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TECHNOBELL LIMITED
Talbot House,
204-226 Imperial Drive
HARROW
MIDDLESEX HA2 7HH
GREAT BRITAIN
Tel. +447900080990
E-mail: techno technobell-ltd.com
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 Site menu |
Company
Technobell is a well founded engineering company specialized in the process and project design, acting in the fields of:
GRP production technology
equipment for production of glass reinforced polyester (GRP) pipes
equipment for production of glass reinforced epoxy (GRE) pipes
equipment for production of glass reinforced polyester (GRP) tanks
equipment for testing pipes
Chemical process technologies
polyester resins plants
phthalic anhydride (PA) and catalysts for production of phthalic anhydride plants
maleic anhydride (MA) plants
plasticizers (DOP) plants
polyvinyl acetate dispersions (PvAc) plants
crude oil / lube oil refinery and petrochemical plants
Technobell is also a producer of tailor made ortophthalic, isophthalic and vinylester resins.
Technobell has commercial and financial capability to supply turnkey projects. Its specialists and consultants, thanks to the long experience achieved, are able to assist the investor starting from the feasibility study to the best solution according to the market requirements.
Technobell’s administrative office is located in Great Britain. Representative/Associated offices are located worldwide: Brazil, Croatia, China, Italy, Libya, Russian Federation, Slovenia and United Arab Emirates.
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 Activities
Commercial
Commercializing chemical products on EU market
Production of Polyester resins
Financial
Supporting investments and Projects mainly in the technological sphere
Technological
Chemical processes
Equipment supply
Glass Reinforced Plastic production technologies
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Experience
Company specialists with their partners, have over 50 years of experience in the sphere of:
Contracting
Feasibility studies (pre-investment studies),
Selection and control of subcontractors.
Process engineering
Energy and heat balances,
Basic engineering based on own or foreign design,
Detailed engineering of plant,
Selection of personnel and training,
Advisory services on start up and commissioning of plants,
Ecological engineering,
Fire protection and safety,
Revamp studies on existing process units for energy and utilities saving.
Construction of plants, start-up supervision, commissioning
Procurement of equipment and material,
Expeditionary services (supervision / inspection) for equipment and material supply,
Erection / mounting and supervision,
Training, plant staff formation,
Technically reliable consulting services and owner’s assistance to assure successful project implementation.
Equipment supply
Design,
Manufacturing,
Quality assurance.
Turnkey projects
Post commisioning services
Maintenance services,
Spare parts supply.
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Manpower
The employees of TECHNOBELL Ltd. are all highly skilled. Without exception and including the management they all come from the Industrial sector – Refineries and Chemical plants.
The employees are graduated engineers and technicians of different business professions. They cover all branches of process design and construction site activities.
Depending on extent of project and complementary works, additional specialists can be immediately engaged to support long term complex projects.
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Business partners
RolleChim
Scientific Design Inc.
Sulzer Chemtech
ABB
SNAM Progetti
Foster Wheler
Technip
Rolle
Nuovo Pignone
Honeywell
Orion
Xomox -Tuflin
Yokogava
Siemens
Fisher Rosemount
Uhde
Manesmann
Ocsam
ABB Analytical
Samson
Woma
KTI
FlowGuard
I.V.A.R.
PALL
VOITH
John Crane
And many other excellent companies.
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GRP production technology
Glass Reinforced Polyester pipes are manufactured with polyester resins and fibrous glass reinforcements and depend on the type with inorganic filler. The design philosophy of GRP pipes is to provide products with suitable properties and the required margin of safety that will enable the pipe to work satisfactory after an extended period of operation (50 years) under typical service conditions.
They represent the ideal solution for conveying any kind of water and most of the chemicals, because they combine the advantage of corrosion resistance, which is typical of plastics, and high mechanical strength, typical of steel.
GRP pipes can be produced with continuous (CFW) and discontinuous (DFW) manufacturing process.
GRP pipes are joined with:
GRP Sleeve
GRP Bell & Spigot
GRP Flanges
GRP Lamination - welding
Available are all standard fittings, which are:
Elbows of any degree
Fix, loose, blind flanges
Equal, reduced, lateral tees
Concentric, eccentric reducers
End caps
Fittings and special items are manufactured using the hand lay-up technique. The chemical barrier and the top coat of fittings are equal to the one of the pipe; the structural wall is made with alternated layers of mat and woven roving.
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GRP pipes
Glass Reinforced Polyester pipes are manufactured with polyester resins and fibrous glass reinforcements and depend on the type with inorganic filler. The design philosophy of GRP pipes is to provide products with suitable properties and the required margin of safety that will enable the pipe to work satisfactory after an extended period of operation (50 years) under typical service conditions.
They represent the ideal solution for conveying any kind of water and most of the chemicals, because they combine the advantage of corrosion resistance, which is typical of plastics, and high mechanical strength, typical of steel.
GRP pipes can be produced with continuous (CFW) and discontinuous (DFW) manufacturing process.
GRP pipes are joined with:
GRP Sleeve
GRP Bell & Spigot
GRP Flanges
GRP Lamination - welding
Available are all standard fittings, which are:
Elbows of any degree
Fix, loose, blind flanges
Equal, reduced, lateral tees
Concentric, eccentric reducers
End caps
Fittings and special items are manufactured using the hand lay-up technique. The chemical barrier and the top coat of fittings are equal to the one of the pipe; the structural wall is made with alternated layers of mat and woven roving.
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Continuous filament winding
CFW Machine
PHTM Machine
SHTM Machine
SJM Machine
SGM Machine
Laboratory
Factory CFW2600
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CFW Machine
The CFW MACHINE is designed for the continuous production of GRP pipes. Pipe manufacturing is done on the rotating mandrel assembled with discs, aluminium beams and steel band, sized according to the required pipe diameter. The steel band is moving in the axial direction, sliding over the bearings inserted in aluminium beams. At the end of the mandrel, exit head guides the steel band into the mandrel inner tube. On the opposite end of the mandrel, the steel band is wounded on the mandrel again. Steel band forms a smooth surface mandrel with simultaneous advancing in the axial direction. Raw materials are applied simultaneously on various mandrel positions depending on production technology. The laminate building-up can be easily made in compliance with the appropriate design by controlling the amount and position of various materials applied.
After the curing oven, the pipe is automatically cut and calibrated to the required length by a suitable cutting unit.
CFW MACHINE TYPES
CFW600 : 300 – 600mm pipes
CFW2600 : 300 – 2600mm pipes
CFW4000 : 300 – 4000mm pipes
The CFW MACHINE is designed for very high production capacity. It is ideal choice when the GRP pipes are used for water transmission and distribution, desalination plants, cooling systems in power plants, irrigation projects and sewage systems.
