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| GB150-2011 | Steel pressure vessel |
| GB151-2014 | Shell and Tube Heat Exchanger |
| NB/T47003.1-2009 | Steel welded atmospheric pressure vessel |
| NB/T4710-2014 | Steel tower vessel |
| GB50341 | Petro-chemical design specification for of vertical cylindrical steel welded storage tanks |
| HG/T20580-2011 | Specification for Design Base of Steel Chemical Vessels |
| HG/T20581-2011 | Specification for Materials Selected of Steel Chemical Vessels |
| HG/T20582-2011 | Standard of Strength Calculationfor Steel Chemical Vessels |
| HG/T20583-2011 | Specification of structural design for steel chemical vessels |
| HG/T20584-2011 | Technical Requirements for Fabrication of Steel Chemical Vessels |
| HG/T20592~20635-2009 | Steel pipe flanges, gaskets, fasteners |
| HG/T21514~21535-2005 | Carbon steel, low alloy steel manholes and handholes |
| JB/T4712.4-2007 | Vessel supports |
| HG/T20678-2000 | Specification on Design of Steel Shell with Liner |
| HG/T20676-1990 | Brick-plate Lining Chemical Equipment |
| HG21563~21572-1995 | Agitation transmission device System combination, selection and technical requirements |
2. The nominal diameter of the container and head should be of the standard series as much as possible.
Equipment flanges should be selected according to design conditions and should be standard flanges close to or one level higher than the pressure level. Non-standard design is allowed only when there is no standard for direct selection. When both plate and forging processing can be used, plate processing is preferred.
Manholes, hand holes, inspection holes, lifting ears, supports, sight glasses, etc. used on the equipment should be in accordance with standards or standard drawings as much as possible; bolts and nuts should be used in accordance with corresponding standards and commercial grades should be used as much as possible.
Main equipment selection
In the past, small and medium-sized sulfuric acid plants used independent sulfur melting tanks, filter tanks, filter aid tanks and intermediate tanks in the sulfur melting section.Currently, all newly built sulfuric acid plants are large-scale plants that use a rapid combination sulfur melting tank, which occupies a small area, has high thermal efficiency, saves investment, and is easy to operate and manage.
Technical characteristics table of sulfur melting tank
In order to ensure the start-up rate of the sulfuric acid plant, a liquid flow storage tank is set up in the sulfur melting section. Its liquid storage capacity is 7 days of production usage. The liquid storage tank is equipped with heating coils and external insulation facilities. The tank top is also equipped with external coils and insulation cotton to ensure the fluidity of the liquid.
Technical characteristics table of liquid sulfur storage tank
The sulphur refining tank is set up as a buffer and metering regulator. A vertical liquid sulphur pump can be installed by installing a sulphur refining tank, thus solving the problem of liquid sulfur leakage during transportation.
Technical characteristics table of sulphur refining tank
The sulfur incinerator has a simple structure and high volumetric strength. Sulfuric acid plants of various sizes at home and abroad generally adopt a steel horizontal cylindrical structure. The sulfur incinerator is lined with insulation bricks and refractory bricks, and a rain cover is installed on the top of the furnace. In order to allow the sulfur vapor and air enough time to mix, three retaining walls are set up in the furnace, with air inlet at the upper front end and air outlet at the rear end of the furnace body.
In order to ensure that sulfur vapor and air can be fully mixed and burned and avoid the formation of sublimated sulfur, an air inlet is set in the furnace. The air is sprayed into the sulfur incinerator at the same time as liquid sulfur through the volute air inlet chamber and the rotating device. Secondary air inlets are set before and after the retaining wall to make the combustion of sulfur and air as complete as possible and adjust the furnace temperature. In order to ensure complete and efficient combustion, the sulfur gun adopts a mechanical atomization type to ensure that the liquid sulfur is fully atomized and burned.
The ends of the sulfur incinerator are sealed with flat plates. Air enters from the ends and reacts with the atomized sulfur after passing through the cyclone device.
Technical characteristics table of sulfur incinerator
The drying and absorption tower refers to the drying tower, the first absorption tower and the second absorption tower.
