Removal systems

In order to be 100% safe from a hydrogen explosion (sources passivation air, CO2), a hydrogen removal system is installed before the CO2 passivation air enters the stripper. 

Equipment. Partial-oxidation gasification section equipment in many plants consists essentially of (/) the gasification reactor (2) the waste-heat exchanger for heat recovery from the hot reactor gas or direct quench system (J) the economizer heat exchanger for further heat recovery (4) the carbon removal system for separating carbon from the reactor product gas and (5) the carbon recovery system for recycle of carbon. 

Mu/tihearth Furnace. Multihearth furnaces are most often used for incineration of municipal and industrial sludges, and for generation and reactivation of char. The main components of the multihearth are a refractory-lined shell, a central rotating shaft, a series of soHd flat hearths, a series of rabble arms having teeth for each hearth, an afterburner (possibly above the top hearth), an exhaust blower, fuel burners, an ash removal system, and a feed system. 

The commercial production equipment consists of a furnace, heat-exchanger tubes, a fractionating column packed with Rachig rings, a KCl feed, a waste removal system, and a vapor condensing system (Fig. 1). 

Carbon Dioxide Removal. The effluent gases from the shift converters contain about 17—19 vol % (dry) carbon dioxide (qv) which is ultimately reduced to a few ppm by bulk CO2 removal, followed by a final purification step. Commercial CO2 removal systems can be broadly classified as... 

Activated tertiary amines such as triethanolamine (TEA) and methyl diethanolamine (MDEA) have gained wide acceptance for CO2 removal. These materials require very low regeneration energy because of weak CO2 amine adduct formation, and do not form carbamates or other corrosive compounds (53). Hybrid CO2 removal systems, such as MDEA —sulfolane—water and DIPA—sulfolane—water, where DIPA is diisopropylamine, are aqueous alkaline solutions in a nonaqueous solvent, and are normally used in tandem with other systems for residual clean-up. Extensive data on the solubiUty of acid gases in amine solutions are available (55,56). 

The choice of a specific CO2 removal system depends on the overall ammonia plant design and process integration. Important considerations include CO2 sHp required, CO2 partial pressure in the synthesis gas, presence or lack of sulfur, process energy demands, investment cost, availabiUty of solvent, and CO2 recovery requirements. Carbon dioxide is normally recovered for use in the manufacture of urea, in the carbonated beverage industry, or for enhanced oil recovery by miscible flooding. 

Most commercial methanator catalysts contain nickel, supported on alumina, kaolin, or calcium aluminate cement. Sulfur and arsenic are poisons to the catalyst, which can also be fouled by carry-over of solvent from the CO2 removal system. 

FGG Gatalyst Goolers. Heat-removal systems have been used in commercial FCCUs since the early 1940s. The three basic designs are internal regenerator bed coils, external cods with ddute-phase upflow, and external cods with dense-phase downflow. 

Chromium Removal System. Chlorate manufacturers must remove chromium from the chlorate solution as a result of environmental regulations. During crystallization of sodium chlorate, essentially all of the sodium dichromate is recycled back to the electrolyzer. Alternatively, hexavalent chromium, Cr, can be reduced and coprecipitated in an agitated reactor using a choice of reducing agents, eg, sodium sulfide, sulfite, thiosulfate, hydrosulfite, hydrazine, etc. The product is chromium(III) oxide [1333-82-0] (98—106). Ion exchange and solvent extraction techniques have also... 

A bleed from the scmbbing system is sent to a sour slurry stripper. The water is then clarified and can be recycled to minimize the volume of effluent to be biotreated and discharged or evaporated. The acid gas from the acid gas removal system and from the sour slurry stripper is fed to a Claus plant, where salable elemental sulfur (qv) is produced. For maximum sulfur recovery and minimal sulfur emissions, the Shell Claus off-gas treating process (SCOT) is used. 

Classified removal of course material also can be used, as shown in Figure 16. In a crystallizer equipped with idealized classified-product removal, crystals above some size ate removed at a rate Z times the removal rate expected for a perfecdy mixed crystallizer, and crystals smaller than are not removed at all. Larger crystals can be removed selectively through the use of an elutriation leg, hydrocyclones, or screens. Using the analysis of classified-fines removal systems as a guide, it can be shown that the crystal population density within the crystallizer magma is given by the equations... 

Based on dryer cost alone, indirect-heat dryers are more expensive to build and install than direct-heat dryers designed for the same duty. As environmental concerns and resulting restrictions on process emissions increase, however, indirect-heat dryers are more attractive because they employ purge gas only to remove vapor and not to transport heat as well. Dust and vapor recovery systems for indirect-heat dryers are smaller and less cosdy to supply heat for drying, gas throughput in direct-heat dryers is 3—10 kg/kg of water evaporated indirect-heat dryers require only 1—1.5 kg/kg of vapor removed. System costs vary directly with size, so whereas more money may be spent for the dryer, much more is saved in recovery costs. Wet scmbbers ate employed for dust recovery on indirect-heat dryers because dryer exit gas usually is close to saturation. Where dry systems are employed, all external surfaces must be insulated and traced to prevent vapor condensation inside. 

Table 14-2 illustrates the observed variations in values for different packing types and sizes for the COg-NaOH system at a 25 percent reactant-conversion level for two different liquid flow rates. The lower rate of 2.7 kg/(s-m ) or 2000 lb/(h-ft ) is equivalent to 4 (U.S. gal/min)/ft and is typical of the liquid rates employed in fume scrubbers. The higher rate of 13.6 kg/(s-m ) or 10,000 lb/(h-fU) is equivalent to 20 (U.S. gal/min)/ft and is more typical of absorption towers such as are used in CO9 removal systems. For example. We note also that two different gas velocities are represented in the table, corresponding to superficial velocities of 0.59 and 1.05 m/s (1.94 and 3.44 ft/s). 

The equipment for the pollutant removal system includes all hoods, ducting, controls, fans, and disposal or recovery systems that might be necessary. The entire system should be engineered as a unit for maximum efficiency and economy. Many systems operate at less than maximum efficiency because a portion of the system was designed or adapted without consideration of the other portions (4). 

As with particulate removal systems, it is apparent that many choices are available for removal of gases from effluent streams. Table 29-5 presents some of the factors that should be considered in selecting equipment. 

Use dry SO, removal systems such as carbon absorption for sinter plants or lime spraying in flue gases. 

Use dry dust collection and removal systems to avoid the generation of wastewater. Recycle collected dust. 

Other Considerations Leakage of cold air into a settling chamber can cause local gas quenching and condensation. Condensation can cause corrosion, dust buildup, and plugging of the hopper or dust removal system. The use of thermal insulation can reduce heat loss and prevent condensation by maintaining the internal device temperature of the above the dew point (EPA, 1982). No pretreatment is necessary for settling chambers. 

Reduce Head on Liner and/or in Leachate Collection System Inspect Leachate Collection/Removal System or French Drain Repair Leachate Collection/Removal System or French Drain Temporary Cap... 

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