LINE CAPACITY
The production line capacity is 200 km/year of DN800mm PN6 bar pipe (based on 300 production days/year, three shifts).
CFW600 area and height required:
Width = 10m
Length = 26m
Height = 5m (under crane hook)
CFW2600 area and height required:
Width = 12m
Length = 28m
Height = 7,5m (under crane hook)
CFW4000 area and height required:
Width = 14m
Length = 30m
Height = 7,5 (under crane hook)
Utilities requirements:
Max. Power Supply = 3 x 400V / 50 Hz
Max. Power Consumption CFW600 =220 Kw
Max. Power Consumption CFW2600 = 240 Kw
Max. Power Consumption CFW4000 = 290 Kw
Max. Compressed Air Consumption = 8 bar - 6 m3/min
Machine Operators Requirement:(workers per shift)
1 machine captain
1 chopper operator
1 roving operator
2 mylar, “C” veil and roller operator
CFW Machine is fully numerically controlled. All machine operations and dosing system is controlled by computer. All production data are available in computer archive.
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PHTM Machine
Pipe hydro-testing is performed on PHTM MACHINE. Pipe hydro-testing machine is designed and constructed to allow the hydrostatic tests on GRP pipes, according to all major international standards.
The pipe is rolled on supports and by lifting tables centred between two heads. Pipe is inserted between sealing plates and closed by hydraulic unit. The pipe hydraulic test is performed by water pressure unit. After successful pressure test, pipe is released from the sealing plates by hydraulic cylinder. PHTM is complete with electric power box and is completely wired.
PHTM area and height required:
Width = 5 m
Length = 20 m
Height = 5 m
Requirement for the concrete water reservoir under the machine (inside dim.):
Width = 3,5m
Length = 15,5 m
Height = 3,1 m
Utilities requirements:
Max. Power Consumption = 50 Kw
Max. Water Supply = 100 l/h
Machine Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
Main characteristics of the PHTM machine:
Max. test pipe length: 12000 mm
Test pipe diameter: 300-2600/4000 mm
Max. end trust load: 640/1100/1600 tons
TESTING CAPACITY
The testing capacity of the PHTM Machine is fully in line with the capacity of CFW Machine, the 100% pipe testing can be achieved.
PHTM Machine is fully automated machine. All operations of pipe sealing and pipe filling are automatic. The testing pressure and time can be easily checked on the measurement equipment, which is also part of the machine.
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SHTM Machine
Sleeve couplings are tested on SHTM MACHINE. Sleeve is inserted by the support trolley and is closed by the upper and lower sealing ring which are mounted on the support plate. Sealing plates are fixed on upper and lower frame. Lower frame is fixed in the basement with anchor bolts, upper frame is moved by hydraulic cylinder during pressure test, support plates are closed by clamps, mounted on the periphery of upper frame. Sleeve is sealed with standard sealing gaskets. Pressure is applied by water pressure unit. After successful pressure test, sleeve is extracted by hydraulic cylinder. Each SHTM is complete with electric power box and is completely wired.
SHTM Machine is fully automated machine. All operations of sleeve sealing and filling are automatic. The testing pressure and time can be easily checked on the measurement equipment.
SHTM area and height required:
Width = 4 m
Length = 7 m
Height = 4 m
Utilities requirements:
Max. Power Consumption = 20 kW
Water Supply = 10 l/h
Machine Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
TESTING CAPACITY
The testing capacity of the SHTM Machine is fully in line with the production capacity of our CFW Machine
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SJM Machine
Sleeves are assembled-joined with pipe on sleeve joining machine.
Sleeve joining machine should be placed near pipe hydro-testing machine, because according to customer requirements pipes are assembled with sleeve joint.
Pipe transport and movement between machines is foreseen by means of pipe transport trolleys and support beams for pipe rolling.
OGM is foreseen for pipe cutting and grinding operations off line. Off line cutting and grinding is needed when shorter pipes, pipes for fittings or some repair work are required.
The pipe is supported by support wheels. Equipment is complete with electric power box and is completely wired. During cutting and grinding, dust is a side product. Grinding and cutting tool are connected by flexible tubes with suction line and dust filter.
SJM area and height required:
Width = 3 m
Length = 17 m
Height = 3,5 m
Utilities requirements:
Max. Power Consumption = 5 kW
Main characteristics of the SJM machine:
Pipe length: up to 12000 mm
Pipe diameter: 300-2600 mm for SJM2600 and 300-4000 for SJM4000
SJM Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
OGM area and height required:
Width = 7 m
Length = 14 m
Height = 2,5 m
Utilities requirements:
Max. Power Consumption = 40 kW
OGM Operators Requirement:
(workers per shift)
1 machine operator
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SGM Machine
SGM is foreseen for sleeve grooving and cutting operation. Sleeves are made from a pipe, which is produced on CFW machine. For an easier pipe manipulation, the pipe has to be cut on 4m lenght. The pipe is supported by the support wheels which are driven by the gear box. Drive motor, belt system and grooving tool set are mounted on hinged support plate connected to the pneumatic cylinder. When grooving is finished, pipe cutting operation starts, while the pipe is still rotating. After sleeve removal, the rest of pipe is moved forward with hydraulic supports toward the correct position for new sleeve production. Equipment is completed with electric power box and is completely wired. During sleeve coupling manufacturing, due to grinding and cuttitng operations, dust is a side product. Grinding and cutting tool are connected by flexible tubes with suction line and dust filter.
SGM area and height required:
Width = 3 m
Length = 5 m
Height = 3 m
Utilities requirements:
Max. Power Consumption = 40 kW
Machine Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
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Laboratory
Technobell equipment for the GRP pipe production includes also laboratory and testing equipment.
Pos.
Description
I.
Mechanical Tests Laboratory
II.
Chemical Tests Laboratory
III.
Laboratory Archive and Library
IV.
Laboratory testing Area
Pos.
Description
1
SD2600 Split Disk Testing Machine
2
CK2800 Stiffness Testing Machine
3
UTM Universal Testing Machine
4
Desk for PC
Pos.
Description
5
Laboratory Furnace
6
Water Bath
7
Magnetic Stirrer
8
Analytical Balance
9
Laboratory Balance
10
Drying and Heating Oven
11
Digital Viscometer
12
Equalising Cupboard
13
Fresh water
14
Wardrobe
15
Desk for PC
16
Desk for PC
17
Books / Standards Archive
18
Desk for Copy Machine and Printer
Technobell suggests and in case assists to obtain quality assurance certificate in accordance with EN ISO 9001.
Technobell Quality Control and Inspection Plan incorporates full traceability of materials according EN 10204 3.1.b.
