Professional Documents
Culture Documents
Contents
MINIATURE PLANT ......................................................................................................................... 2
Ammonia Circulation Section ......................................................................................................... 2
Steam Generation Section (Boiler) ................................................................................................. 4
Types of Boiler ............................................................................................................................. 4
Difference between Fire and Water Tube Boiler ........................................................................ 5
Boiler Characteristics................................................................................................................... 5
Scaling.......................................................................................................................................... 7
Permanent Hardness ................................................................................................................... 7
Treatment Methods .................................................................................................................... 8
Zeolite Method ............................................................................................................................ 8
Condensate Recovery.................................................................................................................. 8
Blow Down .................................................................................................................................. 8
Boiler Efficiency ........................................................................................................................... 9
Cooling Tower Section .................................................................................................................... 9
Main Components of Cooling Tower ........................................................................................ 10
Types of Cooling Tower ............................................................................................................. 11
Instrument Air Compressing Section ............................................................................................ 14
Function of Air Compressor ...................................................................................................... 14
Piping Model ................................................................................................................................. 16
Valves ............................................................................................................................................ 16
Gate Valve ................................................................................................................................. 16
Globe Valve ............................................................................................................................... 17
Check Valves .............................................................................................................................. 17
Ball Valve ................................................................................................................................... 17
Butterfly Valve ........................................................................................................................... 17
Safety Valve ............................................................................................................................... 17
Plant Operation
MINIATURE PLANT
Description of Miniature Plant:
It is a Plant having one sided operation. It does not produce anything. It is only a
closed circuit Plant. It has five major parts. This Plant involves:
Where its pressure lowers up to 3kg/cm2, due to low pressure expansion of gases takes
place and NH3 evolves from the Ammonical Solution of it with water. This evolved
Plant Operation
ammonia is returned towards the absorption unit. To low down the temperature of the
vessel cool water is introduced from the bottom of the vessel where it is used and then
sent to the cooling tower for its reprocessing. Because of the stripping of the NH3 gas
from the stripping section the remaining solution becomes very weak ammonical
solution which goes to the water cooler, where it is cooled with the cool water coming
from the cooling water section. After the cooling of this weak ammonical solution it goes
to the NH3 absorber. This cooled ammonical solution is sprayed at its top. Now NH3
gas and N2 coming from the top of the stripping tower is injected from the bottom of the
absorber tank. In case of incomplete absorption of NH3 gas then this is sent to
antipollution section where it is converted into N2 gas and sent into air. As NH3 is so
much injurious to health so thats why it is not discharged in the air. In short this section
is used for the safe and healthy circulation of Ammonia and its solution.
Plant Operation
Types of Boiler
There are two major types of boiler which are as under:
(a) Fire Tube Boiler
(b) Water Tube Boiler
Plant Operation
(These reactions are of Complete Combustion of fuel. These gases are shifted towards
stack)
Incomplete Combustion:
Incomplete combustion of fuel causes due to the insufficient amount of air for fuel to
burn.
Boiler Characteristics:
Capacity:
Capacity refers to the steam or heat output of a boiler. The term used to express
capacity depends on the size of the boiler. Boiler manufacture indicates the capacities
Plant Operation
of medium and large boilers in pounds of steam per hour (at a specified temperature
and pressure).Capacity of small boilers is expand in term of total square feet of heating.
One boiler horse power equals to a heat output of 33475 Btu/hr. If a boiler produces
more steam than the rated capacity can be given as percentage of rating percentage
equals the actual capacity divided by rated capacity
Pressure:
A boiler is classified by the pressure at which it operates. Fire tube boilers pressure
generally ranges between 50-250Psi.Water tube boiler pressures can be as high as
5000 Psi
Duty:
Duty is the steam demand made on a boiler by the heating process. The duty required
of a boiler determines the load it carries according to design capacity. A boiler can
operate at minimum normal or maximum load.
Economizers and Preheaters:
The devices increase the capacity and efficiency of a boiler by recovering heat from flue
gases. An economizer to a nest of small tubes placed at the flue gases outlet of
the boiler. Feed water at low temperature of the boiler flows through the tubes and
gases and absorb heat from the hot gases passing around the outside of the tubes.
