11 grid bar supports have three to four times greater mechanical strength than the best chemical porcelain, stoneware, or refractory material. The exceptional strength of Aludur 11 ceramic makes possible designs with greater center-to-center spacing.

6 Secondary Supports Systems Grid Blocks A secondary support system using NorPro grid blocks provides greater free space than a system using cross partition rings: Grid bars placed on 8 in. (200 mm) centers with NorPro grid blocks on top have 15 percent more free space than the conventional system of bars on 6 in. (150 mm) centers with cross partition rings. Such a system also requires 33 percent fewer grid bars and 25 percent less secondary support media. Thus, grid blocks save material and shipping costs as well as installation time. Saint-Gobain NorPro manufactures its grid blocks in high-grade Proware chemical ceramic material. Each block weighs 6.1 pounds (2.77kg) and is 3-1/2 in.(89mm) high. When installed atop a grid bar support system with 8 in. centers, the blocks occupy an area of approximately 8 in. by 5-3/4 in.(203mm by 146mm). To determine the quantity of grid blocks required, multiply the tower crosssectional area by Generally, Saint-Gobain NorPro specifies a 5 8% overage for cutting at the tower wall. Cross Partition Rings Saint-Gobain NorPro cross partition rings are available in Proware material. When using 6 in.(150mm) rings as a secondary support, a second layer of 4-in.(100mm) rings is necessary to retain 2-in.(50mm) saddles. Brick Lining Bar Length Grid Bar Support Plate Midspan Support If Required 8 in. (200 mm) Grid Block V in. TYP Steel Shell Brick Support Ledge

7 Installation and Design Information During installation, blocks should be placed between adjacent grid bars where they rest on the support ledge and midspan supports. The blocks provide stability for the bars and will prevent the bars from tipping over when installing secondary support systems. A minimum 1/2 in. (13mm) clearance between abutting bars and between the bars and tower wall is imperative to allow for unrestricted thermal expansion. The tables (right) list the load limits for grid bars on 8-in. (200mm) centers. Model 4817 Grid Bar Supports Allowable Load with 8 in. Centers lb/ft 2 at < 300 F lb/ft 2 at > 300 F Bar Height Bar Height Bar Height Bar Height Bar Length (in.) 8 in. 10 in. 8 in. 10 in Model 4817 Grid Bar Supports Allowable Load with 200mm Centers Kg/m 2 at < 150 C Kg/m 2 at > 150 C Bar Height Bar Height Bar Height Bar Height Bar Length (mm) 200mm 254mm 200mm 254mm

8 Packings for Acidic Applications Saint-Gobain NorPro provides a complete range of random packings, available in highly acid-resistant Proware chemical ceramic. Norton Saddles Norton saddles are the mass transfer industry s packing of choice for reliable, corrosion-resistant performance. Available in sizes from W in. (6mm) to 3 in. (75mm), NorPro s Norton saddles provide approximately 56% greater capacity than Raschig rings. Norton Super Saddles For optimal performance, the Norton Super saddle provides better liquid/gas contact and lower pressure drop than comparably sized standard saddle. The product features a unique scalloped edge that permits maximum usable area for liquid/gas contact and minimal resistance to flow through the column. The NorPro No. 2 Super saddle provides from 5% to 30% greater mass transfer efficiency than the corresponding size of standard saddles, along with approximately 25% lower pressure drop. Carbon Raschig Rings Saint-Gobain NorPro offers carbon Raschig rings for processes where ceramic packing is not viable.

9 Additional Ceramic Products Snowflake heat transfer media For reliable low pressure drop performance, Snowflake media are available in a range of sizes and materials for use in RTOs and other high-temperature heat transfer applications. Denstone catalyst bed support media The NorPro Denstone line offers the industry s broadest selection of standard and specially-formulated catalyst bed support media for refining and petrochemical applications. Request brochure DEN-3. Installation Services Saint-Gobain NorPro has partnered with VIP International, a leading North American company in the removal and installation of ceramic media in regenerative thermal oxidizers. With knowledge, expertise and equipment second to none in the industry, VIP International s highly-specialized crews execute repairs in a fraction of the time of general maintenance groups, resulting in reduced downtime, faster return to production, and thus improved profitability. MacroTrap guard bed media This innovative product effectively filters particulates from refinery feed stock, protecting the catalyst bed from fouling and subsequent pressure drop build-up. Request brochure GB-1. Catalyst carriers Saint-Gobain NorPro customtailors the size, shape, porosity and surface area of catalyst carriers to meet your specific process requirements. Request brochure CAT-3.

10 Process Control: Saint-Gobain NorPro s Assurance of Quality Pre-Qualification Saint-Gobain NorPro qualifies raw materials well in advance of manufacturing. Extensive testing of core samples from the mine site identifies specific areas of prime reserves to ensure a consistent supply far into the future. Standard raw material tests are conducted by the supplier and in our laboratories as well to confirm data accuracy. Lot Qualification Our pre-qualification procedures ensure that only prime mining sites are tapped; but we don t stop there. Each shipment of raw material must pass additional tests prior to acceptance at our manufacturing facilities. Blend Qualification Saint-Gobain NorPro assures a consistently high-quality product, even when our testing reveals subtle changes in raw material composition. Saint-Gobain NorPro s experience in linking material characteristics to the final product enables us to fine-tune the blend at the front end to ensure a consistently high-quality ceramic product. Size and material uniformity characterize the NorPro saddles (left), which are compared to competitors product. Saint-Gobain NorPro s adherence to strict process and material control is evident in the uniform size and shape of NorPro saddles and NorPro Super saddles. Our product consistency ensures that NorPro packings maintain the free space necessary for reliable, low-pressure drop performance and strength for long service life.

11 Process Checks Saint-Gobain NorPro s ISO certification assures that documented procedures are followed at every stage of the manufacturing cycle to guarantee consistent quality. Mixing Forming Drying Firing Screening Packaging Shipping Finished Product Tests Saint-Gobain NorPro inspects the following characteristics of all finished products to further guarantee optimal quality: Strength Size Shape Chemical composition Porosity Chemical resistance A copy of Saint-Gobain NorPro s documented test methods can be provided upon request. Saint-Gobain NorPro worldwide headquarters, sales offices and manufacturing facilities are certified for ISO 9001:1994 and DIN EN ISO 9002,8.94. Certifications are available upon request with any shipment.

12 Saint-Gobain NorPro Corporation P. O. Box 350 Akron, OH Tel: (330) Fax: (330) Saint-Gobain NorPro GmbH Am Bahnhof D Steinefrenz Germany Tel: Fax: The information herein does not constitute a guarantee or warranty. The Saint-Gobain NorPro Corporation warranty is set forth in its standard terms and conditions, which govern sales of Saint-Gobain NorPro products. The standard terms are set forth on Saint-Gobain NorPro quotations and acknowledgements and are also available on request Saint-Gobain NorPro Corporation 01/02 CPIAA-1