Detailed Description of Quality Control Activities
QUALITY CONTROL ON RAW MATERIALS
QUALITY CONTROL DURING PRODUCTION PHASE
QUALITY CONTROL ON FINISHED PRODUCTS
PROCESS AUDIT
FINAL DOCUMENTATION
QUALITY CONTROL ON RAW MATERIALS
QUALITY CONTROL ON RESIN
Density (ASTM D 792)
Viscosity (ASTM D 2393)
Gel time (ASTM D 2471)
Peak temperature (ASTM D 2471)
Monomer content (DIN 16945)
Acid number (ASTM D 1639)
Volumetric shrinkage (ASMT D 2566)
Elongation at failure (ASTM D 638)
QUALITY CONTROL ON GLASS
Mass control (ISO 3374)
Moisture content (ISO 3344)
Organic content (ISO 1887)
QUALITY CONTROL DURING PRODUCTION PHASE
DIMENSIONAL CHECK
According Construction Specification
WALL THICKNESS
According Construction Specification
MATERIAL TRACEABILITY
for raw materials
for GRP components
for other components
for finished product
PROCESS AUDIT & FINAL DOCUMENTATION
Ultimate Tensile Strength, Unit Modulus and Shear Strength
According BS 4994
Visual inspection of cut out pieces
According ASTM D 2563 II
Resin / Glass Percentage
According ASTM D 2584
Final Thickness and Dimension Measurement
According Construction Specification
Stiffness test
According BS5480
Barcol Hardness
According BS 2782 or ASTM D 2583
Pressure hydro-test
According BS 5480 and client requirements
Testing machines are supplied with computer software programs. All testing data are immediately shown on the computer screen and stored in the computer database.
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Factory CFW2600
Machines in the factory can be disposed according to the factory building or special client requirements. Layout drawing shows typical factory arrangement.
Pos. Description
1 Tools Cleaning Room
2 Resin Mixing Room
3 Dosing Pump Room
4 Bridge Crane – 10 tons
5 CFW2600 Machine
6 Resin Storage 4 x 50m3
7 Vapours Suction Ventilator
8 Dust Filter
9 Pipe Transport Equipment
10 OGM2600 Offline Grinding Machine
11 SGM2600 Sleeve Grooving Machine
12 SHTM2600 Sleeve Hydrotesting Machine
13 SJM2600 Sleeve Joining Machine
14 PHTM2600/640 Pipe Hydrotesting Machine
15 Laboratory
16 Air Compressor
17 Main Power Panel
18 Main Control Console
19 Diesel Electric Generator
20 Electro Station
21 Fittings Production Area
22 Pipe Testing Area
23 Catalyst Storage Area
24 Accelerator Storage Area
Factory covered area and height required:
Width = 36m
Length = 78m
Height = 7,5 (under crane hook)
Factory outside uncovered area required:
Area = 25000 m2
Utilities requirements:
Power Supply = 3 x 400V / 50 Hz
Production Line Installed Power =App. 400 kW
Max. Compressed Air Consumption = 8 bar - 6 m3/min
Emergency Diesel Generator = 240 kW
The complete CFW production factory requires approximately 60 employees for the production in 3 shifts (24h per day). They are divided in the following positions:
1 production manager
4 machine captains on CFW machine
16 machine operators on CFW machine
4 machine operators on the SGM machine
4 machine operators on the SHTM machine
6 machine operators on the PHTM machine
2 machine operators on the SJM machine
1 quality control manager
4 quality control operators
4 mechanical and electrical maintenance workers
4 store keepers
10 workers in the fitting manufacturing shop
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Discontinuous filament winding
Moulding the Chemical Resistant Liner
A film of material is applied to the mould and, thereafter, the first plies of special glass reinforcements are laid up and retain a very high percentage of corrosion resistant resin. This operation enables a fully impermeable wall to be obtained with a high resistance to chemicals.
Winding the Reinforcement
The structural part of the pipe is made by the filament winding of continuous glass yarns (roving) impregnated with resin. The pitch of the winding spiral and, thereby, the angle formed between the yarns and the axis of the pipe are determined during the design work and depends on the stresses to be withstood. At the same time as filament winding is taking place.
The internal or box thread of epoxy pipes is made during the initial phase of filament winding process, through the automatic winding of glass and resin on the ends of the pipe.
Curing and facing
To prevent the resin from dropping, the curing operation is carried out while the pipe is rotating in its own axis. Curing of epoxy pipes is made in special oven at temperature ranging up to 150°C.
Then facing of extremities is made so that to allow the extraction of the pipe from the mandrel.
Extraction
The pipe bar is extracted from the mandrel; this operation takes place in a dedicated working station controlled by a system which allows to automatically carrying out the different working phases.
Grinding the Areas of the Joints
After extraction, epoxy pipe is placed on the rectifying machine for rectification of the ends and for machining of the grooves for O-ring and lock joints, where required.
Testing
Manufacturing of the pipes is subjected to constant checking. The checks are carried out on the raw materials, at each production phase and, lastly, on the finished product. The mechanical strength of finished products is tested periodically on lengths of pipe chosen at random from standard products. The test consists in reproducing the conditions which the pipes will have to undergo during working and also, in a dimensional check. The inspected pipe, if accepted, is indelibly marked with indications relevant to manufacturer lot, manufacturing date, diameter, pressure class and then is sent to the factory stockyard waiting for shipping.
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DFW Epoxy/Polyester
UNDER CONSTRUCTION
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GRP Tanks
UNDER CONSTRUCTION
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References
China: Continuous production line DN 250-2600 production capacity 200
km/year
Brazil: Revolving multi mandrel line DN 150 -800 production capacity 80
km/year
Abu Dhabi: Continuous production line DN 250-2600 production capacity 200
km/year
Egypt: Continuous production line DN 400- 2600 production capacity 200
km/year
Abu Dhabi: Continuous production line DN 300-600 production capacity 200
km/year
Abu Dhabi: Continuous production line DN 300- 2600 production capacity 200
km/year
Abu Dhabi: revamping of Owens corning Continuous production line DN 300-2600
Dubai: Continuous production line DN 300 - 3700 production capacity 200
km/year
Dubai: Revamping of Owens corning Continuous production line DN 300- 2600
Saudi Arabia: Continuous production line DN 300- 4000 production capacity
200 km/year
Moscow: 20 GRP tanks volume 50 m3
Syria: Continuous production line DN 300 - 2600 production capacity 200
km/year
Russia: Continuous production line DN 300 - 2600 production capacity 200
km/year
Kazakhstan: Continuous production line DN 300 - 2600 production capacity 200
km/year
Dubai: Continuous production line DN 300 - 2600 production capacity 200
km/year
Saudi Arabia: Continuous production line DN 300 - 2600 production capacity
200 km/year
Saudi Arabia: Discontinuous epoxy production line DN 80 -1200 production
capacity 95 km/year
Saudi Arabia: Continuous production line DN 300 - 4000 production capacity
200 km/year
Dubai: Continuous production line DN 300 - 2600 production capacity 200
km/year
Algeria: Continuous production line DN 300 - 2600 production capacity 200
km/year
Algeria: Discontinuous production line DN 80 -1000 production capacity 95
km/year
Libya: Continuous production line DN 300 - 2600 production capacity 200
km/year
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Chemical process technologies
Under construction
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Maleic anhydride (MAn)
Our system based on Maleic Anhydride (MAn) unit consists of fixed bed reactor(s), continuous gas cooling, continuous product recovery systems by partial condensation and absorption, batch dehydrating and distillation system (or continuous dehydrating and batch refining system) and a continuous incinerator unit.
