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(P =22 kg/cm2 & 51.35 m3/hr ) and this solution is fed to the shell side of E-104.

PRE-CONCENTRATOR FEED DETAILS

COMPONENT Urea NH3

CONCENTRATION(wt.%) 70.65 2.12

MASS FLOW RATE (kg/hr) 161026 4831

CO2 0.42 966 Hydrolyzer feed contains following component of different concentrations namely:WATER 26.81 61096 TOTAL MASS FLOW RATE 227919

VACUUM PRE-CONCENTRATOR

10-V-104

10-E-104

Sight Glass

10-L-104

PROCESS PARAMETERS
FLUID CIRCULATED SHELL SIDE (INLET) SHELL SIDE (OUTLET) TUBE SIDE (INLET) TUBE SIDE VAPORS (OUTLET) TUBE SIDE LIQUID (OUTLET) NH3-CO2-H2O (MIXED PHASE) NH3-CO2-H2O (MIXED PHASE) UREA SOLUTION NH3-CO2-H2O (VAPORS) UREA SOLUTION OPERATING PRESSURE (Kg/cm2g) 18.3 18.3 0.34(abs) 0.34(abs) 0.34(abs) DESIGN PRESSURE (Kg/cm2g) 24 24 1.8 & F.V 1.8 & F.V 1.8 & F.V OPERATING TEMPERATURE (C) 130 115 86 86 102 DESIGN TEMPERATURE (C) 165 165 132 132 132 MASS FLOWRATE (Kg/hr) 173588 173588 208049 17432 190617

VACUUM PRE-CONCENTRATOR OUTLET(BOTTOM)

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

Urea
NH3 CO2 WATER TOTAL MASS FLOW RATE

84.48
0.40 0.10 15.03

161026
757 188 28646 190617

VACUUM PRE-CONCENTRATOR OUTLET (TOP)

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

Urea
NH3 CO2 WATER TOTAL MASS FLOW RATE

10.92 2.09 86.99

4074 778 32450 37302

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

Dimensions of vacuum pre-concentrator

DIMENSIONAL PARAMETERS OF V-104

TAG NO 10-V-104 Manufacturer SUNGJIN GEOTEC CO. LTD Capacity 85.5 m3 Length - 5139 mm Weight 29600 kg (Empty) & 29600 kg (operating weight)

Internal Diameter 4700 mm Shell Thickness 13mm 2:1 Elliptical Head Thickness 16mm(normal), 13.6mm(min.) Insulation ROCKWOOL INSULATION THICKNESS- 70mm

DIMENSIONAL PARAMETERS OF E-104

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

Internal Diameter 3302 mm Shell Thickness 36mm TUBES Number- 2162 O.D- 2 Thickness- 2.1082mm Length- 4293mm Pitch- 63.5mm(triangular)

DIMENSIONAL PARAMETERS OF E-104

FERRULES Number- 2162 O.D- 2 Thickness- 3.5mm Length- 400mm BAFFLES(25% H CUT) Number-4 Baffle Space- 700mm Impinging Baffle-1 Tie Rods- 22 (16) Insulation ROCKWOOL INSULATION THICKNESS- 70mm

DIMENSIONAL PARAMETERS OF L-104

TAG NO 10-L-104 Manufacturer SUNGJIN GEOTEC CO. LTD Capacity 17m3 Length - 3587mm Weight 3900Kg (Empty) & 7310Kg (operating weight) Internal Diameter 1550mm Shell Thickness 8mm 2:1 Elliptical Head Thickness 8mm(normal), 6.8mm(min.) Insulation ROCKWOOL INSULATION THICKNESS- 70mm

GAD

GAD

NOZZLES & CONNECTION DETAILS

NOZZLE NO. N1 N2 NOMINAL SIZE 46 16 SERVICE VAPORS OUTLET UREA SOLUTION INLET

N3
N4 N5 CN1

12
16 16 2

UREA SOLUTION OUTLET

NH3 CO2 H2O INLET NH3 CO2 H2O OUTLET LEVEL CONNECTION

CN2
CN3 M1 SG1

2
2 24 14x600

THERMOCOUPLE CONNECTION
PRESSURE INDICATOR CONNECTION MANHOLE AND DAVIT SIGHT GLASS

SG2
D V PG1,2

14x600
3/8 3/8 3/4

SIGHT GLASS
DRAIN VENT PRESSURE GAUGE

TW1,2

THERMOWELL

MATERIAL SPECIFICATION (V-104 & L-104 )

SHELL PADS SHELL FLANGE NOZZLE CHECK SA240-316L SA266-2 + 316L SA312-TP316L/SA240-316L

NOZZLE FLANGE SKIRT

STUD BOLTS AND NUTS NOZZLE MANHOLE GASKETS GIRTH FLANGE NOZZLE MANHOLE INTERNAL SETTING BOLTS/NUTS

SA182-F316L SA240-316L/SA516-70
SA193-B8/SA194-8 AISI JACKETED ASBESTOS FREE SPIRAL WOUND (14.5) 316L S.S IS 1367 PART 1 & 3 IS 3757 CLASS 8.8 GALVANIZED HIGH STRENGTH BOLT

MATERIAL SPECIFICATION (E-104)

SHELL PADS TUBE SHEET TUBES SA240-316L SA965-316L SA213-TP316L

BAFFLES OR SUPPORT TIE ROD

SPACER IMPINGMENT BAFFLE SHELL NOZZLE NECK SHELL NOZZLE FLANGE STUD BOLTS AND NUTS STATIONARY MANHOLE GASKET SHELL CHANNEL END NOZZLE FERRULES

SA240-316L 316LS.S
SA213-TP316L SA240-316L SA240-316L SA182-F316L SA193-B7/SA194-2H SA193-B8/SA194-8 316L SS JACKETED ASBESTOS FREE SPIRAL WOUND (t4.5) SA213-TP316L

EXTERNAL INSPECTION OF VACUUM PRE-CONCENTRATOR

S.N. 1.

Description of Activity for External Inspection of Vacuum Pre-concentrator Check the conformity of the gaskets between the separator , the exchangers and holders to the mechanical drawings and if the relevant flanges are tightened .

YES

NO

2.
3.

Check that two sight glasses have been provided at holder and they are easily accessible to see the level.
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. 1. 2.

Description of Activity for Internal Inspection of Vacuum Pre-concentrator Check the planarity of liquid distributor. Perform the water test of liquid bell distributor in order to check if its holes are free. Moving the ferrules by hands , check if all are well fixed into the tubes. 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.

YES

NO

3. 4.

INTERNAL INSPECTION

S.N.

Description of Activity for Internal Inspection of Vacuum Pre-concentrator

YES

NO

5.
6. 7.

Verify that the inlet pipe is tangential and stiffener rings has been provided.
Verify that vortex breaker has been provided in holder. Box up the man hole by putting a new gasket.

THANK YOU

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