Thus an economizer lowers steam cost because less fuel is needed to heat feed water
to its boiling point. An air pre heater uses the heat from the flue gases to warm
incoming air that will support combustion. A pre heater is usually placed between the
economizer at the stack.
Sensible Heat:
The heat required to bring change in water is known as Sensible heat.
Plant Operation
Latent Heat:
The heat which does not rise the temperature but bring a change in the state of water is
known as Latent Heat
.Causes of Heat Loss:
Causes of heat loss are as under:
1.Scaling
2.Radiation
3.Decrease in diameter of tubes.
4. Presence of Salts in water
Water Treatment for Boiling:
A boiler requires a supply of purified feed water to produce the high quality steam. The
source is usually natural water from rivers. Water is an active solvent which means it
collects dissolve substances. Natural water therefore contains suspended solids
dissolved gases such as.
Scaling:
The impurities in water which it contains cause corrosion and stop the boiler efficiency
to work properly. It causes due to dissolved salts in water.
Scaling is due to following factors:
1.Process with untreated water .
2. Incomplete Composition due to imbalance ratio of fuel and air.
3. No preheat of air.
4. Overheating which melts the tubes of boiler.
Temporary Hardness:
Presence of bicarbonates of calcium and magnesium causes the hardness of
water which is known as temporary hardness. It can be removed by heating the hard
water.
Permanent Hardness:
Presence of chlorides and sulphates of Calcium (Ca) and Magnesium (Mg) causes
the permanent hardness of under processed water. This hardness cannot be removed
by heating.
Plant Operation
Treatment Methods:
The treatment of water can be done by the following methods:
1.Lime Soda Method
2.Zeolite Method
3.Demin Process
4.Reverse Osmosis Zeolite method
is used in the Miniature Plant for the treatment of water.
Zeolite method and Demin method are also termed as Ion Exchange method.
Zeolite Method:
This method is a type of Ion Exchange Method. In this method softening material
mostly used is called resins. Formula of Zeolite is as under:
After the reaction Sodium Zeolite (NaZe) is regenerated due to following reactions:
Condensate Recovery:
It is a good energy conservation method which improves the system efficiency and
reduces the fuel and water cost. A condensate recovery system returns condensed
steam to the boiler to become a portion steam to the boiler of the feed water supply.
The rest of the feed water supply comes from makeup water replaces water loss
through blow down. High quality water containing few minerals and treated with
chemicals thus condensate requires less treatment than raw make up water to make it
pure to use it as feed water. In this way energy is saved through this process.
Blow Down:
As the boiler generates steam, the condensation method that improves system of
minerals and treatment chemicals that remain in the boiler water increases large
amount of minerals which cause corrosion, boiler tube blockage and scaling. It is
actually a process which water is removed to decrease the concentration of salts.
Plant Operation
Boiler Efficiency:
The main factors that reduce the efficiency of boiler are the greatest loss of heat in
boiler operation. There are two causes of abnormal stack loss which are as under:
1: Excess Air in Combustion Area
2: High Exit temperature of Flue Gasses
Every fuel requires some excess air to burn completely. High flue gas exit temperature
reduces the efficiency of boiler because the heat released through the stack is wasted
heat. Economizer and air pre-heater can recover some of the heat to improve its
efficiency and it also lowers fuel cost. Radiation loss is the heat loss from the boiler and
high temperature piping through radiation to the surrounding air.
Use of Steam:
Steam is of two types:
1.Saturated Steam(Heating purpose)
2.Superheated Steam(turbine operation)
Steam is mainly used in the power generation purposes. Superheated steam carries
vapors in it. Thats why it is used to run Turbines.
Plant Operation
Evaporation:
Cooling occurs in the tower by the mechanisms of evaporative cooling and exchange of
sensible heat. The loss of heat by evaporation lowers the remaining water temperature.
The smaller amount of cooling also occurs when remaining water transfer heat to the
air. The rate of evaporation is about 1.2% of the rate of flow of there circulating water
passing through the tower for every 10ft. decrease in water temperature achieved by
the tower. The decrease in temperature will vary with the ambient dew point
temperature (DPT). Due to evaporation process 4-5% water is shifted towards the air. In
short evaporation causes cooling.
