A special initiative has been launched for the carbonization tower position; we hope everyone will participate actively, with rewards available for responses

Ammonia concentration and carbonation degree: The carbonation degree is used to indicate the ability of ammonia solution to absorb carbon dioxide. Its calculation formula is (concentration of carbon dioxide * 2 / concentration of ammonia) * 100%. The minimum value for carbonation degree is 0, while the maximum value is 200%. The lower the value, the stronger the ability to absorb carbon dioxide. Titer, symbol tt. One-twentieth of the equivalent concentration. It is used to indicate the concentration of ammonia solution in the production of soda ash and ammonium bicarbonate. This post was last edited by jindin312 on 2009-3-7 21:11]

Safety Responsibility System for Carbonization Position 1. Personnel in this position should actively participate in safety production activities, learn safety technical knowledge, and strictly abide by all safety production rules and regulations. 2. Strictly follow the handover procedures; before taking over the shift, it is necessary to carefully check whether the safety measures for the position are in good condition. 3. Operate with care, strictly follow the process procedures, abide by discipline, and keep records that are accurate and neat. 4. Conduct regular inspections on schedule, and accurately analyze, assess, and address any abnormalities that occur during the production process. 5. Use various labor supplies, tools, protective equipment, and fire-fighting equipment correctly and keep them properly stored. 6. Do not carry out operations in violation of regulations; advise or stop others from doing so, and if they refuse to comply, report the matter to management promptly. 7. Take strict precautions against ammonia poisoning; in the event of such poisoning, appropriate emergency measures must be taken and the workshop must be informed. 8. When working inside the tower, a work permit for tower entry must be obtained, and a supervisor must be assigned to oversee the work.

Only these few sentences were found: Operating Procedures for Alkali Production via Shift Gas Process. Chapter 1: General Overview of the Carbon Chemical Section in this Process. After desulfurization and shift reaction, semi-water gas contains hydrogen and nitrogen required for ammonia synthesis, as well as a large amount of CO2. Ammonia mother liquor II reacts with CO2 to produce sodium bicarbonate (soda ash). NaHCO3 is an intermediate product in the production of soda ash (Na2CO3); after filtration, the sodium bicarbonate (NaHCO3) is…

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Responsibility System for Carbonization Process 1. Tasks: Absorb the gaseous ammonia supplied from the synthesis unit using mother liquor and dilute ammonia water to produce high-quality concentrated ammonia water, which is then used for carbonization. Carbonized concentrated ammonia solution absorbs CO2 from the shift gas, eliminating the CO2 present in it and producing high-quality ammonium carbonate as well as feed gas. II. Key operating points: Ensure that the exhaust gas meets the required standards; strive to improve the yield and quality of ammonium carbonate. Make careful adjustments during production to enhance the absorption efficiency, and strictly control the liquid levels and temperatures in each tower to ensure that the exhaust gas meets the specified criteria. Strengthen the coordination among positions related to carbon handling, carbon processing, absorption, and centrifugation, and make every effort to improve the yield and quality of ammonium carbonate. III. Patrol inspections: (1) Check the operation of moving equipment and the leakage of stationary equipment every half hour. (2) Continuously monitor the changes in temperature, pressure, and liquid level at various points, and make adjustments as needed. (3) Keep thorough and detailed job records. IV. Labor Discipline (1) Strictly abide by labor discipline, and strictly implement process discipline and operating procedures. (2) Strictly implement the shift handover system to ensure safe and civilized production. V. Process parameters: (1) NH3 content in exhaust gases: ≤0.1 g/m3; (2) CO2 content in exhaust gases: ≤0.2%; (3) Titer of concentrated ammonia solution: 190–210 TT; (4) Carbonization resistance: ≤2.8 kg/cm2; the size of the carbonized crystals is moderate, with a CO2 content in the concentrated ammonia solution of ≤75

