Synloop Waste Heat Boiler

8/15/2019 Synloop Waste Heat Boiler

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BORSIG Process Heat Exchanger GmbH

Egellsstrasse 21

D-13507 Berlin

Germany

Phone: +49 (0) 30 / 4301-01 Fax: +49 (0) 30 / 4301-2447

E-mail: [email protected] http://www.borsig.de

BORSIG Process Heat Exchanger GmbH

Egellsstrasse 21

D-13507 Berlin

Germany

Phone: +49 (0) 30 / 4301-01 Fax: +49 (0) 30 / 4301-2447

E-mail: [email protected] http://www.borsig.de


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SYNLOOP WASTE HEAT BOILERIN AMMONIA PLANTS

SYNLOOP WASTE HEAT BOILERIN AMMONIA PLANTS

BORSIGPROCESS HEAT EXCHANGER


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Tunnelflow” quench coolers

The Company

BORSIG Process Heat Exchanger GmbH, a member of

the BORSIG Group, is a worldwide leading manufacturer

of pressure vessels, heat exchangers and other systems

for special industrial applications.

Our products Waste Heat Recovery Systems, Quench

Coolers and Scraped Surface Exchangers stand for

high quality, competence and reliability.

BORSIG Process Heat Exchanger GmbH is able to pro-

duce according to all applicable codes and standards and

is certified according to e.g. DIN EN ISO 9001:2000,

SCC, ASME U, U2 and S, SQL PR China, Environmental

Management System DIN EN ISO 14001, EMAS II, etc..

Long time experience, state-of-the-art technology, highly

qualified employees as well as innovative engineering

enables us to find the perfect solution for our customers.

Other products of the BORSIG Group:

Membrane technology, compressors, blowers, boiler

and power plant technology and industrial and power

plant services.

For more information please visit www.borsig.de.

Process gas waste heat recovery system

Process gas waste heat boiler


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Synloop Waste Heat Boilersin Ammonia Plants

More clients decide in favor of BORSIG Process Heat

Exchanger´s HOT/COLD tubesheet design for synloop

waste heat boilers for their waste heat recovery systems

in ammonia plants, as they are aware of the following

advantages:

= Unique patented HOT/COLD BORSIG tubesheetdesign

= Use of ferritic tubes

= Hydraulic expansion of tubes through thickness oftubesheet

= Internal gasinlet chamber

= Tubesheet temperature is below temperature,where nitriding starts

= No stress corrosion cracking

= No crevice corrosion

= No welding overlay of gasinlet channel againsthydrogen attack and nitriding

BORSIG Process Heat Exchanger GmbH offers an indi-

vidual solution for your waste heat recovery system in

your ammonia synthesis loop.

Waste heat boiler for a formaldehyde plant

Ammonia plant with synloop WHB, reformed gas WHB,

steam superheater and steam drum

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1: Ferritic tubes are used, which are not sensitive to stresscorrosion cracking, contrary to incoloy tubes

2: Unique patented HOT/COLD tube arrangement which resultsin tubesheet temperatures below from where nitriding starts

3: Hydraulically expanded tubes avoid crevice corrosion4: Hot incoming gas is guided through internal gas chamber

directly to tube inlet ends, no special protection of combinedgasinlet/outlet chamber against nitriding and hydrogen

embrittlement is necessary


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BORSIG´S Process Heat ExchangerUnique Patented HOT/COLD Tubesheet Design

U-tubes with hot and cold ends are alternately arranged. The hot shank is surrounded by cold

shanks.

Advantage of this design is that the tubesheet and the hot end tube wall temperature inside

the tubesheet can be kept below 380°C to avoid nitriding and to use ferritic tubes.

As a result the inlet ends of the tubes inside the tubesheet as well as the whole tubesheet

itself are at gas outlet temperature.

The U-tubes are arranged in such way that each inlet is located adjacent to an outlet end. Inlet

end ferrules protude approx. 50 mm from the thick tubesheet into the channel and are fitted to

a dummy tubesheet, which is connected to an internal gas chamber of incoloy for the hot inco-

ming gas.

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Principle sketch of HOT/COLD tubesheet design

Combined gasinlet/outlet chamber for HOT/COLD tubesheet design


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Conventional Tube Arrangement Compared to

HOT/COLD Tube Arrangement

The diagram below indicates the temperature distribu-

tion across the tubesheet thickness. With conventional

tube arrangement the tubesheet temperature will be

above the temperature, where nitriding starts.

But BORSIG´s Process Heat Exchanger unique

HOT/COLD tube arrangement achives an even tempera-

ture distribution across tubesheet thickness, which is

below nitriding temperature. This HOT/COLD tube

arrangment is the best technical solution.

