The issue of high-temperature shift condensate

If the water is not drained in time, the liquid level in the separation tank will become too high, leading to gas-liquid entrainment and the introduction of water into the shift reactor; this poses a risk of flooding the catalysts, forcing the system to stop operating. Returning the liquid to the gasification process promptly provides an environmentally friendly way to dispose of it, and it is the best solution.

I have no experience with high-temperature conversion; what I am learning now is low-temperature conversion. Let me talk about low variation; it might be useful to you. In the process from gasification to conversion, there is a heat exchanger to control the temperature of the process gas, and a separation tank to separate water. When the process gas generated by vaporization contains a high amount of water, the outlet temperature of the heat exchanger is generally reduced in order to separate more water and achieve a normal water-vapor ratio. The main impact of water in the transition zone is that it enters the converter and saturates the catalyst, which can easily cause the catalyst to become powdered and shorten its service life. If the regulation is not proper and water enters the converter, as long as the amount of water entering is not large, the plant should not stop operating; measures should be taken promptly to ensure that no water gets in. So, I don’t think they usually park there.

It won’t happen~! The liquid level in the first separator of the high-temperature shift unit is linked to an interlock system; if it rises too high, an alarm will be triggered automatically. If you still don’t make any adjustments at that point, then I have nothing more to say! The consequences are easy to imagine: leaving the post while operating causes a change in parking mode, and in such cases it’s usually possible to go home. There is generally a high-level alarm system in place for monitoring liquid levels, and this alarm triggers the automatic closure of the process gas inlet valves, resulting in the shutdown of the conversion system

The liquid level in the separator must be carefully controlled; if it is too high, liquid will be carried into the converter, which can affect the catalyst. If it is too low, gas leakage may occur. It is essential to properly regulate the amount of gas supplied to the gasification process in order to prevent water from entering there

So, does the high-temperature shift condensate pump have a self-starting interlock? How long is the typical allowable processing time if the pump trips?

I don’t know which condensate pump you are referring to – are you talking about the tank that collects the condensate from various separation tanks? The pump in our tank does not have a interlock; instead, the level is controlled by adjusting the opening degree of the outlet valve. The processing time depends on the size of that tank, as well as the amount of condensate produced by you.

To address this issue in the gasification unit, measures are taken to lower the liquid level in the wash tower, while simultaneously stabilizing the pressure in the gasification furnace (as fluctuations in furnace pressure are usually the cause of liquid entering the shift unit). The following measures are taken in the shift unit: 1. Open the control valve on the condensate pipeline leading away from the gasification unit; if the liquid level does not drop, activate the bypass. 2. Open the backflow valve on the condensate pipeline leading away from the gasification unit and discharge the liquid on-site. 3. Open the backflow valve for feeding water into the conversion furnace to drain water!

Dare to give advice during production! The pressure in the conversion system is generally above 6.35 Mpa; I guess the consequence of activating the drain valve would be the need to shut down the plant! After high-pressure water and process gas are ejected, who would dare to go up and close this valve? It’s likely impossible to close it. Generally, pilot drain valves are stop valves; when they are opened slightly, the flow area becomes quite large, and it’s difficult to control this degree of opening. Even if you set the valve to a lower position, the high-pressure water that is ejected will contain large amounts of process gas and H2S, which is definitely harmful to human health!