alkylation ppt

7/22/2019 alkylation ppt

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Introduction

Reaction of low molecular weight olefins with

an isoparaffin to form higher molecular weight

isoparaffins.


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PROCESS VARIABLES

reaction temperature

acid strength

isobutane concentration olefin space velocity.


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Alkylation Feedstock & Catalyst

Olefins and isobutene

Some refineries include pentenes

Conc. H2SO4and HF acids used commercially


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ALKYLATION PRODUCTS

LPG grade propane liquid

n-butane liquid

C5- alkylate Tar


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HYDROFLUORIC ACID

PROCESSES


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SULFURIC ACID

ALKYLATION PROCESSES


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A

C

B

Rotary Clinker CoolerPeriod :- 18901930 Present Population :- 5 %

BSecondary Air 450 -700 o C Heat Value 233 Kcal

AClinker exit 1200 - 1400 Max Heat Value 370 Kcal

CClinker Exit 200300 o C Heat Value 60 Kcal

D

DRadiation Loss 80 Kcal

Specific Cooling Air :- 0.81.0 Nm3 / Kg Clinker

Capacity :- 20004500 TPD Efficiency :- 5060 %

Over all Heat Loss140 Kcal / Kg Clinker

Power Consumption :- 1- 1.5 Kwh / Ton Clinker


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A

C

B

Planetary Clinker CoolerPeriod :- 19301980 Present Population :- 10 %

BSecondary Air 800 -850 o C Heat Value 270 Kcal

AClinker exit 1100 - 1350 Max Heat Value 370 Kcal


DDRadiation Loss 70 Kcal


Capacity :- 20004000 TPD Efficiency :- 6068 %

Over all Heat Loss140 Kcal / Kg Clinker

Power Consumption :- 1- 1.5 Kwh / Ton Clinker


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A

C

B

Grate CoolerPeriod :- 1940 - Present Population :- 85 %

BSecondary Air 900 -1100 o C

AClinker exit 1300 - 1400 Max Heat Value 370 Kc


E

ERadiation Loss 5 Kcal


Capacity :- 70010,000 TPD Efficiency :- 6075 %

Over all Heat Loss :- 115 Kcal / Kg Clinker

Power Consumption :- 4.5 Kwh / Ton Clinker

DVent air 250280 oC Heat Value 90 Kcal

D


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1stGeneration Grate CoolerGrate Inclination 10o

High Clinker Bed is not Possible400 mm ht

Large Air chamber

Poor air distribution through grate

Un sealed air chamber because of in built drag chain

Not possible to distribute the air to required area

Platform or Water Cooled chute at inlet

Snowmen Formation and un uniform clinker distribution

Simple hole system in Grate plate

Enlarge due to wear and least resistance for air flow

Common air supply for all grate plate in each chamber

Poor air distribution according to clinker particle size


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2ndGeneration Grate CoolerGrate Inclination 3-5 o

High Clinker Bed is not Possible500 mm ht

Optimized air chamber length according to requirement

Slight improvement in air distribution through grate

Improved sealing by introduction of hopper and flap gate

Improvement in air distribution with different location

Dead grate and reduce the width at inlet

Improved the clinker distribution

Simple hole system in Grate plate

Enlarge due to wear and least resistance for air flow

Common air supply for all grate plate in each chamber

Poor air distribution according to clinker particle size


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Conventional Grate PlateWedge shape Hole is provided

Hole enlarge by wear and air velocity reduce

All Grate plates are connected in Common Airchamber leads to Uneven air flow based onresistance by clinker particles

Chance of Hole plugging or Grate ridings

Air leakages through Side and in front of the plate

Pressure drop 25 to 50 mm WC

I t f G t


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Importance of GrateResistance

