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Report on Optimization of Regenerants Consumption at Demin

Process Package Operation with Temporary Modifications SYSTEM DESCRIPTION Cooling tower is used to reduce the temperature of a water stream by extracting heat from water and emitting it to the atmosphere. Cooling towers make use of evaporation whereby some of the water is evaporated into a moving air stream and subsequently discharged into the atmosphere. As a result, the remainder of the water is cooled down significantly. New Cooling Tower comprises six cells and fulfills the cooling water demand of Ammonia, Nitric Acid, LCO2, Utilities & other offsite facilities. The cooling tower has a design circulation capacity of 30,000 m3/hr. However, the present cooling water demand stands at 22,564 m3/hr (based on design CW demand of individual units). Page |2 PROBLEM BACKGROUND On 24th September 2014, fire outbreak at New Cooling Tower resulted in complete burn out of its internals including fan, fills, spray nozzles, drift eliminators & louvers of Cell-A. Fortunately, no casualty occurred and rest of tower cells were saved by vigilant firefighting by PFL personnel. Post fire incident the cooling tower is being operated with five cells and hence at reduced efficiency. To ensure supply temperature of cooling water during forthcoming summer season is maintained below the design figure, it becomes essential to put Cell-A back into operation. Order for procurement of tower internals hasn’t yet been placed due to budgetary constraints. PROPOSAL In order to enhance performance of cooling tower and to ensure supply of cooling water to production facilities at a temperature ≤ deg C Cell-A may be put back into operation post execution of undermentioned temporary modifications/additions; 1) Installation of pre-fabricated spray nozzles (utilizing available material) as per distribution pattern reflected in Annexure-B. Annexure-A: Evaluation of optimum spray nozzle mix for Cell-A [NCT]. Annexure-B: Distribution pattern of spray nozzles. 2) Re-installation of old tower fan (previously used design) to facilitate heat rejection from spray water in Cell-A. 3) Installation of louvers as per arrangement indicated in Annexure-C. 1) INSTALLATION OF SPRAY NOZZLES Each cooling tower cell comprises of 620 spray nozzles for distribution of return hot water over tower fills. Pre-fabricated spray nozzles are available in following sizes for installation; i) ii) Nozzle-1: ID = 30.4 mm, H = 340 mm (SS) Nozzle-2: ID = 40.9 mm, H = 335 mm (CS) Distribution pattern of modified nozzles is indicated in Annexure-B. Page |3 NOZZLE-1 NOZZLE-2 CRITERIA FOR ARRANGEMENT OF SPRAY NOZZLES: Following criteria has been considered to define distribution pattern of spray nozzles with an objective to maximize heat rejection from hot return water. 1) Alignment of water handling capacity of Cell-A with original design. 2) Uniform distribution of heat to maximize heat extraction (By utilizing complete distribution network & keeping total flow area i.e. head in hot water basin unchanged) Page |4 3) Maximize heat transfer area (By utilizing maximum no. of smaller nozzles & keeping total flow area i.e. head in hot water basin unchanged). 2) RE-INSTALLATION OF OLD TOWER FAN During revamp of cooling tower during 2008 old tower fans were replaced with modified design having similar process specifications. Rated Air Flow : 740 m3/s Head : 6.55 mmWc Fan Material : Reinforced Fiberglass Fan Diameter : 30 ft Fan Speed : 125 rpm 3) Fan shall initially be operated at a pre-defined lower blade angle (< rated) and shall gradually be increased up to rated point if permitted by fan behavior (based on recorded vibrations & motor amperage). 4) Vibrations & running amperes of fan shall be closely monitored during run a a pre-defined monitoring frequency. 5) INSTALLATION OF LOUVERS Tower shall be operated with louvers installed on both sides of air intake walls to facilitate in uniform air distribution, impact separation of unwanted matter & to minimize exposure to sunlight.