MAINTENANCE PROCEDURE
MUHAMMAD REHAN KHANMAINTENANCE ENGINEER
HCL synthesizer Furnace Overhaul
R-1660 A/B
HCl Synthesizer Furnace (R-1660a/B)Process Description: Straight Through Synthesis
Maximum feed temperature for H2 and Cl2 is 700C
The burner consists of two concentric tubes, with Cl2 flow through the inner tube and H2 through the outer annulus.
Above the burner, the gases are ignited and burn to produce hydrogen chloride gas. The H2 flow is always greater than the Cl2 flow by at least 5%.
The Hydrogen chloride gas at a temperature of 2000-25000C flows from the combustion chamber into an integral isothermal falling film absorber
The heat of combustion is 0.7 KWh per Kg of HCl and the heat of absorption in water is 0.5 KWh per Kg of HCl. The combustion chamber cooling system and the absorber cooling system each removes about half of the heat generated.
The vent gases contain less than 0.5 ppm HCl.
Vendor: Nantong Long-Trust Graphite Science & Technology Development Co., Ltd.
HCl Synthesizer Furnace (R-1660a/B)Furnace Assembly:
Capacity : 90 tons/day of 31% HClMaterial: GraphiteDesign Pressure: 0.10 MPaG (-500 mmH2O)Design Temperature: 200COperation: 8000 hr/year
Tail Tower:Material: GraphiteDesign Pressure: 0.06 MPaGDesign Temperature: 50C
Fan:Type: CentrifugeMaterial: FRPCapacity: 300 m3/hrInlet Pressure: -200 mmH2ODesign Pressure: 0.06 MPaGKw – 2900 rpm
Synthesis
Receiver
Cooling
Absorption
Denso Meter
RD
Burner Housing
HCl Synthesizer Furnace (R-1660a/B)
Synthesis
Receiver
Cooling
Absorption
Denso Meter
RD
Burner Hosing
RD
1.2bar Bursting pressure Denso meter
Absorption blocks (6)
Cooling blocks (10)
WeirBlocks are made of graphite with addition Bakelite (Phenol-formaldehyde resin) which is no more than 12 percent
HCl Synthesizer Furnace (R-1660a/B)
Synthesis
Receiver
Cooling
Absorption
Denso Meter
RD
Burner Hosing
Tail gas towerBurner assembly
H2 tube Cl2 tube
Burner arrangement
HCl Synthesizer Furnace (R-1660A/B)
Furnace Part Item Code Description
Burner Assembly
4705.1660.0001 Chlorine Burner- highly pure quartz
4705.1660.0002 Hydrogen Burner- highly pure quartz
4705.1660.0003 Burner support for Cl2 impregnated graphite
4705.1660.0004 Burner support for H2 impregnated graphite
4705.1660.0005 Connector tube -impregnated graphite (Nozzle)
Sight glass assembly
4705.1660.0006 Compressed plate for sight glass
4705.1660.0007 Compression board for sight glass
4705.1660.0008 Sight glass
4705.1660.0009 Sight glass
RD / access.
4705.1660.0010 Safety Disc
4705.1660.0011 Spacer of Safety disc
4705.1660.0012 Board of safety Disc
SPARES IN WAREHOUSE
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
A. DISMANTLING OF ABSORPTION SECTION1. Remove RD cover
2. Remove Rupture Disc
3. Remove Pressure equalizer ring
RD
Pressure Equalizer ring
RD Cover
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
A. DISMANTLING OF ABSORPTION SECTION4. Remove associated piping
5. Mark and remove all graphite nozzles
6. Removed furnace top shell
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
A. DISMANTLING OF ABSORPTION SECTION7. Mark orientation of Denso meter
8. Install clamp on Denso meter and rigged down it to ground
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
A. DISMANTLING OF ABSORPTION SECTION9. Remove shell of Absorption section
10. Mark block number and orientation on all 6 blocks
11. Remove and shift all blocks to ground shell was removed and placed to ground for cleaning and painting
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
B. DISMANTLING OF COOLING SECTION12. Remove second shell of cooling water.
13. Mark & remove cooling section blocks using a clamp of different diameter
14. Place all blocks one by one on soft rubber sheet (Total 10 blocks)
Clamp for removal Marking
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
B. DISMANTLING OF COOLING SECTION15. Remove Weir shell and then weir block
Weir block shell
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
C. TAIL GAS SCRUBBER REMOVAL16. Remove and rigged down the tail gas scrubber to ground
17. Dismantle tower on ground
18. Replace packing of tower
Rigging arrangement
Tail gas tower
Tail gas tower
Packing
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
RepairsRepairs that can be done are:
• Broken collar of absorption block• Repair of down comers of
absorption block• Cracks on weir block• Repair of tail gas scrubber nozzle• Replacement of Tail gas scrubber
packing• Power brushing & painting of shells
Repair kit
MAINTENANCE ACTIVITYLEAK TEST OF BLOCKS
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
D. BOX UP OF FURNACE19. Install Tail gas tower
20. Install weir block and cover
21. Install Cooling section
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
MAINTENANCE ACTIVITYQUALITY HOLD POINTS
Mark clearly number and orientation of all blocks
All graphite nozzle to be removed before removal of shells
All blocks to be placed on soft ground.
Top of blocks to be covered all the time
During installation of cooling blocks, nozzles of all blocks should be aligned. Long stick/rod can be used after every block installation to check alignment.
All blocks should be balanced and leveled. Bubble level can be used to check for any inclination.
Cleaning of clamp/ring after every block rigging in order to remove dust/rust.
There is only 3 mm clearance between shell and graphite blocks.
All blocks are inserted into each other making a male/female combination.
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
Outer H2 Tube
Inner Cl2 Tube
E. REPLACEMENT OF BURNER
H2 tube Cl2 tube
Burner arrangement Burner Housing
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
E. REPLACEMENT OF BURNER1. Remove associated piping of burner assembly
2. Remove Hydrogen and Chlorine tube support plates and tube holders
3. Clean tube holders
H2 tube holder
Cl2 tube holder
H2 tube holder Cl2 tube holder
Cleaning of tube holders after removal
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
E. REPLACEMENT OF BURNER4. Assemble the burner as per the following arrangement:
From top to bottom: a. H2 tube holderb. Cl2 tube holderc. H2 tube support plated. Cl2 tube support plate
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
E. REPLACEMENT OF BURNER4. Insert H2 and CL2 burner tubes into the assembly
5. Align tubes with holders and supports
Insertion
Alignment
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
E. REPLACEMENT OF BURNER6. PTFE tape is compact inserted between the H2 tube and tube holder
7. With the help of hydrogen tube support plate, hydrogen tube assembly is inserted into the furnace very precisely through tie-screws
Use wood for compacting PTFE tape
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
E. REPLACEMENT OF BURNER8. Similar PTFE tape packing is done between Cl2 tube and tube holder
9. Now Cl2 tube is installed with the help of tube holder and support plate
MAINTENANCE ACTIVITYJOB METHOD STATEMENT
E. REPLACEMENT OF BURNER10. Install back the piping 11. Check burner tubes assembly from sight
glass nozzle
THANK YOU
MUHAMMAD REHAN KHANMAINTENANCE ENGINEER