Maleic anhydride is produced by the partial oxidation of butane with air over a vanadium/phosphorus catalyst. Low concentrations (PPM range) of a stabilizer (SAS) are added to the feed gas stream to stabilize catalyst activity and selectivity. Water (in the form of steam) is also added under some conditions to modify catalyst performance.
Reactor off-gas from the fixed bed reactor flows through a gas cooling system and then min. 50% of the maleic anhydride is condensed in the partial condenser, the other cc. 45-50% feeds to the scrubber and forms Maleic Acid (MAc) solution by reaction with treated Boiler Feed Water.
The molten pure Maleic Anhydride (product) is recovered from the condensed (called: crude) Maleic Anhydride and Maleic Acid solution in a semi-automatic 7-steps dehydrating-refining procedure. Solvent for the dehydration is xylene. In case of higher capacity requirement the system is divided to continuous dehydrating and batch refining systems.
Recovered heat of the exothermic reaction and back-cooling of the reaction gases are used for steam generation. If the customer requires, the system can produce high pressure (HHP) steam, which can be used for operation of the air compressor steam-turbine driver(s) or to produce electric energy.
The off-gas coming from top of the scrubber contains flammable, environmental polluter materials. This environmental damage can be eliminated by burning away the flammable components of off-gases while the generated heat can be used for steam producing.
Process scheme – WITH BATCH DEHYDRATOR/REFINER COLUMN
Process scheme – WITH CONTINUOUS DEHYDRATOR AND BATCH REFINER COLUMN
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 References (Members Only) |
Phtalic Anhydride
The Phthalic Anhydride (PA)is today produced from two main sources:
production from o-xylene
production from benzene – some old plants
Both main technologies involve specific catalyst for selective oxidation of raw material to product.
Basically the technology consist of 3 main phases:
oxidation (performed in reactor block),
recuperation of Phthalic Anhydride from reactor off-gases (performed in switch condensing section) and
refining to commercial product (performed in distillation unit).
Any of Phthalic Anhydride production technologies include sub sections as:
Steam system – energy recuperation
Waste gases incineration
Is possible to recover Maleic anhydride from off gases of switch condensers in quantity of about 4% calculated on PA
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Basic
The Phthalic Anhydride (PA)is today produced from two main sources:
production from o-xylene
production from benzene – some old plants
Both main technologies involve specific catalyst for selective oxidation of raw material to product.
Basically the technology consist of 3 main phases:
oxidation (performed in reactor block),
recuperation of Phthalic Anhydride from reactor off-gases (performed in switch condensing section) and
refining to commercial product (performed in distillation unit).
Any of Phthalic Anhydride production technologies include sub sections as:
Steam system – energy recuperation
Waste gases incineration
Is possible to recover Maleic anhydride from off gases of switch condensers in quantity of about 4% calculated on PA
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Chemistry
Main reaction
C8H10 + 3 O2 → C8H4O3 + 3 H2O ∆H = -1108,7 kJ/mol
Burning
C8H10 + 7 O2 → 3 CO2 + CO + 4 H2O ∆H = -4380 kJ/mol
Due to released reaction heat the awailable technology result as energeticaly self sustaining and energy exporters.
Side reactions are forming by-products in very small amounts (less than 6%):
Maleic Anhydride, O-toluic aldehide, Phthalide, Benzoic Acid,Citrconic acid
The reaction takes place on catalyst – basically Vanadium/Titanium type.
Typical temperatures of reaction are between :
Reactor (Salt) temperature: 350 - 400°C.
Catalyst temperature (Hot Spot): 390 - 440°C
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Process Description
The technology of PA production offered by
Technobell limited, starts with oxidation of o-xylene in fix bed
tubular reactor on specific catalyst.
Atmospheric air is compressed by compressor. The
o-xylene is feed to air stream and both pass through catalyst installed
in tubular fix bed reactor, cooled by eutectic salt mixture. There
chemical reaction takes place and o- xylene is transformed mainly to
Phthalic Anhydride. Heat released by chemical reactions is removed
through melted salts to heat exchanger where High Pressure steam is
produced. Reactor gases are conveyed through post reactor where almost
90% of by-products are removed.
The reactor off-gases containing PA are then cooled
to appropriate temperature in two heat exchangers producing Medium
Pressure steam. Cooled gases are further conveyed to Switch condensers
section. In this section PA is removed from gas by the process of
de-sublimation – forming solid crystals. After melting the PA in liquid
form is obtained. The technology allow to obtain almost 99,8% of PA
produced in the reactor.
Switch condensers off gases are conveyed to Thermal
or catalytic Incinerator and after it released to atmosphere. The
Incinerator is designed to incinerate also residue from the
distillation (Light and heavy cut). Due to carefull design important
quantity of heat is recovered in form of MP steam.
Liquid PA from Switch Condensers is first thermaly treated and then continously distilled in two distillation columns.
Finally pure comercial product is conveyed to stock
tanks to be sold in liquid form or conveyed to a solidifying section
where PA flakes are produced and packed in 25 kg bags or 1/1,25 tons
big bags.
Other sections of the plant are:
Steam system, with the task of careful energy transformation and recuperation,
Oil system prowiding hot and cold oil for Switch Condenser operation,
Demineralized water station
Other Utilities system, as Instrumental air, nitrogen, el. Power stations.
From brief description could be seen that efficient PA production technology would:
Obtain as high as possible concentration of o-xylene in feed to reactor leading to:
higher production,
smaller equipment.
Elimination of by products with post-reactor technology leading to:
less consumption of energy for distillation,
Less residue on the distillation,
Extremely good commercial product quality,
Smaller columns
As high as possible de-sublimation efficiency Switch Condenser section.