Tubesheet temperature across tubesheet thickness based on FEM-analysis

Comparison of different synloop waste heat boiler designs

FEM models of HOT/COLD tube arrangement


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Synloop Waste Heat Boiler withIntegrated Boiler Feed Water Preheating Zone

The BFW is entering the BFW section close to the bot-

tom of the tubesheet and is passing through it in coun-

terflow to the converter effluent, is heated up close to

saturation temperature and is entering the evaporation

section. Then the steam/water mixture is flowing

upwards through the cone and “chimney”. Above the

upper end of the “chimney” an impingement plate is

arranged to force droplets and water to flow down

through the inside waterjacket. The steam leaves the

synloop boiler by passing a demister. The down-flowing

water is guided through an annular space to the tube-

sheet. At tubesheet the water flows radially to the cen-

terpart and flows upwards by generating steam.

The arrangement of BFW-section, waterjacket and cone

with chimney ensures that up-flowing water/steam mixtu-

re and downflowing water are separated. This circulation

is a natural circulation and the tubesheet is flushed by

cooling radial incoming down-flowing water. Therefore

no pool boiling areas in the center of the tubesheet are

present.

To reduce investment costs, BORSIG Process Heat

Exchanger GmbH is prepared to offer a design of a syn-loop waste heat boiler with integrated BFW-preheating

section.

Principle sketch of synloop waste heat boiler with integrated BFW-preheating section Tube bundle of HOT/COLD design

Sketch of synloop waste heat boiler with integrated boiler feed water preheating zone


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Synloop Steam Superheater

ube bundle of steam superheater

ube to tubesheet welding

Synloop WHB ready for delivery

Steam superheater ready for delivery


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Typical Layouts and Arrangements

for Synloop WHB´s

1 - Synloop WHB horizontal design2 - Synloop WHB designed as reboiler

Synloop WHB with integrated steam drum

Synloop WHB with steam drum designed as compact unit

Arrangement of reformed and synthesis gas waste heat boilers

with one common steam drum:

1 - Reformed gas WHB2 - HP steam superheater

3 - Steam drum4 - Shift WHB

5 - Shift BFW preheater 6 - Synloop WHB

7 - Synloop BFW preheater


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fting of a synloop WHB on site

Engineering and After Sales Services

BORSIG Process Heat Exchanger GmbH has complete

inhouse engineering facilities. Thermal layout and speci-

al heat transfer calculations are performed and checked

with inhouse developed computer programs. For

complex problems the gas flow and the heat transfer are

calculated by three dimensional finite element programs

(computational fluid dynamics).

Calculations of pressure vessels and heat exchangers

are performed according to all worldwide established

codes like AD, TRD, ASME, BS, Raccolta VSR, Codap,

Stoomweezen, IBR, JS, Australian Standard and others.

Critical components are subject to additional strength

calculations by using the finite element analysis.

Flexibility, rooting, foundation loads and forces and inter-

connecting piping are calculated by computer programs.

BORSIG Process Heat Exchanger supplies also the ser-

vice of complete replacement jobs. BORSIG Process

Heat Exchanger supervisors are specialized on replace-

ment performances covering the detailed engineering,

elaborating the shortest time frame, determining the logi-

stic replacement sequence, mobilization of local person-

nel and complete supervision from shutdown to start-upof plant.

Positioning of a synloop WHB on siteSynloop WHB on site


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BORSIG Process Heat Exchanger GmbH with its manu-

facturing methods, workshop facilities and equipment

complies fully with the latest state-of-the-art. The high-

tech welding technology is our core competence:

- Laser controlled narrow gap SAW welding system,

- robot welding technology for GMAW welding for high

pressure vessels,

- TIG-hot wire welding, also on ball valve surfaces,

- mechanical tube to tubesheet welding,

- qualified manufacturing of all steel and nickel-based

alloys.

Quality assurance and control activities are independent

of the manufacturing process or product lines and gua-

rantee that machined and handled materials, compo-

nents, assemblies, products and service operations are

executed in accordance with all specified requirements.

Quality assurance surveils adherence to national and

international specifications, statutory and contract provi-

sions as well as the directives, standards and regula-

tions stipulated by BORSIG.

BORSIG Process Heat Exchanger certification comprise

DIN EN ISO 9001:2000, SCC, ASME U, U2 and S, SQL

PR China, Environmental Management System DIN EN

ISO 14001, EMAS II, etc..

In 2003 BORSIG Process Heat Exchanger GmbH has

introduced the Integrally Management System (IMS)

comprising of quality, works safety and environmental

management systems.

Synloop WHB furnished as kettle type Assembling of a synloop WHB

Automatic SAW nozzle to shell welding

Manufacturing andQuality Assurance

Automatic

tube to tubesheetwelding

Synloop Waste Heat Boiler

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