Plant construction and waste heat systems for the chemical industry

Plant construction and waste heat systems for the chemical industry

2 3 At home in the world Oschatz best technology backed by experience Oschatz is a globally operating plant constructor with over 160 years experience, around 1,300 employees as well as subsidiaries, representative offices and branches around the world. Our plants for cooling waste gases and converting the recovered heat into industrially utilisable steam are used throughout the world in the fields of iron and steel metallurgy, nonferrous metallurgy and chemical as well as power plant industry. In energy-intensive sectors like the chemical industry it is highly important to work energyefficiently and to conserve valuable resources. Therefore, products made by Oschatz are of particular importance in this industrial sector. Oschatz designs and produces turnkey residue combustion systems for the chemical industry and core components for sulphuric acid, nitric acid, caprolactam and hydroxylamine systems. Decades of experience as well as particular expertise in the areas of residue combustion, heat transfer, water circulation, cleaning of heating surfaces, corrosion and erosion processes and damage point analyses make Oschatz a reliable partner when it comes to plant construction for the chemical industry. Depending on their destination, the plants and components are fabricated in either of the two extremely modern production facilities in Kocaeli, Turkey, or Nanjing, China. Needless to say we comply with all quality standards, such as ISO 9001, ASME standard, Pressure Equipment Directive, EU standards etc. All Oschatz products are highly efficient, easy to maintain and offer easy accessibility to the individual components. Our Portfolio Waste heat recovery systems for the chemical industry For many years Oschatz has been offering waste heat recovery systems to companies operating in the chemical industry. Here are some examples of typical chemical processes where Oschatz process gas coolers and waste heat boilers are used all over the world: Nitric acid, caprolactam and hydroxylamine plants In process gas coolers made by Oschatz the base product ammonia is burned catalytically with air or oxygen. The gas thus generated is cooled and the heat energy in the gas is used to generate steam. see p. 4 Thermal disposal plant for gaseous and liquid residues in Antwerp Burner head for an ammonia combustion reactor plant; in the background the suitable pressure vessel is under construction. Sulphuric acid plants In this process sulphuric acid is produced from the element sulphur, using catalytic exothermic processes. Water tube boilers with several heat exchangers allow the gases which accumulate in the combustion chamber to be cooled down to exact required temperatures. see p. 5 Turnkey thermal disposal plants In thermal disposal plants manufactured by Oschatz solid, liquid and gaseous residues can be burned. The plants ensure that the residues are disposed of safely and simultaneously serve as power plants providing the chemical plant with steam. see p. 6 Turnkey plants for the utilisation of gases containing carbon monoxide This section is about an innovative technology for the utilisation of gases containing carbon monoxide, e.g. in metallurgical production units. The gases, which are produced in these processes, are burned and the heat energy in the gas is used to generate steam. see p. 6 Every plant is unique Our customers wishes as well as process-specific requirements always come first when planning and constructing a new plant. Each product manufactured by Oschatz is designed individually; no two plants are the same. Nevertheless, innovative methods and most modern technologies allow for costeffective production. These are the central issues in the design of each individual system: How high is the temperature of the hot gases and are they under pressure? What do the gases consist of? What is the level of dust content? Do the gases contain dusts with different compositions and different properties? Are the gases and dusts corrosive? Do the dusts have erosive properties? Complete process gas cooler during gas-side pressure test

4 5 Steam produced from waste heat Process gas coolers for nitric acid, caprolactam and hydroxylamine plants Waste heat boilers and heat exchangers for sulphuric acid plants Oschatz is an experienced specialist when it comes to waste heat systems for cooling processing gases in nitric acid, caprolactam and hydroxylamine plants. Up to date, more than 200 of these plants have been built by Oschatz throughout the world. The process The ammonia contained in the gas is burned catalytically using air or oxygen. The nitric oxide gas thus produced reaches temperatures of up to 950 C and is then cooled to a temperature of 500 to 180 C, depending on process requirements. The heat energy in the gas is used in the factory to generate industrially utilisable steam. The cooler The process gas coolers developed by Oschatz consist of the following components: the burner head with ignition system and internals for optimum distribution of the in-flowing ammonia gas gauze-clamping device to support and retain the catalyst gauze the spiral heating surfaces to cool the gases to the required temperature. The heating surfaces consist of pre-evaporator, superheater, main evaporator and if required economiser. the cylindrical gas pressure vessel in which the heating surface is mounted. Here a gastight welded tube wall protects the vessel from the high gas temperatures. Rapid drop in temperature Before installation: heating elements for NH3 boiler Checking for leaks In spite of the greatest care taken with design and manufacture leaks can occur in the spiral heating surfaces after years of use in exceptional cases. With the leakage testing system developed by Oschatz the defective tube can be identified easily and reliably. Six metre diameter At Oschatz we are very well acquainted with all types of gauze clamping systems and can build process gas coolers up to a gas volume of 230,000 Nm3/h and a gas pressure of 12 bar. One of the largest process gas coolers in the world was built and put into operation by Oschatz with a net diameter of approx. six metres. Made by Oschatz: the largest completely prefabricated water tube boiler in the world for a sulphuric acid plant in New Caledonia In order to make sulphuric acid from the element sulphur, catalytic exothermic processes are used. These require special cooling sections. Oschatz uses water tube boilers to cool down the gases containing sulphur dioxide which accumulate in the combustion chamber. Several heat exchangers precisely geared to the process requirements for the catalytic converter cool the gases down to the required temperatures. Over the decades Oschatz has built numerous of these waste heat boilers which are now in use all over the world. They are very flexible in application and are ideal for: Installation of an Oschatz waste heat system downstream of a sulphur combustion unit hyper- and hypostoichiometric combustion gas-side overpressure a wide range of steam pressures and temperatures Constant temperatures One of the biggest challenges in this process is maintaining a constant gas outlet temperature from the waste heat boiler independently of the load. Oschatz ensures that this constant temperature is maintained by controlled gasor steamside bypasses. Innovations Made by Oschatz Over the years Oschatz has accumulated a great deal of expertise in the design and construction of waste heat boilers and has incorporated innovations in its production processes which have proved themselves in daily use to the greatest extent for many years: Pressure vessel ready for transportation Provision for vertical and horizontal thermal expansion avoiding the use of compensators as far as possible. Boiler walls are produced to be gas-tight. The heating surfaces can be cleaned easily using simple maintenance procedures during shutdown periods. Heating surfaces can be exchanged in segments, thus reducing shutdown periods. Naturally all systems are designed right from the planning stage for operation with minimum maintenance.