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YIELD’s
This parameters depends on the catalyst used, however generally they turn around the following numbers:
Content of o-xylene in feed to reactor
80-90gr/Nm3
High reactor yield (depends on catalyst)
up to 115 kg/kg of o-xylene
De-sublimation efficiency on SW. C.
up to 99,8wt%
Distillation residues
2-3 wt%
Overall plant Yield (kg/kg)
109 - 106
Expresed in 100% o-xylene and commercial PA
(new catalyst) (old catalyst)
The catalyst life time
4 to 5 years.
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Commercial Product Properties
PROPERTIES:
Unit
Expected Value
Guaranteed Value
Colour in molten form:
Hazen
5
max. 20
Colour Stability:
Hazen
30
max. 60
Melting Point:
°C
131,5
min. 131,3
Colour Stability
Hazen
30
max. 60
(150°C, 1,5 hours)
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Plasticizers
Plasticizers are additives that increase the plasticity or fluidity of the material to which they are added, these include plastics, cement, concrete, wallboard and clay bodies. Although the same compounds are often used for both plastics and concretes, the desired effect is slightly different.
Plasticizers for plastics are additives, most commonly phthalates, that give hard plastics the desired flexibility and durability. They are often based on esters of polycarboxylic acids with linear or branched aliphatic alcohols of moderate chain length. Plasticizers work by embedding themselves between the chains of polymers, spacing them apart, and thus significantly lowering the glass transition temperature for the plastic and making it softer.
Groups of plasticizers names as phthalates, maleates, sebacates have origin in the name of dicarboxiclic acid used e.g. Phthalic, Maleic, etc. Depending on desired characteristics and application also the Alcohols used may vary.
Technobell ltd can offer to the clients plants designed to produce different plasticizers: phthalates, maleates, sebacates, trimelitates and others. Once defined the production range of Plasticizers during Contracting the plant is specificaly designed to alow easy interchangability between production range.
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Basic
Plasticizers are additives that increase the plasticity or fluidity of the material to which they are added, these include plastics, cement, concrete, wallboard and clay bodies. Although the same compounds are often used for both plastics and concretes, the desired effect is slightly different.
Plasticizers for plastics are additives, most commonly phthalates, that give hard plastics the desired flexibility and durability. They are often based on esters of polycarboxylic acids with linear or branched aliphatic alcohols of moderate chain length. Plasticizers work by embedding themselves between the chains of polymers, spacing them apart, and thus significantly lowering the glass transition temperature for the plastic and making it softer.
Groups of plasticizers names as phthalates, maleates, sebacates have origin in the name of dicarboxiclic acid used e.g. Phthalic, Maleic, etc. Depending on desired characteristics and application also the Alcohols used may vary.
Technobell ltd can offer to the clients plants designed to produce different plasticizers: phthalates, maleates, sebacates, trimelitates and others. Once defined the production range of Plasticizers during Contracting the plant is specificaly designed to alow easy interchangability between production range.
... |
Process description
Production of plasticizers can be shortly divided in few steps:
Esterification
Esterification is an equilibrium chemical reaction which is caried
out as a batch process in the reactor containing an agitator and other
equipment – particularly for water separation and removal which is
formed during chemical reaction.
First phthalic anhydride and the 2-ethyhexanol are mixed in the
reactor in order to form the monoester - mono-2-ethylhexylphtalate. The
reaction takes place at about 150°C. Further the reaction mixture is
heated to 170 - 180°C. At this point the catalyst tetrabutyl-titanate
is added. Before the addition care must be taken to separate all the
water formed in chemical reaction from the system. The evolution of
reaction takes place and water formed must be continously carefully
separated in the alcohol water separator. The temperature in the
reactor is further increased up to 220-235°C to terminate the
esterification. The Raw DOP is obtained.
Distillation and Neutralization
Raw DOP is transferred to the distillation section which consists
of an reactor equipped with the stirrer, vapors condenser, cooler and
alcohol water separator.
The alcohol is distilled first under mild vacuum distillation and at
the end with vacuum distillation and steam stripping. At about
170-180°C sodium carbonate is introduced to neutralize the traces of
the monoester. The hydrolysis of the tetrabutyltitanate is performed in
next step by adding small amounts of water. After the hydrolysis filter
aid (diatomite earth) is added and DOP is dried under vacuum and a
light flow of nitrogen.
Filtration
In this phase, solids formed or aded (diatomite earth) during
neutralization and hydrolysis of the catalyst are removed by
filtration.Other types of plasticizers are produced on the same
equipment using different raw materials.
... |
Consumption & Utilities
Raw materials
Expected consumption per ton of product
DOP [kg]
DBP [kg]
Phtalic Anhydride
382
542
2 – Ethyl Hexanol
671
n- Butanol
560
Catalyst
1
1
Sodium carbonate NaOH
7 (30 % sol.)
4
NaOH
20 (15% sol.)
Filter Aid
2
3
Active carbon
1
NaCl
10
... |
Fumaric Acid
The Fumaric Acid (FA) is today produced from two main sources:
production from furfural – oxidation process
production from Maleic Anhydride and from Off gases / washing waters from proceses for production of Phthalic Anhydride and/or Maleic Anhydride – transformation process
Both main technologies involve specific catalyst:
for oxidation from furfural and
for transformation of maleic acid to fumaric acid in second case.
Technobell ltd is able to offer to clients the transformation process in both cases as production from Maleic Anhydride and from Off gases of two mentioned processes.
In both cases the feed for technology process is Maleic acid solution from where the Maleic anhydride is transformed with specific catalyst to Fumaric Acid.
To the transformation process follows the stages of purifying, solidifying and packing of commercial product.
... |
Basic
The Fumaric Acid (FA) is today produced from two main sources:
production from furfural – oxidation process
production from Maleic Anhydride and from Off gases / washing waters from proceses for production of Phthalic Anhydride and/or Maleic Anhydride – transformation process
Both main technologies involve specific catalyst:
for oxidation from furfural and
for transformation of maleic acid to fumaric acid in second case.
Technobell ltd is able to offer to clients the transformation process in both cases as production from Maleic Anhydride and from Off gases of two mentioned processes.
In both cases the feed for technology process is Maleic acid solution from where the Maleic anhydride is transformed with specific catalyst to Fumaric Acid.
To the transformation process follows the stages of purifying, solidifying and packing of commercial product.
... |
Chemistry
Maleic Acid
C4H4O4 (Z)-Butenedioic acid cis isomere
Is in the process transformed to
Fumaric Acid
C4H4O4 2-Butenedioic acid trans isomere
... |
Process description
Introduction and Preliminary Process Description
Fumaric Acid (FA) production plant starts with preparing Maleic Acid solution as a raw feed for final product. This can be an absorption unit in case of production from off gases or a disolving unit in case of production from maleic anhydride.
Following is the transformation unit - batch process which is further followed by dehydrating / refining and solidification Units which usually are continous processes.