Resistance is the cumulative of pressure drop by

Clinker bed depth

Distribution of Coarse and fine particle

Pressure drop over the grate plate

The Cooling air will always take the path of leastresistance

It makes uneven air distribution and causes formationof red river

To Over come this the air should pass through a

resistance before going to clinker bed

To Increase the resistance, resistance type grate plate

has Developed


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Air Beam Technology

Coarse sideFine Side

Air EntryAir Entry

Resistance Grate Plate

Air is supplied to Grate platethrough separate duct and airbeam

Group of Grate plate is supportedin a fixed or Movable air beam

Air can be throttled by valve

to individual group


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IKN Jet Plate

S shape slot inclined towards the direction of transport

Cool the plates Surface and bottom layer of Clinker

Convey the fine fraction to top surface

Re entrain the air for repeated contact to clinker

Longer air chamber, resulting high pressure drop

IKN is only developed the term resistance grate first

It has only 2-3 % open grate area compared to 8 to 12% in conventional grate

This pattern is followed for the entire cooler length


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IKN Grate Plate

T-Bolt

SealThrough Rod

Grate Beam

Lock

Stop Nut

Hinge Air Slot Cooling Rib

Vorf = 40m/sec

V = 1 m/sec


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Mulden & CFG Grate Plate

The Pocket or Trough are filled with static layer of clinker

Reduce the Surface wear

Give resistance to air flow

Always keep the bottom surface Cool

The air slots are provided by side ways to avoid dust fallthrough

Different pattern with same concept followed for directaerated Grate and Chamber aerated Grate andStationary Grate

KHD developed Stepped grate plate and Omega Grateplates

Polysius developed Jet - ring and Jet - Stream Grateplates


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Cladius Peters Trough Grate Plate

FLS (CFG) Grate Plate

Mulden & CFG Grate Plate


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So all the supplier Develop a Fixed inlet Grate

Clinker Inlet Distribution System (KIDS) - IKN Controlled Impact System (CIS) - FLS -Fuller

High Efficiency Module (HEM)Claudius - Peters

The Worst affected area of cooler is inlet well below thekiln discharge

Also High potential for gaining the heat fromdischarged clinker

Air Beam technology and Resistance Grate plates areused

High Bed and more heat recupation

Fixed Inlet Grate

Protection of Grate plate from wear and temperature

by Static Clinker bed


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Objective of Fixed inlet grate is to create a homogeneousclinker bed of uniform resistance against the passage of air.

5 to 6 Rows of Fixed grates(3 meter)are fixed in a step manner and forma 15 Deg Slope

Because of rigidity withstand high

Impact and Temperature

Material Slide naturally or by Airblaster

Fixed Inlet Grate


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Grate Loading

Conventional Cooler2540 T/m2.d

Modern Cooler 60 - 70 T/m2.d

For 70 m2 Grate area

Capacity conventional Cooler2800 - 3200 TPD

Capacity Modern Cooler4800 - 5200 TPD

Air Loading per M2grate area

Conventional Cooler -Air density 0.90 Nm3

/m2

.Sec Modern CoolerAir loading 1.5 Nm3/m2.Sec

Modern Cooler Occupies less space

Investment is same for per tone capacity

Grate Loading has increased by direct aeration systemwith Resistance type Grate plate


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Cooler Bed Thickness

Conventional Cooler 450-500 mm

Modern Cooler 700 - 800 mm

Secondary air temperature

Conventional Cooler800 oC

Modern Cooler1100 oC

Air loading at Cooler Inlet

Conventional Cooler100 kg/min/m2

Modern Cooler200 Kg/min/m2

Air Pressure at Cooler Inlet

Conventional Cooler400500 mm WC

Modern Cooler600750 mm WC

We can maintain high Bed Thickness by Direct aerationsystem with Resistance type Grate plate


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Requirement of New Development

high-performance

compact in size

Low-wear

Flexible during operation

Favorable price Easy to maintain

To Achieve, 2 primary functions of cooler has Separated

Cool the Clinker by Grate plateConvey the Clinker by travel bars

FLS Fuller - Cross Bar Cooler

Krupp Polysius -Polytrack Cooler

Modern CoolerFully Static Grate Plate


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Day to Day Inspection

On the outside , over the grate:

Check for hot spots,which may indicate Lining

failure on the mild-steel casing.

