A Means of Avoiding Sulfur Recovery Reaction Furnace Fired Tube Boiler Failures

2009 ◽  
Author(s):  
Mike Porter ◽  
Dennis Martens ◽  
Sean McGuffie ◽  
John Wheeler
Keyword(s):  
Heat Flux ◽  
Waste Heat ◽  
Local Heat ◽  
Sulfur Recovery ◽  
Steam Generation ◽  
Waste Heat Boiler ◽  
Flux Limit ◽  
Local Water ◽  
Reaction Furnace ◽  
Tube Failure

One of the common causes of premature tube failure in fired tube boilers — technically described as film boiling — is overheating of the tubes caused by steam blanketing. Current literature contains a significant amount of information on this problem, but not much in the way of definitive guidance for avoiding the problem. General “rules of thumb” are available for identifying the heat flux limit required to avoid the problem as in Martens et al [1]. Unfortunately, the values presented by different sources are often in disagreement. This paper will look at a sulfur recovery unit (SRU) Claus waste heat boiler application and, through the use of Computational Fluid Dynamics (CFD), develop a means of predicting the conditions that lead to steam blanketing and resultant tube failure. Local heat flux conditions at gas side discontinuities (such as the tube inlet ceramic ferrule terminations) combined with associated local water side steam entrainment, and steam generation with coupled velocity effects are discussed.

scholarly journals Kinetic Reactions Modeling and Optimization of Claus Process

2020 ◽  
Author(s):  
Muhammad Arslan Zahid ◽  
Faisal Ali ◽  
Muhammad Mubashir ◽  
Faheem Iqbal
Keyword(s):  
Waste Heat ◽  
Aspen Plus ◽  
H2 Production ◽  
Sulfur Recovery ◽  
Waste Heat Boiler ◽  
Ammonia Gas ◽  
Claus Process ◽  
Simulation And Optimization ◽  
Catalyst Life ◽  
Reaction Furnace

There are many pollution and environment problem in the human ecosystem. There are different methods are used to removal of sulfur from sour gases for example Basic Claus process and Modified Claus process . There are different chemical software are used for simulation and optimization of Claus process for example Aspen Plus and Chemcad ECT. The Gibbs free energy method is introduced and model of Claus process. There are new parameter are introduced in reaction furnace to reduce the error from 33% to 7 %. The waste heat boiler is installed at the reaction furnace in which high pressure stream is produced and study the decomposition the hydrogen sulphide. The new rate of reaction is introduced of the enhancement of H2 production in chemical process. The simulation of reaction furnace in Aspen plus software is the maximum utilization of process. Due to suitable operating condition of reaction furnace is caused the maximum destruction of ammonia gas in the reactor. When we are increasing the oxygen concentration and temperature of feed is causing decreasing the ammonia production in reaction furnace. It is below than acceptance value of ammonia is 150 ppm in the reaction furnace. The presence of oxygen components, Sulfur oxide, hydroxide components are effect on decreasing the amount of ammonia in furnace and temperature is about at 1350⁰C. It is noted that when the production of sulfur recovery is decrease in Claus process and the production of carbon monoxide is increase in the thermal section at the existence. Now we are work on parametric studies of furnace that could be causes the production of ammonia destruction and CO emission in the Claus process. Due to optimize the reaction furnace parameter are help to get large of sulfur production, ammonia gas destruction, increased the catalyst life and decreased of dangerous gases.

Investigating Three Different Models for Simulation of the Thermal Stage of an Industrial Split-Flow SRU Based on Equilibrium-Kinetic Approach with Heat Loss

2018 ◽  
Vol 14 (1) ◽  
Author(s):  
Mohammad Hossein Kardan ◽  
Reza Eslamloueyan
Keyword(s):  
Kinetic Model ◽  
Heat Loss ◽  
Conversion Efficiency ◽  
Waste Heat ◽  
Molar Ratio ◽  
Percentage Error ◽  
Sulfur Recovery ◽  
Waste Heat Boiler ◽  
Split Flow ◽  
Reaction Furnace

Abstract Modified Claus process is the most important process that recovers elemental sulfur from H2S. The thermal stage of sulfur recovery unit (SRU), including the reaction furnace (RF) and waste heat boiler (WHB), plays a critically important role in sulfur recovery percentage of the unit. In this article, three methods including kinetic (PFR model), equilibrium and equilibrium-kinetic models have been investigated in order to predict the reaction furnace effluent conditions. The comparison of results with industrial data shows that kinetic model (for whole the thermal stage) is the most accurate model for simulation of the thermal stage of the industrial split-flow SRU. Mean absolute percentage error for the considered kinetic model is 4.59 %. For the first time, the consequences of considering heat loss from the reaction furnace on calculated molar flows are studied. The results show that considering heat loss only affects better prediction of some effluent molar flow rates such as CO and SO2, and its effect is not significant on the results. Eventually the effects of feed preheating on some important parameters like sulfur conversion efficiency, H2S to SO2 molar ratio and important effluent molar flows are investigated. The results indicate that feed preheating will reduce the sulfur conversion efficiency. It is also noticeable that by reducing the feed temperature to 490 K, H2S/SO2 molar ratio reaches to its optimum value of 2.

