Incredible levels of carbonized exhaust gases
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After restarting the plant following maintenance, the liquid level in the carbonization tower was around 20 meters. Gas was introduced under light load (the AII pump was started more than ten minutes later). About one and a half hours later, the carbon dioxide content in the exhaust gases increased; manual analysis showed 24% (27% for carbon dioxide in the shift gas). The high concentration of carbon dioxide entered the copper washing tower, and the ammonium carbonate crystals caused the tower to become clogged. The plant had to be shut down again and cleaned with steam and water before it could be restarted, resulting in a production disruption of over ten hours. It would be understandable if the carbon dioxide level rose during the gas introduction phase, as the AII pump wasn’t running at that time and the tower’s liquid level wasn’t high. But after more than an hour had passed, why was the carbon dioxide level still so high?
After starting up the equipment following maintenance, the liquid level in the carbonization tower is around 20 meters. What is the composition of the liquid inside the carbonization tower? Gas is being introduced under light load (the AII pump started more than ten minutes later). How is the flow rate on Pump 2 for ammonia? How about ammonia as a two-component system? About one and a half hours later, the carbon dioxide level in the exhaust gases increased; the manual analysis showed 24% (27% for carbon monoxide). What is the flow rate of carbonization? What is the air intake volume? Is it more or less than usual? Is there a partial blockage in the carbonization tower?
Following up on this post, I hope that when Super Version has time, they will move those material-sharing posts to the material sharing section.
The carbonization load of 2# Steinback is only one-fourth of normal; the AII composition is being adjusted. The situation isn’t great, but it shouldn’t result in exhaust gas levels of 24 either. The carbon dioxide concentration in the gas after passing through the water scrubber might drop below 10. Which section’s data is the moderator referring to? If it’s from this section, you have the authority to move it; if it’s from the upload area, I’ll need to look for it first.
It belongs to this section; since it’s real*, there’s no permission to move it. The carbonization load is only one-fourth of normal. Do you mean the air intake volume? If the air intake volume is lower than before and the composition of the intake air remains stable, it can basically be ruled out that the problem lies with the air intake. There are basically no changes in the inlet gas and the raw gas; the copper washing tower is clogged. It can be said with certainty that the analysis is correct, and the gas inside the carbonization tower has basically not reacted with the mother liquor. At first, there was no problem with the air intake, but then it started to fail at higher speeds. It can be basically concluded that it is a carbonization issue. If the pump is started late, the air intake at that point is equivalent to pre-carbonization. If it is not ammonia mother liquor to which no CO2 has been introduced, then as the aeration time increases, the reaction zone will move upward. If the original process parameters are still used, it is very likely that CO2 will not be absorbed completely. Please, Super Edition, explain the situation in more detail. There are many experienced users on the forum (excluding me) who can help resolve your doubts.
By the way, I have moved the files. The carbonization exhaust gas content is high; think about it in reverse. This will help solve the problem.
The carbonization process typically involves two towers connected in series; it is necessary to check whether there is internal leakage in the series valves, whether they are not closed properly, or whether crystals have gotten stuck in the valve cores.
Not being familiar with the original poster’s process may lead to incorrect judgments.