Maleic Anhydride Absorption
In the absorption system, maleic anhydride is absorbed into process water from the cooled reactor off-gas, which contains the MA. When the gas containing maleic anhydride passes through the absorber and contacts water, the MA is converted into maleic acid, and the maleic acid solution (Mac) is formed. The MA-free gases leaving the MA Absorber are routed to the Incinerator for disposal.
In case of production from Maleic anhydride the Absorption Unit is replaced by Disolving Unit where maleic anhydride is dissolved to Maleic Acid solution.
Maleic Anhydride Transformation
The Mac solution batch is charged to reactor at defined temperature. Catalysts are added into the reactor for increasing the reaction yield and reducing formation of by-products. Reaction takes place at a defined temperature, which is controlled by steam heating and air cooling inside of the reactor.
After the isomerization reaction the product slurry is cooled down and concentrated by vacuum. Under vacuum the fumaric acid slurry starts concentrating and forming crystals.
Concentrating, drying and packing
The fumaric acid slurry is fed to centrifuge, where cc. 80% of the water content is removed as filtrate. Centrifuge outlet can be loaded into big-bags and dispatched as „wet” fumaric acid product.
In case of dry fumaric acid production the concentrated „wet” fumaric acid is dried by a fluidized dryer operated with steam heated hot air. After the dryer the fumaric acid is supplied into a filtration / sizing system and further to storage in a silo, from where it is fed to the weighing and packing system.
... |
Product Quality
Due to different source of Maleic Acid – pure Maleic Anhydride or Off Gases containing Maleic Anhydride having source in Maleic or Phthalic anhydride production process the final quality of the product is highly influenced.
Generally the process originated with pure Maleic anhydride is able to produce “food grade” quality of fumaric acid.
For a difference in quantity of by products contained in the off gases of Maleic or Phthalic anhydride production process the process starting with Maleic anhydride in Off gases is able to produce only “technical grade” quality of fumaric acid. With additional purifying unit is however possible to assure the “food grade” quality also in this case.
... |
References
Omsk – Phthalic Anhydride plant - Oxidation section revamp
Omsk – Phthalic Anhydride plant - Reactor 12000 tubes -Salt mixer for reactor
Angarsk – Phthalic Anhydride Plant - Condensation section
Angarsk – Phthalic Anhydride Plant - Condensation section – Switch condenser and Control panel
Salavat – Phthalic Anhydride Plant - Flaking section
Salavat – Flaking section
Perm – Polyester resins
Perm – Polyester resins - Reactor
Budapest – MAn– Oxidation and Condensing section – 3D Design
Budapest – MAn– Oxidation and Condensing section – Reactor 20.000 tube
Budapest – MAn– Oxidation and Condensing section – Running plant by night
Other references in field of Chemical process technologies
SALAVATNEFTEORGSINTEZ – PA Distillation unit reconstruction
SALAVATNEFTEORGSINTEZ – Catalyst supply for PA plant
SALAVATNEFTEORGSINTEZ – PA plant flaking section – key turn basis
SALAVATNEFTEORGSINTEZ – Catalyst supply for PA plant
SALAVATNEFTEORGSINTEZ – PA reactor Upgrade
SALAVATNEFTEORGSINTEZ – Catalyst supply for PA plant
SALAVATNEFTEORGSINTEZ – Catalyst supply for PA plant
INA – Refinery Rijeka – Crude oil fractionation – Topping, Merox LPg, MEROX gasoline
INA – Refinery Rijeka – Electrical energy production from steam
INA – Refinery Rijeka – visbreaker unit
INA – Refinery Rijeka – Steam boiler station
INA – Refinery Rijeka - With BP – C5, C6 isomerization unit
INA – Refinery Rijeka – hydroalkylation unit
INA – Refinery Rijeka – Tank storage and Product movement
INA – Refinery Rijeka – FCC complex – feasibility study, with UOP and Foster Wheeler, detail design, start-up
IPLAS – Koper – Polyvinyl acetate plant – turnkey basis
IPLAS – Koper – Revamp and Upgrade of PA plant – Unit 2
IPLAS – Koper – Revamp and Upgrade of PA plant – Unit 1
IPLAS – Koper – Plasticizer plant revamp
IPLAS – Koper – PA plant Unit 2 – revamp
Dar es Salam – refinery port – product movements and tank modernization
4-D-engineering -San Marco Petroli – pump station - Detail design of piping, heat exchangers, tanks and other equipment
4-D-engineering – GPL and fuel distribution - Detail design of piping, heat exchangers, tanks and other equipment
Novorosijsk – Railway unloading station for heavy oil
Kamtex Perm – Polyester resin’s plant – key turn basis
Kamtex Perm – PA plant – Equipment deign and supply – heat exchanger
Kamtex Perm – MAn plant – Equipment design and supply – heat exchanger
Angarsknefteorg – Plasticizers plant – Basic and Detail engineering
Angarsknefteorg – PA plant Condensation section Reconstruction – key turn
Angarsknefteorg – PA plant Oxidation section revamp – Basic and detail engineering
BADEL Zagreb – Loading station and Tank storage
LABUD Zagreb – Liquid detergents plant
KRASITEL – Rubezhnoe – various equipment and machinery
UPC – Kaoshiung - Catalyst supply for PA plant
HARBIN PETROCHEMICAL - Catalyst supply for PA plant
OMSKHIMPROM – PA plant – Oxidation section revamp
MOL – Budapest – MAn plant – Heat exchangers and condenser modification
MOL –Budapest – MAn plant – Reactor replacement
REPSOL YPF – Buenos Aires – MAn plant – Feasibility study for Incinerator
LONZA – China plant – MAn Reactor supply
OXIPAR – Sao Paolo – Fumaric Acid plant
ANHYDROS DE VENEZUELA – 2-ethyl hexanol plant
PETROM – Sao Paolo – MAn plant upgrade
NESTE - Nol – PA plant – Unit 3 – semi industrial catalyst testing plant
NESTE – Nol – PA plant – Condensation section
ELEKEIROZ – Sao Paolo – MAn plant upgrade
... |
Business Partners
RolleChim
Scientific Design Inc.
Sulzer Chemtech
ABB
SNAM Progetti
Foster Wheler
Technip
Rolle
Nuovo Pignone
Honeywell
Orion
Xomox -Tuflin
Yokogava
Siemens
Fisher Rosemount
Uhde
Manesmann
Ocsam
ABB Analytical
Samson
Woma
KTI
FlowGuard
I.V.A.R.
PALL
VOITH
John Crane
And many others excellent companies ....