The main structure of the drying and absorption tower is basically similar.The tower body is a vertical cylindrical structure, with carbon steel lining and acid-resistant bricks.The packing support device adopts a combined spherical arch with a large opening rate, and is covered with 3000mm ø76 iso-saddle ring packing. The tubular acid distributor is buried in the foam-catching layer of ø38 iso-saddle ring packing to reduce the acid foam generated during acid distribution. A high-efficiency demister is installed on the upper part of the tower to collect acid foam and acid mist in the gas.
The tubular acid distributor is made of acid-resistant alloy and has a tubular downward spraying structure, consisting of a main pipe and multiple branch pipes. The acid is pumped into the main pipe by the acid pump, and then distributed to each branch pipe and flows out from the small holes. Due to a certain pressure, the acid distribution in each small hole is relatively uniform.
The tubular acid distributors has a simple structure, light weight, and is easy to manufacture, install and maintain. The number of acid separation points per unit area is 27/m2, which is relatively reasonable. The bottom of the tower is a flat bottom structure, and the acid outlet is at the lowest point of the bottom.
In order to improve the defoaming efficiency, the drying tower adopts a wire mesh defoamer. The first and second absorption towers use column fiber demisters. It is used in many domestic sulfuric acid plants and has good effects when the process conditions are guaranteed.
Technical characteristics table of drying and absorption tower
The converter is a five-stage conversion type with a built-in catalyst and a vertical cylindrical external heat preservation structure. The converter shell is made of carbon steel and lined with clay insulating refractory bricks. The equipment is installed with several columns, partitions and grilles from bottom to top. The columns and grilles are mainly made of heat-resistant cast iron, the partitions and top plates are made of 304 stainless steel, and semicircular tubes are added as expansion rings. This structure not only ensures no air leakage but also solves the problem of thermal expansion. Each layer of partitions is welded into a whole to ensure that the gases in each layer do not flow through each other. The grid is placed on the column boss, and a layer of heat-resistant ceramic balls and stainless steel wire mesh are laid on it, and then the catalyst is placed. The top cover material is made of stainless steel and reinforced with angle steel. A gas guide device is provided at each air inlet to ensure uniform distribution of the gas entering the catalyst layer.
Gas distribution throughout the catalytic layer is one of the key design issues. Reasonable equipment structure design helps achieve higher conversion rates and longer operating cycles as required by process conditions.
The converter is designed based on the principle of economy and applicability. It can be used stably for 30 years.
Technical characteristics table of converter
The shell-and-tube heat exchanger adopts a scaling tube large hole plate heat exchanger, and the shell is made of low alloy steel and carbon steel. The shell side of the thermal heat exchanger is enlarged and a gas guide plate is added to make the air flow evenly distributed. The bottom of the cold and hot heat exchanger is lined with acid-resistant bricks to prevent condensed acid corrosion.
The characteristics of this heat exchanger are: the gas in the tube side and shell side is subjected to enhanced heat exchanger through the turbulent system, the overall heat exchanger coefficient is high, the production is stable and reliable, and it is especially suitable for use in large and medium-sized sulfuric acid plants.
Technical characteristics table of heat exchanger
Technical characteristics table of heat transfer II
Technical characteristics table of heat transfer III
The waste heat boiler adopts a specially designed natural circulation fire tube boiler. The boiler is divided into upper and lower drums and front and rear smoke boxes. The upper drum is a steam drum, which is connected to the lower drum through ascending and descending pipes. The ascending pipe also serves as the support of the steam drum. The upper and lower drums are made of steel plates (20g-GB713) rolled and welded. An evaporation heating surface (fire tube) is arranged in the lower drum.
The fire tube specification is DN50.The tube sheet adopts flexible tube sheet, the furnace gas side of the front tube sheet is protected by special heat-resistant concrete, and the furnace gas inlet end of the fire tube is equipped with a high-strength, heat-resistant corundum casing to ensure that the tube sheet withstands smaller temperature difference stress.
