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Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance. 6 th to 10 th of May 2013. AGADIR MOROCO. Neville Jordison Solex Thermal Science Inc. Canada. A Brief History. - PowerPoint PPT Presentation
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Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating
performance
Neville Jordison Solex Thermal Science Inc. Canada
6th to 10th of May 2013. AGADIR MOROCO
A Brief History
o Indirect Heat Exchanger introduced to the fertilizer industry approximately 25 years ago
o Today more than 100 coolers installed in fertilizer plants round the world
o Equipment operating successfully in every type of fertilizer- Urea (prills & granules), AN, CAN, LDAN, NPK, MAP, DAP, AS
o Company History
• 1990 - creation of Bulkflow Heat Exchangers – a technology division within Cominco Engineering Services Ltd
• 1999 - BULKFLOW TECHNOLOGIES is incorporated with headquarters in Calgary, Canada
• 2008 - Rebranded as Solex Thermal Science Inc to enhance profile as a world leader in the science of heating and cooling bulk solids
Advantages compared to Air Cooling (Rotary or Fluid Bed)
o Low energy consumption
o No air usage – eliminates chillers, fans ducts and scrubber
o Compact design
o Lower installed capital cost
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
The Secret to Long Term Operating Performance
What causes Caking ?HYGROSCOPIC
PRODUCT
WATER COOLEDPLATES
HUMIDITYIN VOID SPACE
CONDENSATION
CAKING ON PLATES ×
The Secret to Long Term Operating Performance
Preventing the Caking MechanismADD PURGE
AIR TO LOWERDEWPOINT
CORRECTWATER TEMP
PROFILE
ELIMINATECONDENSATION
NO CAKING
PURGEAIR
The Secret to Long Term Operating Performance
The CRH Curve
The Secret to Long Term Operating Performance
Thermal Modelling – Process Input Conditions
The Secret to Long Term Operating Performance
Thermal Modelling – Output Temperature Profile
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
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
Pilot Testing at OCP Jorf Lasfar
o DAP
o Product Inlet Temperature 65 – 75°C
o Maintain discharge temperature below 50°C
o Demonstrate long term run capability without caking
Pilot Testing at OCP Jorf Lasfar
Test Set-up
oDouble Bank Exchanger
oControlled Cooling Water Temperatures
oPurge Air system
oDemonstrate long term run capability without caking
PURGE AIR
PRODUCT IN
PRODUCT OUT
Pilot Testing at OCP Jorf Lasfar
Product WaterPurge
Air
Steady-State Averages for
each run:
T° in
T° out
Rate
TOP BANKT° in
BOTTOM BANKT° out
Run 1 (July 17) 66-74°C 44-58°C 180 kg/h 65-72°C 43-58°C yesRun 2 (July 18) 71.5-74°C 45-46°C 230-370 kg/h 61°C 44-45°C yesRun 3 (July 20) 63-72°C 39-44°C 200 kg/h 58.5-60°C 40-45°C yes
Results
Pilot Testing at OCP Jorf Lasfar
Plate Banks checked after each run
oRemovable Plexiglas plate
oPlate surfaces stayed clean throughout testing
Typical DAP Cooler
o Product Flowrate: 100 t/h
o Product Size: 1 – 4 mm
o Product Temperature in: 85C
o Required Product Temp. out: < 50C
o Cooling Water: Cooling Tower at 28C
o Purge Air: Required
A = 10740B = 1650C = 1580E = 150F = 1800G = 2470J = 1390
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
Recent Fertilizer Projects
Company Location Product CapacityYara Fertilizers Porsgrun, Norway NPK 210 t/hGemlik Gubre Gemlik, Turkey Amm. Nitrate 80 t/hNational Fertilizers Jagdishpur, India Urea Prills 2 x 155 t/h Zuari Fertilizers and Chem. Zuarinagar, India NPK 75 t/hJPMC Jordan DAP 2 x 70 t/h
Large urea prill cooler during installation in India
Long Term Operating Performance
“This campaign the CAN Plant started up on 5th of June and until now The Solex Cooler hasn’t needed cleaning yet and is operating perfectly”.
Quote from Alp Bulent GULESGemlik Gubre Sanayii A.S.Sept 26th 2010
Thank you for your attention