... |
| Contact us |
Download our catalogues
Company presentation Continuous filament winding machine Sleeve grooving machine Sleeve hydro-testing machine Glass reinforced polyester pipes Factory CFW 2600... |
| Other Menu |
| Plasticizers |
Basic
Plasticizers are additives that increase the plasticity or fluidity of the material to which they are added, these include plastics, cement, concrete, wallboard and clay bodies. Although the same compounds are often used for both plastics and concretes, the desired effect is slightly different.
Plasticizers for plastics are additives, most commonly phthalates, that give hard plastics the desired flexibility and durability. They are often based on esters of polycarboxylic acids with linear or branched aliphatic alcohols of moderate chain length. Plasticizers work by embedding themselves between the chains of polymers, spacing them apart, and thus significantly lowering the glass transition temperature for the plastic and making it softer.
Groups of plasticizers names as phthalates, maleates, sebacates have origin in the name of dicarboxiclic acid used e.g. Phthalic, Maleic, etc. Depending on desired characteristics and application also the Alcohols used may vary.
Technobell ltd can offer to the clients plants designed to produce different plasticizers: phthalates, maleates, sebacates, trimelitates and others. Once defined the production range of Plasticizers during Contracting the plant is specificaly designed to alow easy interchangability between production range.
... |
Process description
Production of plasticizers can be shortly divided in few steps:
Esterification
Esterification is an equilibrium chemical reaction which is caried
out as a batch process in the reactor containing an agitator and other
equipment – particularly for water separation and removal which is
formed during chemical reaction.
First phthalic anhydride and the 2-ethyhexanol are mixed in the
reactor in order to form the monoester - mono-2-ethylhexylphtalate. The
reaction takes place at about 150°C. Further the reaction mixture is
heated to 170 - 180°C. At this point the catalyst tetrabutyl-titanate
is added. Before the addition care must be taken to separate all the
water formed in chemical reaction from the system. The evolution of
reaction takes place and water formed must be continously carefully
separated in the alcohol water separator. The temperature in the
reactor is further increased up to 220-235°C to terminate the
esterification. The Raw DOP is obtained.
Distillation and Neutralization
Raw DOP is transferred to the distillation section which consists
of an reactor equipped with the stirrer, vapors condenser, cooler and
alcohol water separator.
The alcohol is distilled first under mild vacuum distillation and at
the end with vacuum distillation and steam stripping. At about
170-180°C sodium carbonate is introduced to neutralize the traces of
the monoester. The hydrolysis of the tetrabutyltitanate is performed in
next step by adding small amounts of water. After the hydrolysis filter
aid (diatomite earth) is added and DOP is dried under vacuum and a
light flow of nitrogen.
Filtration
In this phase, solids formed or aded (diatomite earth) during
neutralization and hydrolysis of the catalyst are removed by
filtration.Other types of plasticizers are produced on the same
equipment using different raw materials.
... |
Consumption & Utilities
Raw materials
Expected consumption per ton of product
DOP [kg]
DBP [kg]
Phtalic Anhydride
382
542
2 – Ethyl Hexanol
671
n- Butanol
560
Catalyst
1
1
Sodium carbonate NaOH
7 (30 % sol.)
4
NaOH
20 (15% sol.)
Filter Aid
2
3
Active carbon
1
NaCl
10
... |
| Fumaric Acid |
Basic
The Fumaric Acid (FA) is today produced from two main sources:
production from furfural – oxidation process
production from Maleic Anhydride and from Off gases / washing waters from proceses for production of Phthalic Anhydride and/or Maleic Anhydride – transformation process
Both main technologies involve specific catalyst:
for oxidation from furfural and
for transformation of maleic acid to fumaric acid in second case.
Technobell ltd is able to offer to clients the transformation process in both cases as production from Maleic Anhydride and from Off gases of two mentioned processes.
In both cases the feed for technology process is Maleic acid solution from where the Maleic anhydride is transformed with specific catalyst to Fumaric Acid.
To the transformation process follows the stages of purifying, solidifying and packing of commercial product.
... |
Chemistry
Maleic Acid
C4H4O4 (Z)-Butenedioic acid cis isomere
Is in the process transformed to
Fumaric Acid
C4H4O4 2-Butenedioic acid trans isomere
... |
Process description
Introduction and Preliminary Process Description
Fumaric Acid (FA) production plant starts with preparing Maleic Acid solution as a raw feed for final product. This can be an absorption unit in case of production from off gases or a disolving unit in case of production from maleic anhydride.
Following is the transformation unit - batch process which is further followed by dehydrating / refining and solidification Units which usually are continous processes.
Maleic Anhydride Absorption
In the absorption system, maleic anhydride is absorbed into process water from the cooled reactor off-gas, which contains the MA. When the gas containing maleic anhydride passes through the absorber and contacts water, the MA is converted into maleic acid, and the maleic acid solution (Mac) is formed. The MA-free gases leaving the MA Absorber are routed to the Incinerator for disposal.
In case of production from Maleic anhydride the Absorption Unit is replaced by Disolving Unit where maleic anhydride is dissolved to Maleic Acid solution.
Maleic Anhydride Transformation
The Mac solution batch is charged to reactor at defined temperature. Catalysts are added into the reactor for increasing the reaction yield and reducing formation of by-products. Reaction takes place at a defined temperature, which is controlled by steam heating and air cooling inside of the reactor.
After the isomerization reaction the product slurry is cooled down and concentrated by vacuum. Under vacuum the fumaric acid slurry starts concentrating and forming crystals.
Concentrating, drying and packing
The fumaric acid slurry is fed to centrifuge, where cc. 80% of the water content is removed as filtrate. Centrifuge outlet can be loaded into big-bags and dispatched as „wet” fumaric acid product.
In case of dry fumaric acid production the concentrated „wet” fumaric acid is dried by a fluidized dryer operated with steam heated hot air. After the dryer the fumaric acid is supplied into a filtration / sizing system and further to storage in a silo, from where it is fed to the weighing and packing system.
... |
Product Quality
Due to different source of Maleic Acid – pure Maleic Anhydride or Off Gases containing Maleic Anhydride having source in Maleic or Phthalic anhydride production process the final quality of the product is highly influenced.
Generally the process originated with pure Maleic anhydride is able to produce “food grade” quality of fumaric acid.
For a difference in quantity of by products contained in the off gases of Maleic or Phthalic anhydride production process the process starting with Maleic anhydride in Off gases is able to produce only “technical grade” quality of fumaric acid. With additional purifying unit is however possible to assure the “food grade” quality also in this case.
... |
| Phtalic Anhydride |
Basic
The Phthalic Anhydride (PA)is today produced from two main sources:
production from o-xylene
production from benzene – some old plants
Both main technologies involve specific catalyst for selective oxidation of raw material to product.