In addition, the lower drum is equipped with two supports, one of which is a fixed support at the furnace gas inlet end and a sliding support at the other end. The bottom of the sliding support uses a polytetrafluoroethylene plate as a support pad, which has a small friction coefficient and is conducive to the thermal expansion of the furnace body.
Equipment arrangement
The equipment layout of this device is combined with the actual situation, taking into account the characteristics and requirements of process, operation, management, maintenance, etc., and the specific performance is as follows:
1. The equipment layout should be arranged according to the process sequence as much as possible, and strive to make the pipeline direction reasonable and the appearance neat.
2. The equipment is arranged in the open air. Except for the raw material section, sulfur melting section and fan room, the rest of the equipment is arranged in the open air.
3. When arranging equipment, similar equipment is arranged in a centralized manner. For example, the dry absorption section, drying tower, and absorption tower are arranged on the same axis, and the acid cooler is also arranged in the same area, which is convenient for operation and maintenance; in the conversion section, the converter is the center, and the heat exchange equipment is arranged around it. Thermal engineering professional equipment is also arranged as centralized as possible to facilitate piping.
4. When arranging equipment, fire protection, operation and maintenance channels are fully considered. For example, a channel is set up next to the dry absorption tower platform to facilitate the cleaning and replacement of the tower filler in the future. A maintenance area is reserved on one side of the converter to facilitate the replacement and filling of the catalyst.
5. In accordance with the relevant regulations on the production and management of hazardous materials, the finished sulfuric acid storage tank and the sulfur storage tank must be equipped with a cofferdam to prevent the leakage of sulfuric acid.
Main equipment design, manufacturing and inspection standard requirements
1)sulfur incinerator
1. This equipment is manufactured, constructed, tested and accepted in accordance with NB/T47003.1-2009 and HGJ227-84.
2. Arc welding is used for welding, and the electrode model is E4303.
3. Except as noted in the figure, the types and dimensions of welding joints shall comply with the provisions of GB/T985.2-2008. The waist height of fillet welds shall be based on the thickness of the thinner plate. The welding of flanges shall comply with the provisions of the corresponding flange standards.
4. After the shell is manufactured, a kerosene leakage test is carried out and internal masonry can only be carried out after passing the test.
5. Before bricklaying, use water glass to paste two layers of δ=3mm asbestos board on the inner wall of the shell.
6. The furnace baking and cooling must be carried out according to the furnace baking curve.
2)drying and absorption tower
1. This equipment is manufactured, installed and accepted in accordance with the conditions of NB/T47003.1-2009 and HG/T 20678-2000.
2. After the shell is manufactured, a kerosene leakage test shall be carried out and brick laying can only be carried out after passing the test.
3. The tower installation elevation error is less than 5mm, and the vertical error is 1/1000 of the height.
4. Before filling the ceramic ring, it should be cleaned and dried, and no debris or sludge should be brought into the tower.
5. Filling method: First pile up the main filling, and after the acid separation device is installed, pile up the defoaming filling. When loading the filling material, it is required to lift and place it gently to avoid breaking.
6. Use a drawer-type wire mesh demister, and the manufacturer providing the product will be responsible for the installation.
7. After the equipment is manufactured, the outer surface will be painted with IPN8710 series anti-corrosion paint.
3)Concentrated sulfuric acid circulating tank& underground tank
1. The shell of this equipment is manufactured, tested and accepted in accordance with GB/T985.2-2008 and HG/T20678-2000.
2. The steel parts are welded by electric welding, the welding rod is E4303, and the weld height is the thickness of the thinner part of the two welds. After welding, all welds are checked with kerosene.
3. The lining bricks of this equipment shall be constructed, inspected and accepted in accordance with HGJ20229-2017.
4)Converter
1. This equipment is manufactured, tested and accepted in accordance with NB/T47003.1-2009.
2. The steel parts are welded by electric welding, the welding rod is E4303, and the weld height is the thickness of the thinner part of the two welds. After welding, all welds are checked with kerosene.