6 7 Oschatz Services & Solutions s.r.o. Expert support around the clock Oschatz builds individually designed turnkey plants for the disposal of liquid and gaseous residues all around the world. Individual and turnkey Thermal disposal and heat recovery Disposal of liquid and gaseous residues Since the beginning of the 1990s Oschatz has built eight plants for the disposal of liquid and gaseous residues throughout the world. These were mainly disposal systems for acrylic acid, butanediol, and THF. The plants which were designed by Oschatz in close collaboration with the customers and delivered ready for operation according to the individual requirement profile consist of: a brick-lined combustion chamber for burning residues the burner system developed individually for the process to guarantee compliance with the required emission levels the waste heat boiler consisting of superheater, evaporator, economiser, heating surface cleaning system and air and gas pre-heaters process control system for the highest level of plant safety and availability Safe, cost effective, durable The thermal disposal plants manufactured by Oschatz immediately provide the customer with two benefits: they ensure that the residues are disposed of safely and simultaneously serve as power plants providing the chemical plant with steam. All Oschatz systems are designed and built for large volumes, long operating periods and constant availability. Up to now systems have been built with a gas disposal volume of up to 390,000 Nm3/h and steam production capacity of 200 t/h. Utilisation of gases containing carbon monoxide Oschatz has developed a custom-built waste heat system for metallurgical production units to generate steam in this type of plant by burning gases containing carbon monoxide. These gases, which are produced in these processes, are thus burned with proper provision for the extremely high load fluctuations which occur. In order to balance these fluctuations natural gas is added as required. In this way it is always possible to generate the desired amount of steam. Even the best product can go wrong some time; parts may need to be repaired or replaced. In such instances, our customers can rely on the expert service provided by Oschatz. Our subsidiary Oschatz Services & Solutions s.r.o. (OSS) pulls out all the stops to keep downtimes at your plant to an absolute minimum. The speedy availability of spare parts, which can be installed on site by our specialists if required, helps us ensure that your plant can resume production as quickly as possible. The components are built or repaired in the OSS manufacturing facility in Vysocˇany, Praha. Total floor space: 1,650 m2 (17,760 ft 2). A water tube boiler made by Oschatz is professionally transported to be shipped. What our service provides: The quickest possible plant availability in the event of breakdown or repair Highly qualified repair personnel with plant-specific know-how 24/7 emergency service Consulting services from our team: Optimisation of operating costs Improved technical and personnel planning of resources and costs Planning of environmental protection measures Conversion of furnaces Performance-enhancing adjustment of steam parameters Our service team is ready to help you around the clock. The OSS manufacturing facility in Vysocˇany Praha ensures the speedy availability of spare parts. Our service team do their utmost to keep plant downtimes as short as possible.

Oschatz GmbH Westendhof 10-12 45143 Essen Germany Phone +49 201 1802-0 Fax +49 201 1802-165 www.oschatz.com Production plant in Nanjing, China Production plant in Kocaeli, Turkey Oschatz has been producing boilers and waste heat systems in the Turkish region of Kocaeli, not far from Istanbul, for customers all around the world since 1997. In 2011, production was expanded and relocated to a new site. The new premises of around 60,000 m² (646,000 ft²), situated right by the sea at a deep-water port, provide perfect conditions for production and transport of the components. Oschatz products are manufactured in accordance with ASME standards, the Pressure Equipment Directive, TRD/AD standards and ISO 9001 on an area of about 10,000 m² (108,000 ft²) in four production buildings up to 22 metres high. The cornerstone for the second phase of construction was laid in July 2012. To be able to serve the markets in Asia, Australia and Oceania quickly and cost-effectively, Oschatz has maintained a production plant in Nanjing, China, since 2005. On premises extending to 50,000 m² (538,000 ft²) with a link to the port of Changjian, the company has seven production bays with a total floor space of 15,000 m² (161,000 ft²) producing waste heat boilers and cooling stacks in accordance with Chinese GB standards, ASME standards, TRD/AD standards and ISO 9001. About 600 employees work here in sales, engineering/design, in production, finance and procurement.