Look for cracks at the seal welds.


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Through inspection ports under the grate

Check the grates.

Look for flawed and loose grate parts,coverplates etc.

Examine supporting .

Check for any Spillage if a spillage is there,increase the air flow in that compartment


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Through Inspection ports over the grate:

Check the grates.

Look for flawed and loose grate parts, coverplates etc.

Inspect brickwork chain curtain and coarse

grate.

Check the sectors for seal at kiln shell.


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Grate Inspection (During Shutdown)

Check the vertical distance between thegrate elements. The distance must be3mm +/- 2 mm.

Check the gap between shoes and grateplates for air quenching .The gap must ne3mm+/- 2 mm

Check the support rollers at under

compartment to prevent distortion of thedrive arm

Check the flexible joints.


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Trouble Shooting

IrregularityGrate Movement failure

Possible cause 1:

Deformed or loose grate units or cover plates.

Remedy:

Replacement or fixation of the parts.


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Trouble Shooting

IrregularityGrate Movement failure

Possible cause 1:

Incorrect vertical distance between the grate

units because of worn supporting rollers.

Remedy:

Insert thicker intermediates under the plummerblocks, or, if necessary, replace the entiresupporting roller arrangement.

Trouble Shooting


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Trouble Shooting

IrregularityBlow through of air

beside the grate

Possible cause :

Defective sealing plates at grates and framescaused by thermal impacts or skew running

frames.

Remedy:

Parts to be replaced or aligned and positioned

with the necessary clearance at the frame.


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THE (SMIDTH-FULLER)

SF CROSS-BAR COOLER

SF Cross Bar Cooler


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SFCross Bar Cooler

To Cool the Clinker

Stationary Grid

Having a self-regulated supply of cooling air

To Convey the Clinker

Simple, Cross Bar Conveying SystemSeparate and independent from grate line


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Cross Bar CoolerCross-Sectional View

MovableRetainerBracketMovableCrossBar

MovableFrameAssembly

StationaryRetainerBracket

SealingStationaryPlatesDrivePlate

MovableFrameBearing

Profiles


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Stationary Air Grid

No Moving Grate Plates

No conveying function and is protected by layer of

clinker

No interface between air plates and refractory

No side seals

No need to remove refractory to replace a Grate

Plate

RESULT

Extended Grate Life & Less Maintenance

S i Ai G id


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No clinker fall-through

No Spillage hopper & Flap valves No under-grate clinker transport system

No internal piping

No inefficient sealing air required to prevent spillage

RESULT

Less Maintenance

Lower Head Room Requirements

Kiln & Preheater Height will be reduced

Stationary Air Grid


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Independent Clinker Conveying

Wear Components Have No Effect on Cooling Efficiency

Static Clinker Layer above Cross Bars Protects Air

Distribution Plates from Heat & Wear

Cross-Bars Effectively Convey, Mix, and Shear Clinker to

Maximize Heat Exchange

Quick and Simple Replacement of Wear Parts

Hydraulic drive for efficient drive

Variable Speed for each Module line to Control Red river


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Air Distribution Plates With Mechanical Flow

Regulators

Constant Air Flow through the Clinker

Bed, Independent of Process Conditions

MFR Results in Reduced ElectricalPower

Optimum Air Distribution throughout

the Lifetime of the Cooler

Supply required air to each plate

according to Clinker bed Resistance

Operate by principle of Differential

pressure between chamber and Grate

plate bottom

MFR acts as a variable orifice control the cooling air

automatically to compensate the changes in the clinkerlayer such as temperature, bed depth, and granularity


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Air Distribution Plates With Mechanical Flow

Regulators


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Mechanical Flow Regulators

HIGHER

VALVE DP

LOW BED

RESISTANCEHIGH BED

RESISTANCE

LOWER

VALVE DP

C O N S T A N T A I R F L O W

F i f M h i l Fl R l
http://localhost/var/www/apps/conversion/tmp/scratch_2/FLOW.AVI


