The exit temperature on the first layer is abnormal; seeking help.
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At around 2:30 p.m., the outlet temperature on the first floor of our plant’s sulfuric acid system dropped from 590 to around 575 (with the inlet temperature and furnace gas concentration remaining unchanged); by around 4:00 p.m., it gradually returned to normal levels. This situation persisted for several days in a row. I wonder if anyone else has encountered such a phenomenon.
Have you checked the temperature difference of the catalysts at the same level?
What is flue gas acid production? What heat exchange process is used for conversion? With so little information, it’s like trying to understand an elephant by touching it – it’s impossible to grasp the true situation.
Please provide a detailed description of the operating conditions. Additionally, check whether there are any abnormalities with the thermocouples and secondary instruments at the exit temperature on the first floor, as well as any factors that might have an impact.
This requires checking the changes in the inlet temperature at that time, the changes in the outlet temperature of the combustion furnace, as well as the changes in the gas. As for whether the concentration of gas has changed or not, it is impossible to tell or measure.
Currently, sulfur concentrate is used to produce acid, with a process that involves two rotations and two absorptions; the heat exchange sequence is III, I, IV, II. In the past, there was a phenomenon where, on rainy days, the temperature at the first outlet would drop. As one colleague once said, it seemed to be an indicator of weather conditions. I’m not quite sure about the actual reason for this – could you please provide some guidance?
Check the thermocouple used to measure the outlet temperature of Layer 1, as well as the insulation.
The reason for the formation of a \"barometer\" is clearly an insulation issue: the seams of the outer insulation layer are not tight, allowing water to seep in when it rains, which naturally leads to a significant drop in temperature. Once, during the summer, in a sulfuric acid plant, a heavy rainstorm occurred and it was observed that the temperature of the entire conversion system dropped sharply. Upon coming out, I saw steam rising vigorously from the converter as well as the heat exchangers and pipes in its vicinity; it was a truly spectacular sight.
Mainly, the waterproofing effect of the aluminum sheet on the outside of the insulation layer is poor, especially at the top of the equipment. Thermal insulation and rain protection are details that are not given much attention in the industry; it was once suggested to add a rain shelter on top of the converter.
Perhaps I didn’t explain it clearly enough. What I mean is that, under the same external conditions and with basically stable operating conditions, the same phenomenon occurs over several days at a certain time period: the outlet temperature first drops and then rises again (with the operating conditions remaining unchanged)
It’s best to provide sufficient details so that everyone doesn’t have to guess, and it will also address the key points.