Improved Valve Maintenance and Quality for Delayed...

Improved Valve Maintenance and Quality for Delayed Coking

Experience from related industries

Dr. Martin FrankCEO

SchuF was founded by Ludwig Schwärzel und (and) Josef Frank . Their initials were used to form the company name…

Sch

SchuF HQ Frankfurt, Germany - 1911 and 2003

uF

SchuF Company Information

• SchuF today operates across the globe and is represented in over 75 countries

• SchuF has designed and delivered over 1 million valves – mostly highly customised and engineered for specific processes

• The key areas of industry focus for SchuF are the Chemical, Petrochemical, Pharmaceutical, Oil, Gas & Refining, and Plastics and Polymer industries

• SchuF is the inventor of many valve types (Bottom Outlet, Lift Plug, Tank Emergency Shut-off etc.), but is best known for designing special valves for severe media, difficult operating environments or new processes

• SchuF valves are characterised by:

Unique designs

High performance and longevity

Use of high quality materials

German precision engineering

Unique designs

High performance and longevity

Use of high quality materials

German precision engineering

• Today SchuF has five full scale manufacturing plants in Germany, Ireland, USA, Brazil and India with 300 employees of which over 50 are design engineers.

Skippack, PA, USA 1967 Indaiatuba, SP, Brazil 2006

Coimbatore, India, 2007Cork, Ireland 1991

…Worldwide

Industrial Processes to be Reviewed

• Polymers & PTA

• Gasification

• Heavy Oil Upgrading

• Coal Liquefaction

• Mining

• Coking

High flow rates

Pressure drops of up to 160 bar

Slurries with 50% + solids content

Flashing

Corrosion & erosion

Vibrations

Non standard valve alignment

Crystals in process

Severe Operating Conditions

SchuF designs valves for industries that operate under severe conditions. Our valves typically have to counter the effects of two or more of the following factors:

Polymers andPTA (Purified Terephtalicacid)

PTA Crystalliser Arrangement

SchuF designTypical design

Main Differences

● Body geometry constant acceleration

● Flow to Open i.e. flashing takes place outside and no direct stream

● material and surface treatment selection

Designed to Meet Process Requirements

• Spindle protector to improve particle size distribution

• SchuF x³ bell curve to enhance controllability between optimum and max

• 3 Phase flow calculation

Unlike commonly used ISA formulas

SchuF's Cv calculation is a true 3 phase programme

SchuF Proprietary Features

Polymer Filter Switching Valves

Multiport Switching Valves

Mining – Alumina, Copper& Nickel

Alumina Production Challenges

Alumina is produced by refining hydrate or trihydrate bauxite:

•Bauxite is an extremely dirty, and erosive substance

•The process results in the build up of a hard abrasive scale

•Valves must be able to handle high solid contents

•It subjects machinery to thermal and mechanical shock

•Operator abuse is common

•The Alumina production process destroys valves rapidly

SchuF Alumina Approach

Through a combination of design, process knowhow and materials used, valve life and efficiency can be improved. Some examples include:

• Disk grinding mechanism

• Integral body and bonnet

• Renewable seat with hardened facing

• Graphite packing and spring washers

• Reinforced graphite or spiral wound gaskets

Oxidative Leaching Mining Processes

Process Name Developed by Temperature Particle size Pressure Used forTotal pressure oxidation Placer Dome 225°C n/a 3400 kPa Copper, NickelChlorine enhanced pressure leeching (CSEL) Cominco 150°C 40 microns 1100 kPa Copper, GoldDynatec Dynatec 150°C 30-40 microns NickelAAC/UBC Anglo American 150°C 10-20 microns 700 kPa Zinc, CopperActivox Western Minerals 100-110°C 10-15 microns 1000 kPa Copper, NickelAlbion Mount Isa Mines 85-90°C 5-15 microns CopperNSC (Nitrogen Species Catalyised) Sunshine 125°C 400 kPaAmonia Leech Processes Arbiter, Coloso CopperAcid Leech Process Sherrit 120° - 225°C Nickel, PlatinumPlatsol Platsol 220°C 3200 kPa Cooper, GoldIntec Intec 85°C atmp. Cooper, Gold

• Autoclave isolation Models 71KS and 50• Autoclave vent valve Model 74CS• Flash Cooling letdown Model 74CS• Autoclave discharge letdown Model 74CS

• Flash Cooling letdown Model 74CS• Autoclave discharge letdown Model 74CS• Autoclave Feed Model 28KS• Drain Valves Ram Seal

