NEW SULFUR MELTING TECHNOLOGY Mark Gilbreath - USA.
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Transcript of NEW SULFUR MELTING TECHNOLOGY Mark Gilbreath - USA.
NEW SULFUR MELTING TECHNOLOGYMark Gilbreath - USA
COMPANIES• Devco
- Sulfur Forming Units- EPC Contracts and PM- Modular construction methods and experience
• River Consulting- Engineers for Material Handling, Balance of Plant , Marine, Electrical &
Controls• CTI
- Decades of Sulfur Technology and Operations- Former Freeport Sulfur staff experts- Proven Melter Technology
Established 1979 Offices: Tulsa, OK; Al-Khobar, KSA; Doha,
Qatar; Beijing, China Owned and operated California Sulphur
Company, Bay Sulfur Company & Devco Australia
Process Engineering, Project Engineering, Project Management, Project Controls, Procurement & Facilities Integration of Natural Gas & Refining Processes
Projects Range from Equipment sale to Turn-Key installation
SOUTH YOLOTAN TURKMENISTANPETROCHINA SULPHUR FORMING
Established 1981 Offices - Columbus, OH; New Orleans,
LA; Pittsburgh, PA; Tulsa, OK 230 + Designers, Engineers & Project
Managers Industries Served – Natural Gas,
Refining, Power, Food, Materials Handling, Marine
Project Management Project Controls Multidiscipline Engineering Design- civil, structural, mechanical,
instrumentation, electrical Control System Integration Procurement Estimating Construction Management
HI – CAP SULFUR MELTER SYSTEM
1950
Pit Melters Agitated Tank Melters
1964 1993
Agitated Tank Melters
Internal Coils External Heat Exchangers
Continuous Removal of Non-Meltables
Easy Clean Out Pump Tank
External Heat Exchangers
Freeport Sulphur Company
Freeport Research & Engineering CTI
1998
Submerged Combustion
Melting
SULFUR MELTING EXPERIENCE TIMELINE
CTI Melter, 1,000T/d
CENTRAL ASIA
MODULARIZATION – SULFUR MELTER PLANT• External Heat Exchangers – NO COILS IN
MELTER VESSEL• Thermal efficient – small melter vessel• Solids clean out during operation• HEX maintenance during operation
HI – CAP MELTER FEATURES –
• Designed for 155 stph dry basis, Higher moisture, Moderate acidity• No steam coils in melter vessel• Based on proven concepts• External Heat Exchanges (HEX) give high heat transfer coefficients• Installed spare Heat Exchanger and Sulfur HEX Pump• Melter tank elevated with concave bottom allows for continuous removal of
melter non-meltables to the pump tank• Pump tank designed for quick non-meltables removal while hot• Above allows longer periods between major turnarounds resulting in higher
availability• Simple controls – flow rate of solid sulfur feed
KEY FEATURES CTI SULFUR MELTER
• Tank, baffles and agitator all designed to create strong vortex
• Liquid height to diameter ratio sized for effective agitation
• Solid sulphur and high temperature liquid sulphur inlet feeds both directed & mix in vortex
• Vortex causes immediate immersion of sulphur solids in liquid sulphur, expeditiously wetting all surfaces, melting the solids
• Raised tank with conical bottom and sump to collect larger non-meltable solids.
• Continuous underflow constantly removes non-meltables creating a “Self-Cleaning” melter.
MELTER TANK DESIGN FEATURES
• High volume sulphur melting units with capacities up to 4,000 tons per day.
• External heat exchanger (HEX) gives high heat transfer coefficient, allowing high melting rates
• High circulation rate through HEX for efficient heating and melting
• All vessels and equipment are above ground.
• Vertical “in-tank” pumps.
• All molten sulphur is contained during unplanned shutdown.
• Customizable to meet specific customer requirements.
KEY MELTER SYSTEM COMPONENTS
CTI SULFUR MELTER DESIGN GA
AIR
FLOW PATTERNS - CTI SULFUR MELTER
Flow pattern of molten sulfur.
Vortex formed with hot area in vortex, along bottom and side walls.