scholarly journals The influence of a radiated heat exchanger surface on heat transfer

2015 ◽  
Vol 36 (3) ◽  
pp. 161-174
Author(s):  
Sławomir Morel
Keyword(s):  
Heat Flux ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Ceramic Coatings ◽  
Furnace Chamber ◽  
Waste Heat Boiler ◽  
Exchange Effect ◽  
Intensification Of Heat Exchange ◽  
Surface Development ◽  
Heating Medium

Abstract The experiment leads to establish the influence of radiated surface development heat exchangers on the values of heat flux transferred with water flowing through the exchangers and placed in electric furnace chamber. The values of emissivity coefficients are given for the investigated metal and ceramic coatings. Analytical calculations have been made for the effect of the heating medium (flame) – uncoated wall and then heating medium (flame) – coated wall reciprocal emissivity coefficients. Analysis of the values of exchanged heat flux were also realized. Based on the measurement results for the base coating properties, these most suitable for spraying the walls of furnaces and heat exchangers were selected, and determined by the intensification of heat exchange effect. These coatings were used to spray the walls of a laboratory waste-heat boiler, and then measurements of fluxes of heat absorbed by the cooling water flowing through the boiler tubes covered with different type coatings were made. Laboratory tests and calculations were also confirmed by the results of full-scale operation on the metallurgical equipment.

Numerical analysis of local heat flux and thin-slab solidification in a CSP funnel-type mold with electromagnetic braking

2020 ◽  
Vol 117 (6) ◽  
pp. 602
Author(s):  
Heping Liu ◽  
Jianjun Zhang ◽  
Hongbiao Tao ◽  
Hui Zhang
Keyword(s):  
Heat Flux ◽  
Casting Speed ◽  
Shell Growth ◽  
Local Heat ◽  
Operating Conditions ◽  
Thin Slab ◽  
Wide Face ◽  
Slab Width ◽  
Steel Grades ◽  
Local Heat Flux

In this article, based on the actual monitored temperature data from mold copper plate with a dense thermocouple layout and the measured magnetic flux density values in a CSP thin-slab mold, the local heat flux and thin-slab solidification features in the funnel-type mold with electromagnetic braking are analyzed. The differences of local heat flux, fluid flow and solidified shell growth features between two steel grades of Q235B with carbon content of 0.19%C and DC01 of 0.03%C under varying operation conditions are discussed. The results show the maximum transverse local heat flux is near the meniscus region of over 0.3 m away from the center of the wide face, which corresponds to the upper flow circulation and the large turbulent kinetic energy in a CSP funnel-type mold. The increased slab width and low casting speed can reduce the fluctuation of the transverse local heat flux near the meniscus. There is a decreased transverse local heat flux in the center of the wide face after the solidified shell is pulled through the transition zone from the funnel-curve to the parallel-cure zone. In order to achieve similar metallurgical effects, the braking strength should increase with the increase of casting speed and slab width. Using the strong EMBr field in a lower casting speed might reverse the desired effects. There exist some differences of solidified shell thinning features for different steel grades in the range of the funnel opening region under the measured operating conditions, which may affect the optimization of the casting process in a CSP caster.

Impact of viscosity variation on oblique flow of Cu–H2O nanofluid

2017 ◽  
Vol 232 (5) ◽  
pp. 622-631 ◽  
Author(s):  
R Tabassum ◽  
Rashid Mehmood ◽  
O Pourmehran ◽  
NS Akbar ◽  
M Gorji-Bandpy
Keyword(s):  
Heat Flux ◽  
Friction Coefficient ◽  
Skin Friction ◽  
Volume Fraction ◽  
Variable Viscosity ◽  
Solid Volume Fraction ◽  
Local Heat ◽  
Skin Friction Coefficient ◽  
Viscosity Parameter ◽  
Local Heat Flux

The dynamic properties of nanofluids have made them an area of intense research during the past few decades. In this article, flow of nonaligned stagnation point nanofluid is investigated. Copper–water based nanofluid in the presence of temperature-dependent viscosity is taken into account. The governing nonlinear coupled ordinary differential equations transformed by partial differential equations are solved numerically by using fourth-order Runge–Kutta–Fehlberg integration technique. Effects of variable viscosity parameter on velocity and temperature profiles of pure fluid and copper–water nanofluid are analyzed, discussed, and presented graphically. Streamlines, skin friction coefficients, and local heat flux of nanofluid under the impact of variable viscosity parameter, stretching ratio, and solid volume fraction of nanoparticles are also displayed and discussed. It is observed that an increase in solid volume fraction of nanoparticles enhances the magnitude of normal skin friction coefficient, tangential skin friction coefficient, and local heat flux. Viscosity parameter is found to have decreasing effect on normal and tangential skin friction coefficients whereas it has a positive influence on local heat flux.