Safe Operation and Prevention Measures for the Centrifuge Station 1. Starting up: 1) Open the cooling water valve for the oil tank and adjust the amount of cooling water. 2) Check that there are no debris inside and outside the sieve basket; the sieve basket should rotate smoothly when turned by hand, with no signs of friction. 3) Start the oil pump first, and once the oil pressure system is operating properly, then start the main machine. 4) After the main machine is running under no load normally, open the discharge valve and add the suspension evenly for separation. 2. Shutting down: 1) Once the suspension has been separated, close the discharge valve. After all the mother liquor has been drained, open the steam valve to clean the mother liquor pipelines and valves, then adjust the valves properly. 2) First shut down the main machine, and after two to three minutes, shut down the oil pump as well. 3) Use a special tool to remove the filter cake from inside the sieve basket. It is strictly prohibited to insert hands or other tools into the drum while the centrifuge is running, either to retrieve items or to stop the drum. 4) It is forbidden to use shovels or similar tools to push the filter cake, as this could cause injuries or damage to the sieve basket. 5) It is not allowed to use the rotation of the main machine to force the fertilizer in the drum to one side in order to start the machine and remove the fertilizer; this can lead to severe imbalance in the drum, increased load, motor damage, and damage to the sieve basket. 6) If maintenance is required for the system, use steam and clean water for flushing, and take samples for analysis. An oxygen content of more than 20% indicates that the system is in good condition. 7) Reasons for vibration of the machine body and sieve basket: A. Uneven feeding, resulting in uneven thickness of the filter cake or damage to it. B. Damaged bearings. C. Loose foundation bolts. D. Large deviation in the concentricity of the sieve basket, or damage to the basket that causes loss of balance. 8) Low oil pressure leads to slow feeding speed, or a sudden increase in current, as well as rapid feeding and blockages in the mother liquor pipes due to crystallization. 9) Blockages in the recovery pump can cause seal failure and motor damage (due to inadequate cleaning after use, or improper operation of the valves). Carbonization Workshop

Work Hazard Analysis Form
Work Task: Dismantling of the Ammonia Carbonization Tower
Work Location: Carbonization Workshop
Analyst:
Reviewer:
Analysis Date: November 15, 2007
Review Date: November 16, 2007
Sequence Number Work Step Hazard Controls 1 Installing a blind flange Gas release (fire/explosion); the blind flange being too thin or not sealing properly, resulting in sparks; hands and upper limbs getting trapped; head hitting the valve Open the drain valve to confirm it seals tightly without leaks; wear protective equipment. Blind plates must meet the requirements; asbestos boards cannot be used as a substitute. The tower must first be purged with steam; hitting it with a hammer is strictly prohibited. Use tools for the operation; hands must not be inserted inside the flange, and protective equipment must be worn. 2. Clean and purge the toxic gases; if the purification is not satisfactory. Fill the equipment with water, then drain it from a height; take samples for analysis – the ammonia content in the water should not exceed 5 TT. The flushing time must be at least 30 minutes. 3. Disconnect the pipes and foundations. Welding wires can trip people, and sparks can ignite surrounding flammable materials; there is also a risk of electric shock or falls from heights. It is necessary to obtain permits for working with fire and for working at heights, ensure that there are no leaks in the area, take protective measures, keep the site free of debris, ensure that the welding machine is properly grounded, wear protective gear, use safety ropes, and ensure that the scaffolding is stable. 4. Lift the entire structure out. There is a risk of people falling, fishing hooks breaking, steel cables being cut, insufficient height of the lifting arm, objects falling and causing injuries, or the tower tilting. Use safety ropes, assign experienced personnel, ensure that the lifting lugs are secure and in the correct position. Choose a crane that meets the requirements, leaving some margin. The steel wire rope is properly tied. Set up a safety zone; no one should be in the vicinity. The lifting rope must be securely fastened and under stress before it can be cut.

Safety operating procedures for the carbon chemical section: 1. Tower inversion operations must be carried out slowly in accordance with the established procedures, to ensure that the composition of the feed gas remains appropriate; it is strictly prohibited to build up pressure or to reverse the direction of flow in the tower, as this could cause the gasses to surge and damage the padding. 2. Strictly control the level of the combined tower and cleaning tower liquid to prevent the desulfurization agent from coming into contact with water or being carried into the compressor, which could lead to liquid slugging accidents. 3. When the centrifuge is in operation, it is prohibited to insert hands or other tools into the drum to retrieve items. 4. Strictly control the carbonization process to prevent carbonized gas from flowing back into the ammonia tank. The direct use of liquid ammonia to produce ammonia water is prohibited. 5. Strictly control the levels of CO2 and ammonia in the feed gas to stay within the specified process parameters. 6. It is strictly prohibited to seal leaks while the carbonization tank is under pressure. 7. When taking samples from the mother liquor or concentrated ammonia solution, care must be taken to prevent ammonia from getting into the eyes or on the skin. 8. It is strictly prohibited to strike the ammonia tank and the mother liquor tank with iron tools. When performing welding or other fire-related operations inside these tanks, a \"fire permit\" must be obtained in accordance with the relevant regulations, and measures must be in place to prevent sparks from spreading. 9. When maintaining the carbonization system, gas displacement and analysis must be conducted to ensure compliance, regardless of whether welding is involved; it is strictly prohibited to use iron tools for striking, and bolts should be removed slowly. A strict shift-handover system and the rules of “three preparations before starting work, eight prohibitions during duty, and five conditions under which one must not leave work”.