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Plant Operation
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Plant Operation
faster cooling than in a spray pond. Due to evaporation and drift there is some water
loss which has to be replaced by make up water. In order to get maximum evaporation
from a cooling tower, the air should be provided in a large amount.
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Plant Operation
with solid sides the induced air travels most of the time in an opposite direction from
falling water. In both these towers the air volume flowing through the tower is controlled
by the speed of the fans and the amount of opening of side louvers with solid sides the
induced air travels most of the time in an opposite direction from falling water. In both
these towers the air volume flowing through the tower is controlled by the speed of the
fans and the amount of opening of side louvers.
Why We Use Water for Cooling:
The importance of water in industry is due to its specific heat. Specific Heat is the
measure of how well a substance can absorb heat. Water is so good at absorbing heat
as compared to all other substances. It has a specific heat value which is 1.0. We will
compare it with Methanol which has specific heat value 0.39 which is very less as
compared to the value of water. Outstanding ability to absorb and release heat of water
through evaporation makes it an ideal for the use in Industries for cooling. Water is used
in industries due to the following reasons
1. Plentiful
2.Readily available
3.Inexpensive
4. Easy Handling
5.It can carry heat
6.Does not decompose
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Plant Operation
the air is dry. In damp humid days a cooling tower works not as well as it work sin
usually dry season. A factor that affects the rate of evaporation is the amount
of humidity or moisture in the air in contact with the water.
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Plant Operation
direction out of thecylinder. The power required to move the piston is usually supplied
by a motor. Themotor moves a crank shaft. There are two types of reciprocating air
compressor:
1.Single Acting Compressor
2.Double Acting Compressor
Intake Filter:
This filter removes dirt from the air before it enters the compressor. Dirty air can result in
rapid valve wear and cylinder wear.
After Cooler:
Compression causes the air to get very hot. The air after cooler cools the compressed
air. Most after coolers are hot exchangers. They contain a network of tubes that have
cold water circulating through them. As the hot compressed air flows around the tubes it
is cooled by these tubes having cool water.
Moisture Separator:
This component removes moisture that condenses after the compressed air has cooled.
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Plant Operation
Moisture separator s usually has manual or automatic drain traps to remove the
collected moisture from the compressor.
Piping Model
In a Chemical Plant piping has been installed for the transfer of fluid from one
equipment to the other. Following are the different parts of a piping model.Piping
Diagram:
Valves
Valves are the devices used to control the rate of flow of fluids in a pipeline. Several
valves are provided in the piping model valves are classified as given below:
Gate Valve
Gate valves are mostly used in plants. These valves are used to cut the flow of liquids
or to control its flow rate. In a gate valve diameter of the opening through which the fluid
passes is nearly the same as that of pipe. These valves are usually used to complete
cut of the pipeline liquid. The other end of the stem extends through the stuffing box in
the valve bonnets connects to the hand wheel. In a rising stem, gate valve is not
connected with the stem directly to its wheel. Instead of the stem is threaded through a
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Plant Operation
fitting called stem bashing. In a non-rising stem gate valve the stem is directly attached
to the hand wheel.
Globe Valve
So called because in the earliest design the body of the valve was spherical. The globe
valve is mainly used for flow rate control. The opening increases almost linearly with
stem position and wear distributed around the disc. The fluid passes through a
restricted opening and changes direction several times. As a result the pressure drop in
this kind of valve is large.
Check Valves
Check valves are used when unidirectional flow is desired. They are automatic in
operation. It is opened by the pressure of the fluid in the desired direction, automatically
closes by gravity or by a spring pressing against a disk.
Common types of check valves are:
1.Lift Check
2.Swing Check
Ball Valve
The ball valve is used at a place where quick switch over from fully closing fully
opening or vice versa is required. This valve is used for fluids containing suspended
solids.
Butterfly Valve
It is used at a place where leakage of fluid with this fully closed does not matter much. It
can be fully closed does not matter much. It can be fully closed. These are used in low
pressure low temperature applications.
Safety Valve
The safety valve protects the equipment and piping from damage duet enters pressure
when pressure in equipment rises above a specified level. This valve opens
automatically to prevent equipment damage.
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