Inverse Heat Conduction Applied to the Measurement of Heat Fluxes on a Rotating Cylinder: Comparison Between an Analytical and a Numerical Technique

2008 ◽  
Vol 130 (8) ◽  
Author(s):  
Fabien Volle ◽  
Michel Gradeck ◽  
Denis Maillet ◽  
Arsène Kouachi ◽  
Michel Lebouché
Keyword(s):  
Heat Flux ◽  
Numerical Technique ◽  
Rotating Cylinder ◽  
Local Heat ◽  
Heat Fluxes ◽  
Inverse Heat Conduction ◽  
Analytical Technique ◽  
Inner Radius ◽  
Direct Model ◽  
Stable Estimation

A method using either a one-dimensional analytical or a two-dimensional numerical inverse technique is developed for measurement of local heat fluxes at the surface of a hot rotating cylinder submitted to the impingement of a subcooled water jet. The direct model calculates the temperature field inside the cylinder that is submitted to a given nonuniform and time dependent heat flux on its outer surface and to a uniform surface heat source on an inner radius. In order to validate the algorithms, simulated temperature measurements inside the cylinder are processed and used by the two inverse techniques to estimate the wall heat flux. As the problem is improperly posed, regularization methods have been introduced into the analytical and numerical inverse algorithms. The numerical results obtained using the analytical technique compare well with the results obtained using the numerical algorithm, showing a good stable estimation of the available test solutions. Furthermore, real experimental data are used for the estimation, and local boiling curves are plotted and discussed.

A New Nusselt Number for Complicated Configurations

2013 ◽  
Author(s):  
Tom I-Ping Shih ◽  
Srisudarshan Krishna Sathyanarayanan
Keyword(s):  
Heat Transfer ◽  
Heat Flux ◽  
Nusselt Number ◽  
Local Heat ◽  
Negative Slope ◽  
Test Problems ◽  
Rectangular Duct ◽  
Circular Duct ◽  
Flow And Heat Transfer ◽  
Local Heat Flux

Convective heat transfer over surfaces is generally presented in the form of the heat-transfer coefficient (h) or its nondimensional form, the Nusselt number (Nu). Both require the specification of the free-stream temperature (Too) or the bulk (Tb) temperature, which are clearly defined only for simple configurations. For complicated configurations with flow separation and multiple temperature streams, the physical significance of Too and Tb becomes unclear. In addition, their use could cause the local h to approach positive or negative infinity if Too or Tb is nearly the same as the local wall temperature (Twall). In this paper, a new Nusselt number, referred to as the SCS number, is proposed, that provides information on the local heat flux but does not use h and hence by-passes the need to define Too or Tb. CFD analysis based on steady RANS with the shear-stress transport model is used to compare and contrast the SCS number with Nu for two test problems: (1) compressible flow and heat transfer in a straight duct with a circular cross section and (2) compressible flow and heat transfer in a high-aspect ratio rectangular duct with a staggered array of pin fins. Parameters examined include: Reynolds number at the duct inlet (3,000 to 15,000 for the circular duct and 15,000 and 150,000 for the rectangular duct), wall temperature (Twall = 373 K to 1473 K for the circular duct and 313 K and 1,173 K for the rectangular duct), and distance from of the inlet of the duct (up to 100D for the circular duct and up to 156D for the rectangular duct). For the circular duct, Nu was found to decrease rapidly from the duct inlet until reaching a minimum and then to rise until reaching a nearly constant value in the “fully” developed region if the wall is heating the gas. If the wall is cooling the gas, then Nu has a constant positive slope in the “fully” developed region. The location of the minimum in Nu and where Nu becomes nearly constant in value or in slope are strong functions of Twall. For the SCS number, the decrease from the duct inlet is monotonic with a negative slope, whether the wall is heating or cooling the gas. Also, different SCS curves for different Twall approach each other as the distance from the inlet increases. For the rectangular duct, Nu tends to oscillate about a constant value in the pin-fin region, whereas SCS tends to oscillate about a line with a negative slope. For both test problems, the variation of SCS is not more complicated than Nu, but SCS yields the local heat flux without need for Tb, a parameter that is hard to define and measure for complicated problems.

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