Assessment Test for New Employees in the Carbonization Workshop Name: Score: I. Explanations (5 points per question, 30 points in total) 1. Three-level training refers to: , , . 2. The tasks of this position are: . 3. Characteristics of fertilizer production: . 4. Main structure of the carbonization tower: . 5. When entering workplaces with a strong ammonia smell, a gas mask should be worn. 6. In what scenarios are CO2 fire extinguishers used?: . II. Essay Questions (70 points in total) 1. Describe the process flow for gas, liquid, and steam cleaning in this position. (15 points) 2. The main control points during the operation – how is the tower inversion using the liquid-pressure method carried out? (15 points) 3. What are the hazards of blockages at the base of pipes and towers, which prevent the main tower pump from pumping liquid? (20 points) 4. What abnormal phenomena have you encountered during operation, and how can they be prevented? (20 points)

Under what conditions does crystallization become finer during the carbonization process?

Emergency Plan to Prevent Concentrated Ammonia Solution from Entering the Main Ammonia Gas Pipeline I. Reasons for liquid inclusion: 1. Excessive negative pressure draws ammonia solution from the ammonia absorption intensifier into the main ammonia gas pipeline. 2. The outlet valve of the ammonia suction pump was opened too rapidly, preventing an effective vacuum from being established in the cone section of the ammonia suction unit. 3. The central tube of the high-position ammoxidizer has ruptured, causing the liquid to take a shortcut; the nozzle tube in the conical section is damaged, resulting in poor vacuum levels. 4. The inlet valve of the absorption cooling exhaust pipe is not open or has fallen off, and the exhaust pipe is blocked and not unobstructed. II. Emergency measures: 1. Immediately close the outlet valve of the absorption pump, and open the drain valve at the main ammonia gas pipeline to discharge water. 2. Contact the on-duty supervisor of the chiller workshop and the dispatcher promptly. 3. Identify the cause of the liquid leakage; if it is a equipment issue, switch the pump promptly and consult a mechanic for repair. III. Preventive measures: 1. During absorption operations, the valves must be carefully checked to prevent accidental opening or closing. Frequently check the temperature of each layer of the coiled tubes by touch to determine whether there is any blockage in them; also, control the concentration of ammonia and the CO2 level appropriately to prevent crystallization from causing blockages in the coiled tubes. 2. The outlet valve of the pump should be opened slowly; it is best to open it in stages in a gradual manner. 3. Regularly inspect the high-position ammonia absorber; you can feel the temperatures of the reaction area and the air intake area of the absorber with your hand. 4. It is strictly prohibited to absorb with negative pressure in the main ammonia pipeline.

What factors during the carbonization process cause the crystals to become finer? 1. Excessive amount taken out. 2. The temperature of the secondary tower is too low. 3. The temperature of the primary tower is too high; the crystals are soft and turn into water when pressed. 4. The liquid levels in the main and auxiliary towers are improperly set too low. 5. Excess liquid level in the secondary tower causes liquid to flow over into the primary tower. 6. The ammonia water TT is too low. 7. The amount of additive suddenly becomes too low.

In actual carbonization production, it is not good if the crystals are too fine; however, it is also not ideal if they are too coarse. This not only results in higher requirements for ammonia concentration, longer residence time during carbonization, as well as side reactions and increased ammonia consumption, but it also hinders an increase in production volume.

