Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance
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1 Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance 6 th to 10 th of May AGADIR MOROCO Neville Jordison Solex Thermal Science Inc. Canada
2 A Brief History o o o o Indirect Heat Exchanger introduced to the fertilizer industry approximately 25 years ago Today more than 100 coolers installed in fertilizer plants round the world Equipment operating successfully in every type of fertilizer - Urea (prills & granules), AN, CAN, LDAN, NPK, MAP, DAP, AS Company History creation of Bulkflow Heat Exchangers a technology division within Cominco Engineering Services Ltd BULKFLOW TECHNOLOGIES is incorporated with headquarters in Calgary, Canada Rebranded as Solex Thermal Science Inc to enhance profile as a world leader in the science of heating and cooling bulk solids
3 Advantages compared to Air Cooling (Rotary or Fluid Bed) o o o o Low energy consumption No air usage eliminates chillers, fans ducts and scrubber Compact design Lower installed capital cost
4 Principle of Operation Combines the science of mass flow with indirect heat transfer Product flows slowly by gravity between water cooled plates Product flows in uniform velocity mass flow Water flows counter-current inside plates Heat Exchange by conduction
5 The Secret to Long Term Operating Performance What causes Caking? HYGROSCOPIC PRODUCT HUMIDITY IN VOID SPACE WATER COOLED PLATES CONDENSATION CAKING ON PLATES
6 The Secret to Long Term Operating Performance Preventing the Caking Mechanism PURGE AIR ADD PURGE AIR TO LOWER DEWPOINT CORRECT WATER TEMP PROFILE ELIMINATE CONDENSATION NO CAKING
7 The Secret to Long Term Operating Performance The CRH Curve
8 The Secret to Long Term Operating Performance Thermal Modelling Process Input Conditions
9 The Secret to Long Term Operating Performance Thermal Modelling Output Temperature Profile
10 The Secret to Long Term Operating Performance Ensuring Water Temperature is above the Dew Point Water temperature must be to right of dewpoint line to prevent condensation mechanism
11 The Secret to Long Term Operating Performance Complete System o Tempered Water Module to provide controlled cooling water temperatures o Purge air system controlled flowrate and dewpoint o Instrumentation and Control System
12 Pilot Testing at OCP Jorf Lasfar o DAP o Product Inlet Temperature C o Maintain discharge temperature below 50 C o Demonstrate long term run capability without caking
13 Pilot Testing at OCP Jorf Lasfar PRODUCT IN Test Set-up o Double Bank Exchanger o Controlled Cooling Water Temperatures PURGE AIR o Purge Air system o Demonstrate long term run capability without caking PRODUCT OUT
14 Pilot Testing at OCP Jorf Lasfar Results Steady-State Averages for each run: Product T in T out Rate TOP BANK T in Water BOTTOM BANK T out Purge Air Run 1 (July 17) C C 180 kg/h C C yes Run 2 (July 18) C C kg/h 61 C C yes Run 3 (July 20) C C 200 kg/h C C yes
15 Pilot Testing at OCP Jorf Lasfar Plate Banks checked after each run o Removable Plexiglas plate o Plate surfaces stayed clean throughout testing
16 Typical DAP Cooler o Product Flowrate: 100 t/h o Product Size: 1 4 mm o Product Temperature in: 85C A = B = 1650 C = 1580 E = 150 F = 1800 G = 2470 J = 1390 o Required Product Temp. out: < 50C o Cooling Water: Cooling Tower at 28C o Purge Air: Required
17 Typical DAP Cooler o Water Temperature Control Module o Primary water supply can be cooling tower or sea water use 254SMO or titanium plate heat exchanger o Purge Air Supply o Unit typically installed immediately following the screens
18 Recent Fertilizer Projects Company Location Product Capacity Yara Fertilizers Porsgrun, Norway NPK 210 t/h Gemlik Gubre Gemlik, Turkey Amm. Nitrate 80 t/h National Fertilizers Jagdishpur, India Urea Prills 2 x 155 t/h Zuari Fertilizers and Chem. Zuarinagar, India NPK 75 t/h JPMC Jordan DAP 2 x 70 t/h
19 Large urea prill cooler during installation in India
20
21 Long Term Operating Performance This campaign the CAN Plant started up on 5 th of June and until now The Solex Cooler hasn t needed cleaning yet and is operating perfectly. Quote from Alp Bulent GULES Gemlik Gubre Sanayii A.S. Sept 26 th 2010 Thank you for your attention
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