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Function of Mechanical Flow Regulators

POLYTRACK C l


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The POLYTRACK - a unique combination ofHorizontally positioned static aeration floor

Over floor transporting system

POLYTRACK Cooler

Ideal transversedistribution of the clinker

extremely low construction height

Ai Di t ib ti S t


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The Grates are located between the transport tracks

Air Distribution Systems

Large boxes integrated into the aeration elements arepermanently filled with clinker

No Dust Fall through GrateThis provide autogenously wear protection

The air is distributed via the labyrinth construction of thestatic aeration Grate

Transport tracks


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Transport tracks are arranged in line with the direction ofclinker conveyance

The rows of transport tracks are positioned a certaindistance from each other and the aeration elements arelocated between them

The number of transport track rows is determined bythe required width of the cooler

Every row of tracks runs the entire length of the cooler

To convey the clinker, the transport tracks move forwardtogether and then move backward individually

Transport tracks


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Stable kiln & cooler performance due to less dust circulation andno blowing of cooling air

Low maintenance costs due to minimum wear on grate plates

and movable parts

Benefits

Less red river tendency due to the Controlled Flow Grate system

Control red river by varying the speed of Individual line of module

Very Good Heat recuperation and high secondary air temperature1100 o C Will give uniform Flame

Less snowman tendency

No Fall through of dust

Reduction in clinker temperature80-90 oC

Operational Advantages

Reduction in cooler losses -30-40 Kcal/kg

Reduction in power consumptionfrom 4.5 Kwh to 3.5 Kwh /Ton

dvantages of New Generation Cooler

Oth B fit


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Small overall dimensions due to high specific grate load

70 t/m2.Day than 40 t/m2.Day for conventional cooler

Other Benefits

Reduction in cooling and vent volumes by 30 % andleads to smaller fans

No Spillage hopper and Bottom dust handling

equipments

Less Head room and reduce the Kiln pier and Preheater

height by 3 Meter

Because of Lower exit clinker temperature the Furtherconveying equipment perform well

Because of Lower exit clinker temperature the CementGrinding mill perform well

Clinker Cooling Efficiency in Various Grate Cooler


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100

200

300

400

500

600

700

800

9001000

1100

1200

1300

1400

1500

0

0.2

0.4

0.6

0.8 1

1.2

1.4

1.6

1.8 2

2.2

2.4

Cooling air Nm3/Kg Clinker

ClinkerTemperatureoC

Heat Recovery Cooling

Low Efficiency Cooler

Good Conventional Cooler

Air beam Technology Cooler

Fully Static Cooler

Clinker Cooling Efficiency in Various Grate Cooler

Secondary Air Required 0.866 Nm3/Kg

675 oC

560 oC

475 oC

390 oC

1500

1400

1300

1200

1100

1000900

800

700

600

500

400

300

200

100

C l C i


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RotaryCooler

PlanetaryCooler

GrateCooler

Air beamGrateCooler

StationaryGridCooler

Efficiency % 55-60 60-70 65-70 70-75 % 75-80%

Sec.Air TempoC 440-700 700-850 800-950 950-1100 1100-1220

Tertiary Air Temp oC NA NA 700-750 750-900 900-1000

Vent air Temp oC NA NA 250-275 225-250 200-225

Clinker exit Temp oC 150-300 120 - 200 100-120 80-100 60-80

Radiation Loss Kcal/Kg 50-80 3040 56 45 45

Cooler air volumeNm3/Kg

1.2-1.5 1-1.1 23 1.7-1.8 1.5-1.7

Air venting Nm3/kg 0.3 Nil 0.8-1.2 1.5-1.6 0.75-0.95

Specific power Kwh / ton 0.6 - 1.3 5 - 7 56 3.54.5

Heat Loss in Kcal /kg 160 142 130 100 85

Cooler Comparison


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THANK YOU

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alkylation ppt