Valves provided by SchuF

Valves provided by SchuF

Angle Control Valves for Activox Process

Control valve for autoclave let down

Autoclave Isolation for Copper & Nickel Mining

Y Globe Control ValveAngle Control Valve

GasificationClean Coal Technology

Gasification – Clean Coal Technology

Gasification Process

Gasification Process

o Coal

o Lignite

o Petcoke

o Gas

o Oil Residue

o Biomass

o Orimulsion

SynGas

(CO+H2)

o Electricity

o Steam

• Ammonia

• Methanol

• Hydrogen

• Other chemicals

oTown Gas

oTransportation Fuel

IGCCCombined

Cycle Power Generation

Chemicalfeedstock

Condition/Distribution

Liquefaction

• Gasification transforms feedstocks and residues to higher valve energy sources

Lurgi/Sasol Gasifier

Shell Gasification Process – Feed Control Valve

• Application: Coal gasification dry feed

• Medium: Pulverised coal with nitrogen

• Valve design: incorporates many features including:

special trim design

unique disk contour

only special hard metal materials are used

yoke bellows construction

easy to replace trim parts

Black Water/Gas Control Valves

• Application: Coal gasification dry feed

• Medium: Inert gas and gas particles

• The design incorporates many special features including:

special trim design

unique control contour

only special hard metal materials are used

energy dissipation mechanism

easy to replace trim parts

• Application: Black Water Gasification

• Medium: Black water

• The design incorporates many special features including:

the medium is injected into the flash drum below water level

design funnel to reduce pressure

continuous accelerating design of body and funnel

special hard metal materials are used

design leads to lower wear and tear

Siemens Gasification Process – Feed Control Texaco (GE) Gasification Process –Control Let Down

Other Gasification Valves

• Application: Feed Start-up Diverter Valve

• Medium: Coal dust and particles• The Diverter valve design features :

No dead space Intrinsic regulation mechanism Integral flushing ports

• Application: Black Water Diverter Valve

• Medium: 70% solids coal slurry• The Diverter valve design features :

No dead space Hard faced sealing surfaces Integral flushing ports

Heavy Oil Upgrading & Coal Liquefaction

Severe conditions3 phase flow,Large pressure differences with P1=Pv i.e. extreme flashingHigh temperatures (material stress)Difficult media (coal, vacuum bottoms, PTA etc.)

SchuF Experience:• Valve design and construction (e.g. opening out or in control valve, diverter, angleor wedge plug instead of ball valves)•Material selection (Tungsten Carbide, Ceramics, Titanium Grade 5, C12, Hastelloy, TiN coating etc.)•Best 3 phase sizing programme•CFD simulations•Collaboration with KAB engineers for heavy oil upgrading and coal liquefaction

Liquefaction and Heavy Oil Upgrading

5-way diverter valve

Blocking valve

Control valve

HPHS

to MPHS

Flushing valve

Let Down Service

Heavy Oil Upgrading Switching Valve ++

Vacuum Residue Switching

Kohle Öl Anlage Bottrop

Hydrocracker Let Down

Delayed Coking

Bringing It all Together

• Custom design• Material choice• Process adjustment

• Process Knowledge• Special valve design• Special materials• Process adjustment

• Custom design• Material choice• Process adjustment

Gate Valve for Coking (Petrobras)

Coker Portfolio I

IsoPlug SwitchPlug

Coking Defence System (CDS)

Flushing ports Purge to Drain Valve Retractable Bottom

Common in Polymer, and slurry type industries

Common in the chemical and pharmaceutical industry

Common in Mining industry

Coker Valves II - Injection & Quench Valves

III - High Pressure Decoking Control Valve

• Operating Position Features:

guarantees minimum flow to pump in the closedposition

Equal % flow control of water to pump and some minimum recirculation in partially open position

No piston in flow path. Absolutely minimum pressure loss (₯). No wear on seat or contour in open position

• Operating conditions: 3000 PSI, 85°C

• Typical sizes: 2” to 6” (or higher upon request) ASME2500

• Body Material: Carbon Steel WC6 or C12

• Superior design – few moving parts

• Low maintenance valve due to reduced wear and tear

• Available with electric, pneumatic or hydraulic actuators

• Can be modified according to customer wishes

IV - New Coker Valve Assembly

Conventional Coker Set Up for isolation, steam, quench, condensate, and drain

Steam, Quench, Isolate Multi-Valve Assembly

The new SchuF assembly replaces valves, multiple functions and all unnecessary piping minimising dead space

This slide is to be presented during the conference

Valve Assembly Comparison to Traditional Layout

The drawings below illustrate the space saving of the valve assembly compared to the traditional piping and multiple valves approach. In additional the valve assembly minimises dead-space and number of potential leak points.

SchuF Valve Portfolio

Thank You!

Improved Valve Maintenance and Quality for Delayed...

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