3. The lining bricks of this equipment shall be constructed, inspected and accepted in accordance with HGJ20229-2017.
5)Heat exchanger
1. The shell and pipes of this equipment are manufactured, tested and accepted in accordance with NB/T47003.1-2009 and B151-1999.
2. Electric welding is used for welding, the electrode number is E4303, and the welding joint type is in accordance with the provisions of GB985.1-2008.
3. Before connecting the heat exchange tube to the tube sheet, the shell expansion joint should be pre-compressed by 4 to 5 mm.
4. When installing the tube sheet, the upper and lower tube sheet surfaces should be parallel to each other and perpendicular to the center line of the tubes.
5. The cross-sectional area at both ends of the heat exchange tube should be perpendicular to the center of the tube.
6. After the heat exchange tube is connected to the tube sheet, the connection needs to be tested with 0.055MPa air pressure for 30 minutes. There must be no leakage. If the connection is found to be loose, reconnection is allowed, but the number of reconnections shall not exceed two times.
7. After the shell is completed, use kerosene and chalk powder to check the tightness of the weld.
Quality assurance
Quality assurance
1. The general contractor guarantees that the equipment parts supplied are brand new and produced with first-class technology, and fully meet the quality, specifications and performance requirements stipulated in the agreement. The general contractor guarantees that its equipment will have satisfactory performance during its service life under the conditions of correct installation, normal operation and maintenance.
2. If any problem occurs with the equipment during the warranty period, the general contractor shall respond within 24 hours after receiving the notification (by phone, email or fax, etc.); for defects that do not affect the safe operation of the equipment, if no defect is remedied or a relevant rectification plan is formulated within 7 days, the buyer may take necessary remedial measures, but the risks and costs shall be borne by the general contractor.
3. The termination of the quality assurance period cannot be regarded as the release of the liability for potential defects that may cause damage to the equipment. Potential defects refer to potential defects caused by design, materials and manufacturing processes that occur when the equipment is operated and maintained as required under normal operating conditions after the end of the quality assurance period, rather than normal aging and wear. For the parts with potential defects, the general contractor shall promptly repair or replace them free of charge.
Warranty period
The warranty period is 12 months after the equipment is put into use or 18 months after the equipment arrives, whichever comes first. The warranty period for installation projects is 12 months.
Unless otherwise specified, the performance assessment qualification date shall be based on the signature date of both the buyer and the general contractor on the performance assessment confirmation form, and the specific professional contents shall be implemented in accordance with the latest national standards.
The buyer clearly states the brand requirements in the bidding documents. The buyer has the right to trace the equipment and accessories that are installed inside the equipment before leaving the factory and whose brand and quality cannot be verified before on-site installation (such as bearings, etc.), which will automatically terminate after replacement.
If the high-temperature circulating acid pump and the acid discharge pump do not meet the requirement of 12 months of trouble-free operation, the general contractor shall be responsible for the repair. If the repair is not good, a new pump shall be replaced free of charge. The service life shall be recalculated from the date of replacement until the whole pump runs without trouble for 12 months, and the right of traceability will automatically disappear.
System life
The overall design life of the system is not less than 20 years, and the annual continuous stable operation time is greater than 8000 hours.
Environmental Protection
Environmental quality standards and emission standards implemented in the design
"Ambient air quality standard" GB3065-1996
"Environmental quality standard for surface water" GH3838-2002
"Integrated emission standard of air pollutants" GB16297-1996
"Integrated wastewater discharge Standard" GB20425-2006
"Standard of nolse at boundary of industrial enterprlses" GB12348-2008
"Noise control design regulations for chemical construction projects" HG20503-92
Main pollution sources and main pollutants
1)Main pollution sources and main pollutants
This design uses sulfur to produce acid. Solid sulfur iodine is melted, burned in air, and then converted into sulfuric acid. The brief process flow is as follows:
The main pollution sources and pollutant emission points of the 120t/d sulfur acid production project are detailed in the following block flow chart:
2)Types, emissions, components and concentrations of major pollutants
The quotation will include construction drawing design, equipment production, transportation (domestic), overseas installation fees, and system device startup guidance fees.
Related Certificates
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