15
0 1 2 3 4 5 6 7 80
20
40
60
80
100
120
SULFUR HEAT TRANSFER COEFFICIENTS
LINEAR VELOCITY (ft/sec)
HEA
T TR
AN
SFER
CO
EFFI
CIEN
T (B
TU/H
R FT
2 °F
)
HEAT EXCHANGERS
STEAM COILS
HEAT EXCHANGERS VS STEAM COILS FOR MELTING SULFUR
• Bucket elevators and screw conveyors – stainless steel
• Concrete in silos - epoxy lined acid resistance concrete
• Silo cones - Stainless Steel lined Carbon Steel structure
• Melter vessel is carbon steel – ceramic brick in splash zone (top)
• Sulfur pump tank - carbon steel
• Heat exchangers -carbon steel
• Piping, valves, sulfur filters in contact with molten sulfur – carbon steel
MELTER DESIGN – MATERIALS OF CONSTRUCTION
MODULARIZATION – SULFUR MELTER PLANT
Advantages:
• Greater estimate accuracy • Controlled fabrication environment• Consistent workforce
- Drives quality- Controls schedule attainment
• Labor cost exposure reduced vs. field construction
• Simpler foundation design• Superior material control• Schedule risk reduced• Relocation of Equipment would be
cost effective
Candidates for modularization
Melter – partial modularization – partial field erected
Sulfur Filters
Piperacks, Utilities
Motor control rooms/ control room
MODULARIZATION
Misraq Filtration Unit
FILTER UNIT – MODULAR DESIGN
• Silo on left – Filter modules on right
MODEL VIEW OF MELTER PLANT
SUPPLEMENT INFORMATION ON FOLLOWING PAGES:
Mark [email protected]
6846 S. Canton Suite 400Tulsa, OK 74126USAwww.houstoninterests.com
SUPPLEMENTAL INFORMATIONMark Gilbreath - USA
MODEL MELTER PROJECT OVERVIEW
• Truck unloading on right – Silo in Center – Lime silo and melter left.
MODEL VIEW OF MATERIAL HANDLING
• Truck unloading on right – Filter modules on leftMODEL VIEW OF MELTER FACILITY
• Piperack Foundations
SITE PROGRESS PHOTOS
• Site View – May 2015
SITE PROGRESS PHOTOS
• Pipe Rack Foundations
SITE PROGRESS PHOTOS
• Silo Roof Preparation –
SITE PROGRESS PHOTOS
• Truck Unloading Deck Steel
SITE PROGRESS PHOTOS
SITE PROGRESS PHOTOS
SITE PROGRESS PHOTOS
• Bucket Elevator Base
SITE PROGRESS PHOTOS
• Sulfur Tank Modules in Fabrication
SITE PROGRESS PHOTOS
• HEX Modules• Scheduled ready to ship – 4.5.2015 - 5.5.2015
SITE PROGRESS PHOTOS
• Sulfur Filter Modules in Fabrication
SOUTH YOLOTAN TURKMENISTANPETROCHINA SULPHUR FORMING
2x 2,000 mtpd Devco II Sulphur Forming Units
2x 2,000 mtpd Silo Feed Conveyors
Structural, Instrumental & Electrical Design, Conveyor Design / Supply
Process / Project Engineering, Project Management and Procurement
Joint projects across multiple offices from employees in Tulsa, Columbus & Pittsburgh.
Piping Design
SOUTH YOLOTANPETROCHINA/TURKMENGAS
Civil, Structural, Instrumental & Electrical Design
Project Engineering, Project Management and Procurement
Joint projects across multiple offices from employees in Tulsa, Columbus,
New Orleans & Pittsburgh.
500,000 TPY Sulphur Purification Facility
TIC: $78.5 MM
Start date – December 13, 2012On-line (Projected) – Jan 2015
Fabrication
Plant Layout & Piping Design
Project Oversight, Process / Project Engineering
MISHRAQ STATE SULPHUR COMPANYMOSUL, IRAQ
Equipment with long deliveries • Pressure Leaf Sulphur Filters: 30-46 weeks• Sulphur Pumps: 36 weeks• Heat Exchangers: 30 weeks• Scrubber
– Scrubber proprietary equipment: 36 weeks– Scrubber ID fan: 36 weeks
MELTER FILTER PLANT -LONG LEAD EQUIPMENT
Sulfur Storage
• The sulfur storage system consists of two 60 ft. diameter concrete silos with elevated 50 degree cones and a screw feeder reclaim system.
