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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 4, Issue 2, February 2016

Web Site: http://www.ipasj.org/IIJME/IIJME.htm


Email: editoriijme@ipasj.org
ISSN 2321-6441

Study on Failure of Dephlegmator in Ammonia


Distillation Column
Mallikarjuna Yeligar , Chandearshekar Hiregoudar, MD Tauqeer Hussain A
a

Department of Mechanical Engineering, Rao Bahadur Y Mahabaleshwarappa Engineering College, Bellary, Karnataka, India,
b
Department of Industrial and Production Engineering, Rao Bahadur Y Mahabaleshwarappa Engineering College, Bellary,
India.
c
M.Tech (Production Management), Department of Mechanical Engineering, Rao Bahadur Y Mahabaleshwarappa
Engineering College, Ballari, Karnataka, India.

ABSTRACT
In the process of distillation to separate aqueous solution in coke oven by-product unit, the aqueous solution which is highly
corrosive chemical responsible for the failure of the components in distillation column specially in dephlegmator, that causes
the cracks, dents, rupture in pipe, shell, and variation in the flow process. Water used for cooling causes impurities due to mix
of ammonia leads to leakages in inner parts of dephlegmator and increases the maintenance cost to the company indirectly.
The different alloy has been used as the trail material based on its good properties. After using different alloy the failure rate of
dephlegmator is reduced one by one and the life span is increased. The overall maintenance cost of plant is reduced to half
percentage as off previously been. Based on this material been used, the efficiency of the distillation process is increased
without any failure of the dephlegmator and the output product parameters of distillation column that is ammonia vapor and
waste water is improved.

Keywords: Distillation column, aqueous solution, Dephlegmator, Ammonia, Alloys.

1. INTRODUCTION
Coke oven By-product unit is an integral part of the recovery type coke oven plant; the by-product unit sucks coke gas
from batteries maintaining the thermal regime in ovens and recovers valuable like tar and removals of impurities like
Hydrogen sulfide and ammonia, Physical and chemical separation processes. Removal of these impurities gives clean
coke oven gas which can be used for heating purpose in batteries and also by other purposes [1-3].
In order to make raw gas suitable as a fuel for some burning purpose, so this By-product plant is very much required.
The main Process carried out in the By-product unit is:
Cool the coke oven gas to condense out water vapor and contaminate.
Remove tar aerosols to prevent gas line equipment foul and process contamination.
Remove ammonia to prevent gas line oxidization.
Remove naphthalene to prevent gas line foul by reduction.
Remove hydrogen sulfide to meet emission regulations governing the combustion of coke oven gas.
1.1. Dephlegmator
The Dephlegmator is a device surmounting the rectifying column, function is to condense portion of the vapor and
return the condensate to the column as reflux where as it is also called as multi-component vapor stream. Dephlegmator
is one type of reflux condenser which is either Total condenser or partial condenser [4].
In the year 1982 T.Charng and F.Lansing studied about the corrosion cause and corrosion control technique in which it
undergoes various Physicochemical corrosion such as galvanic corrosion, concentration-cell corrosion, stress corrosion,
dezincification and erosion-impingement-cavitations corrosion each category is explained in this journal. It also gives
information about different corrosion parameters which includes solution acidity, oxidizing agents, temperature, films,
dissolved slats, fluid velocity, impurities etc [5].
In year 2010, Ashwini K.Sinha AGM (NETRA), NTPC Limited studied about condenser tubes failure due to
Physicochemical corrosions many types of failure mode that can be identified in the condenser/Dephlegmator tubes
failure .Ashwini K.Sinha in the investigation report in sea water it states that the Contributing minimal corrosion
products to the condensate in a hostile environment that is aerated, wet and at a high velocity. In this paper it is
specified that alloying additions of aluminum, Zinc, Tin, Iron, and Nickel are used to dope the corrosion product films,
and they generally diminish corrosion rates extensively [6].

Volume 4, Issue 2, February 2016

Page 11

IPASJ International Journal of Mechanical Engineering (IIJME)


Web Site: http://www.ipasj.org/IIJME/IIJME.htm
Email: editoriijme@ipasj.org
ISSN 2321-6441

A Publisher for Research Motivation........