Emergency plan for high system pressure in the carbonization unit: Emergency actions: 1. Contact the dispatching, conversion, and desulfurization teams promptly to reduce the flow rate and carry out venting as necessary. 2. When the tower is knocked down, the system pressure rises; immediately restore it to its original state before checking for obstacles again. 3. Blow out pipes, valves, tower tops, and gas distributors using steam. 4. Appropriately reduce the liquid level in the relevant tower. Causes and prevention: Crystalline blockages in gas pipelines and valves, as well as severe scarring inside the main tower. The liquid level in the main tower, auxiliary tower, or scrubber tower is too high. Caking of the advanced desulfurization agent, etc. 1. Strengthen routine inspections; operations must be carried out in accordance with the Safety Operating Procedures. 2. During shift handover, it is necessary to follow the \"Shift Handover Procedures,\" and pay attention to the operating pressure of this system, the pressure difference, the reaction temperatures in the main and auxiliary towers, as well as the liquid levels in each tower and any changes in gas composition. 3. Insist on periodically purging relevant components such as gas pipes, valves, gas distributors, and the tower top in segments. 4. When starting up, shutting down, or operating at low production loads, be careful to avoid excessive decarburization flow; since the gas flows in the main and auxiliary carbonization towers are low, this can lead to gradual blockage of these towers and the occurrence of a false pressure difference. 5. Insist on regularly toppling the tower twice a day to remove the scabs inside it. 6. Strengthen the waste discharge process in the desulfurization tower to prevent the desulfurizing agent from absorbing water and becoming caked due to moisture. 7. Fill in the operation and routine inspection records carefully.

Crystallization occurs when a solution becomes saturated. The formation of crystals can be divided into two stages: the formation of crystal nuclei and the growth of those nuclei. At the onset of crystallization, if the saturation of the solution is too high, the rate of nucleus formation exceeds the rate of nucleus growth, resulting in fine and numerous crystals. The supersaturation of the solution is related to the temperature of the solution. Therefore, in order to obtain coarse and uniform crystals, during the carbonization process, the temperature is kept slightly higher in the areas where nuclei form and at the initial stage of crystal growth, after which cooling is gradually applied to continue the carbonization process.

The problem of continuous illumination of the carbonization level electrode: After being in use for a certain period of time, the level electrodes in the carbonization tower experience the issue of continuous illumination. The main problem is the formation of scale at the location of these electrodes inside the tower. Due to the decarburization system in place, the load on our carbonization tower with a diameter of 2600 should not be high; the actual volume of gas processed is roughly less than 10,000 NM3/h. Nevertheless, we still insist on adjusting the tower every 8 hours in order to dissolve the scale buildup within it. Yet, even after less than a month of use, the carbonization level electrodes started to exhibit continuous illumination. When we tried to relieve pressure in the tower, the scale covered the electrodes completely, preventing them from being removed. We spray ammonia directly into the tower, and we also add composite fertilizer additives. The temperature in the tower is generally maintained between 30 and 35°C. We’re not sure what exactly is causing this problem. How do you guys solve the issue of continuous illumination of the carbonization level electrodes? I hope all experts will kindly share their insights...! Thank you!

1. Adjust the tower at the specified time； 2. Strictly control the carbonization degree of the main and auxiliary towers (especially the auxiliary tower and the carbonization liquid) ； 3. Appropriately increase the concentration of concentrated ammonia solution ； 4. If nothing else works, then the only option is to use a steam cooking tower ； 5. Control the content of additives in concentrated ammonia solution within the process specifications, etc. Could it be related to the device or the way the electrodes are installed? For example, could it be due to the electrode not being at the proper height above the water tank, the electrode having an insufficient length, an incorrect inclination in its installation, or an improper angle between the electrode and the liquid feeding tube, as a result of which it is not exposed to ammonia spray over an extended period of time? It could also be related to the manufacturing process. For example, maybe the temperature at the top of the tower is controlled too low, resulting in premature crystallization; or improper control of additives might cause the crystals inside the tower to become soft and float around, thereby blocking the electrodes Haha, I hope all experts can discuss this from various perspectives and share their own solutions! Thank you

How to increase carbonization yield and how to control it in practice. What is the relationship between factors such as the level of components in the main tower and the ammonia concentration?

The temperature at the base of the main tower is too high, the concentration of concentrated ammonia is too high, and the time for tower cultivation is too short

1. The amount taken out is too large, so the crystals do not have enough time to grow. 2. Improper temperature control of the main tower. 3. Excessive gas volume leads to overloaded carbonization production. 4. The high hydrogen sulfide content leads to the formation of ammonium sulfide and ammonia hydrosulfide during the carbonization process, resulting in finer crystals. 5. The method of adding the additive is incorrect or the quality of the additive is poor.