• Each of the two silos will be designed to store 6,000 tons of sulfur at 65 pcf. The final silo design including hopper slope and height is based on material testing.– Silos equipped with elevated cones (50 degree slope) for gravity feed to the reclaim
system.– The hopper are mild steel construction with a S.S. liner.– The hoppers have vibrators around the perimeter to assist with material flow.– A Screw feeder is used to feed to the melter feed conveyors at a variable rate up to
200 tph @ 65 PCF. – Openings are placed in the bottom of the silo for ventilation and access.
DRY SULFUR STORAGE - SILO
Melter Feed System
• The melter feed system consists of two 24” BW conveyors rated at 200 tph at 65 pcf to feed the melter. Only one conveyor is needed to feed the melter at a time assuring sulfur feed to the melter while allowing for maintenance on the conveyors.
• The lime storage system consists of a 12 ft. diameter welded steel silo with a target box and bin vent filter to receive hydrated lime by self- unloading trucks. The lime silo will be located in a tower over the melter feed conveyors and gravity feed the melter feed conveyors.
• Conveyors:– Two (2) 24” BW feed conveyors is located in an open common gallery to the melter.
• Lime Storage Silo:– Lime silo is 12’ diameter equipped with a bin vent filter and piping for receiving lime
from self-unloading pneumatic trucks.
DRY BULK STORAGE AND HANDLING
Sulfur filtering is a fairly simple process:
• After melting and neutralizing, dirty sulfur is collected in the filter feed tank, located next to the sulfur melter.
• The filter feed pumps draw sulfur from the tank and provide sufficient pressure to send sulfur through the filters and into the clean sulfur collection tank.
• The actual filtration is done by filter aid, which is deposited on the screens during the pre-coating process, prior to filtering.- The filter screens provide structure to hold a thin layer of filter aid in place.- As the dirty sulfur passes through the filter aid, the fine solid contaminants are too
large to pass through
• After passing through the filters, the filtrate sulfur (clean sulfur) is collected and pumped to offsite liquid sulfur storage
SULFUR FILTRATION PROCESS
MISHRAQ MODULES DURING ASSEMBLY
MISHRAQ
MODULE ASSEMBLY
& TRANSPORTATION
MODULE INSTALLATION
200 MMSCFD Gas Processing Plant
Start Date – June 1, 2012On-line – June 2013
ENERGY TRANSFER PARTNERS GODLEY FACILITY
Civil, Structural, Piping, Instrumentation & Electrical DesignMan Hours: 23,442
Process / Project Engineering & ProcurementMan Hours: 1,542
Fabrication and Construction
Joint projects across multiple offices from employees in Tulsa, Columbus & Pittsburgh.
200 MMSCFD Gas Processing Plant
TIC $250 MM
ENERGY TRANSFER PARTNERS GODLEY FACILITY
200 MMSCFD Natural Gas Processing Plant
Start date – October 8, 2012 On-line – August 2013
ENERGY TRANSFER PARTNERS RED BLUFF FACILITY
Civil, Structural, Mechanical & Electrical DesignMan Hours: 25,613
Process / Project Engineering & ProcurementMan Hours: 3,765
Plant Layout & Piping DesignMan Hours: 13,313
Joint projects across multiple offices from employees in Tulsa, Columbus & Pittsburgh.
200 MMSCFD Natural Gas Processing PlantTIC: $350 MM
Fabrication & Construction
ENERGY TRANSFER PARTNERS RED BLUFF FACILITY
Energy Transfer / Regency Red Bluff - Texas
SUPPLEMENT INFORMATION ON FOLLOWING PAGES:
Mark [email protected]
6846 S. Canton Suite 400Tulsa, OK 74126USAwww.houstoninterests.com