The issue of excessive ammonia content in gas
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115,000 cubic meters per hour of gas is processed, using two saturators with a diameter of DN4800. Since a maintenance operation resulted in the complete shutdown of these saturators, the ammonia content in the gas flowing after them has remained above the acceptable level, at around 200 mg/m3. Every possible method was tried, but none of the individuals passed the test (all saturators were replaced, the acidity was increased to 5-6%, and the amount of spraying was increased, among other measures). Could someone knowledgeable please explain the reasons behind this and provide solutions? Have you met colleagues who have encountered the same situation?
Check the gas preheater for any leaks. Before sampling, turn off the steam to the gas preheater, and wait a few minutes before taking samples for testing. If the ammonia level detected is lower, there is a leak in the preheater.
Check for any blockages in the pipes, as well as issues with the saturator spray box and the nozzles inside the saturator
The spray box’s bottom plate is deformed, causing a short circuit in the mother liquor and preventing it from reaching the contact point. The problem is solved now