Volume 4, Issue 2, February 2016


2. METHODOLOGY:

The methodology of the study contains different types of alloys used in dephlegmator to improve the distillation column
efficiency. The first step was to understand the dephlegmator principle, as the type of condensation of volatile solution
which is like reflux condenser. Initially 316L stainless steel as a dephlegmator material was used in distillation column
and its properties were studied. Next Titanium grade 7 alloy was considered for study in order to overcome the
drawbacks of the earlier considered material and to reduce the failure rate especially in the core material that is
dephlegmator tubes [7-9].
2.1 Objectives:
The objective of the study is to avoid the failures that are occurring in the Dephlegmator;
1. To Investigate and eliminate the effective causes of failure in control and regulatory systems through substitute
materials.
2. To Identify and analyze the process variation in failure due to various forms of ammonia.
Table 1: Chemical Composition of the materials used
TYPICAL ANALYSIS
Material

Composition

Ni

Cr

Mo

Fe

Ti

Si

Pd

Stainless steel 316L

0.03

11-14

16-18

2-3

0.05

..

..

<1

<0.045

Titanium Gr7

0.1

..

..

0.03

0.3

Bal

..

0.12-0.25

Table 2: Mechanical properties of the material used


TYPICAL MECHANICAL PROPERTIES
Material

properties

Yield point
(Mpa)

Tensile strength
(Mpa)

ELONGATION
% ON
50mm

HB

230
340

560
430

50
20

145
80

Stainless steel 316L


Titanium Gr7

3. RESULT AND DISCUSSION:

Fig 1: SS 316L tubes replacement work

Volume 4, Issue 2, February 2016

Page 12

IPASJ International Journal of Mechanical Engineering (IIJME)


Web Site: http://www.ipasj.org/IIJME/IIJME.htm
Email: editoriijme@ipasj.org
ISSN 2321-6441

A Publisher for Research Motivation........

Volume 4, Issue 2, February 2016

Table 3: Comparison table of SS316L alloy with Titanium grade 7 alloy:


Tensile
strength
Mpa

Corrosive
resistance

THERMAL
CONDUCTIVITY at
100 C

SPECIFIC
HEAT

Reduction
size
%

Pervious
SS316L

560

Starts
cracking
above 60C

15

500

50

Present
Titanium
(Grade 7)

430

16.4

523

20

Comparison
Alloy

Starts
Crevice
cracking
above
250C

Life span and


maintenance

Every 4
months

Every 1* year

(* may be more than a year)

Fig 2: Comparison graph

Fig 3: Titanium grade 7 dephlegmator


From table and comparison graph we can say that titanium grade 7 is more superior to that of stainless steel 316L.

Volume 4, Issue 2, February 2016

Page 13

IPASJ International Journal of Mechanical Engineering (IIJME)


A Publisher for Research Motivation........

Volume 4, Issue 2, February 2016

Web Site: http://www.ipasj.org/IIJME/IIJME.htm


Email: editoriijme@ipasj.org
ISSN 2321-6441

4. CONCLUSION:
The dephlegamtor study through different material/alloy selection technique which extended the service life of the core
alloy without any variation in the process parameters which causes the ammonia and its forms on core material and
failure rate on pipes and different failure methods are reduced and functional efficiency of the dephlegmator, hence, in
this direction the study was conducted and concluded to increase the overall efficiency and maintenance performance of
the dephlegmator in the distillation column. From table and comparison graph we can say that titanium grade 7 is more
superior to that of stainless steel 316L.

References:
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]

www.jsw.co.in
JSW ltd coke oven operation process manual By-product unit.
Distillation an introduction Copyright 1997-2006 by M.T. Tham.
Thermopedia Of dephlegmator Lintern, A.C.
T.Charang and F.lansing, DNS engineering section, Review of corrosion causes and corrosion control in a
technical facility. April 1982.
Ashwini K. Sinha , AGM (NETRA), NTPC Limited , Aspects of Failure of Condenser tubes and their Remedial
Measures at Power Plants AKS/Journal/2010.
Stainless steel, en.m.wikipedia.org
Steel properties of materials/ www.azom.com/materail properties
www.amarequip.com,product/pressure-reactor-autoclaves-vessels-system material selection guide

Volume 4, Issue 2, February 2016

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