Basically the technology consist of 3 main phases:
oxidation (performed in reactor block),
recuperation of Phthalic Anhydride from reactor off-gases (performed in switch condensing section) and
refining to commercial product (performed in distillation unit).
Any of Phthalic Anhydride production technologies include sub sections as:
Steam system – energy recuperation
Waste gases incineration
Is possible to recover Maleic anhydride from off gases of switch condensers in quantity of about 4% calculated on PA
... |
Chemistry
Main reaction
C8H10 + 3 O2 → C8H4O3 + 3 H2O ∆H = -1108,7 kJ/mol
Burning
C8H10 + 7 O2 → 3 CO2 + CO + 4 H2O ∆H = -4380 kJ/mol
Due to released reaction heat the awailable technology result as energeticaly self sustaining and energy exporters.
Side reactions are forming by-products in very small amounts (less than 6%):
Maleic Anhydride, O-toluic aldehide, Phthalide, Benzoic Acid,Citrconic acid
The reaction takes place on catalyst – basically Vanadium/Titanium type.
Typical temperatures of reaction are between :
Reactor (Salt) temperature: 350 - 400°C.
Catalyst temperature (Hot Spot): 390 - 440°C
... |
Process Description
The technology of PA production offered by
Technobell limited, starts with oxidation of o-xylene in fix bed
tubular reactor on specific catalyst.
Atmospheric air is compressed by compressor. The
o-xylene is feed to air stream and both pass through catalyst installed
in tubular fix bed reactor, cooled by eutectic salt mixture. There
chemical reaction takes place and o- xylene is transformed mainly to
Phthalic Anhydride. Heat released by chemical reactions is removed
through melted salts to heat exchanger where High Pressure steam is
produced. Reactor gases are conveyed through post reactor where almost
90% of by-products are removed.
The reactor off-gases containing PA are then cooled
to appropriate temperature in two heat exchangers producing Medium
Pressure steam. Cooled gases are further conveyed to Switch condensers
section. In this section PA is removed from gas by the process of
de-sublimation – forming solid crystals. After melting the PA in liquid
form is obtained. The technology allow to obtain almost 99,8% of PA
produced in the reactor.
Switch condensers off gases are conveyed to Thermal
or catalytic Incinerator and after it released to atmosphere. The
Incinerator is designed to incinerate also residue from the
distillation (Light and heavy cut). Due to carefull design important
quantity of heat is recovered in form of MP steam.
Liquid PA from Switch Condensers is first thermaly treated and then continously distilled in two distillation columns.
Finally pure comercial product is conveyed to stock
tanks to be sold in liquid form or conveyed to a solidifying section
where PA flakes are produced and packed in 25 kg bags or 1/1,25 tons
big bags.
Other sections of the plant are:
Steam system, with the task of careful energy transformation and recuperation,
Oil system prowiding hot and cold oil for Switch Condenser operation,
Demineralized water station
Other Utilities system, as Instrumental air, nitrogen, el. Power stations.
From brief description could be seen that efficient PA production technology would:
Obtain as high as possible concentration of o-xylene in feed to reactor leading to:
higher production,
smaller equipment.
Elimination of by products with post-reactor technology leading to:
less consumption of energy for distillation,
Less residue on the distillation,
Extremely good commercial product quality,
Smaller columns
As high as possible de-sublimation efficiency Switch Condenser section.
... |
YIELD’s
This parameters depends on the catalyst used, however generally they turn around the following numbers:
Content of o-xylene in feed to reactor
80-90gr/Nm3
High reactor yield (depends on catalyst)
up to 115 kg/kg of o-xylene
De-sublimation efficiency on SW. C.
up to 99,8wt%
Distillation residues
2-3 wt%
Overall plant Yield (kg/kg)
109 - 106
Expresed in 100% o-xylene and commercial PA
(new catalyst) (old catalyst)
The catalyst life time
4 to 5 years.
... |
Commercial Product Properties
PROPERTIES:
Unit
Expected Value
Guaranteed Value
Colour in molten form:
Hazen
5
max. 20
Colour Stability:
Hazen
30
max. 60
Melting Point:
°C
131,5
min. 131,3
Colour Stability
Hazen
30
max. 60
(150°C, 1,5 hours)
... |
| Continuous filament winding |
CFW Machine
The CFW MACHINE is designed for the continuous production of GRP pipes. Pipe manufacturing is done on the rotating mandrel assembled with discs, aluminium beams and steel band, sized according to the required pipe diameter. The steel band is moving in the axial direction, sliding over the bearings inserted in aluminium beams. At the end of the mandrel, exit head guides the steel band into the mandrel inner tube. On the opposite end of the mandrel, the steel band is wounded on the mandrel again. Steel band forms a smooth surface mandrel with simultaneous advancing in the axial direction. Raw materials are applied simultaneously on various mandrel positions depending on production technology. The laminate building-up can be easily made in compliance with the appropriate design by controlling the amount and position of various materials applied.
After the curing oven, the pipe is automatically cut and calibrated to the required length by a suitable cutting unit.
CFW MACHINE TYPES
CFW600 : 300 – 600mm pipes
CFW2600 : 300 – 2600mm pipes
CFW4000 : 300 – 4000mm pipes
The CFW MACHINE is designed for very high production capacity. It is ideal choice when the GRP pipes are used for water transmission and distribution, desalination plants, cooling systems in power plants, irrigation projects and sewage systems.
LINE CAPACITY
The production line capacity is 200 km/year of DN800mm PN6 bar pipe (based on 300 production days/year, three shifts).
CFW600 area and height required:
Width = 10m
Length = 26m
Height = 5m (under crane hook)
CFW2600 area and height required:
Width = 12m
Length = 28m
Height = 7,5m (under crane hook)
CFW4000 area and height required:
Width = 14m
Length = 30m
Height = 7,5 (under crane hook)
Utilities requirements:
Max. Power Supply = 3 x 400V / 50 Hz
Max. Power Consumption CFW600 =220 Kw
Max. Power Consumption CFW2600 = 240 Kw
Max. Power Consumption CFW4000 = 290 Kw
Max. Compressed Air Consumption = 8 bar - 6 m3/min
Machine Operators Requirement:(workers per shift)
1 machine captain
1 chopper operator
1 roving operator
2 mylar, “C” veil and roller operator
CFW Machine is fully numerically controlled. All machine operations and dosing system is controlled by computer. All production data are available in computer archive.
... |
PHTM Machine
Pipe hydro-testing is performed on PHTM MACHINE. Pipe hydro-testing machine is designed and constructed to allow the hydrostatic tests on GRP pipes, according to all major international standards.
The pipe is rolled on supports and by lifting tables centred between two heads. Pipe is inserted between sealing plates and closed by hydraulic unit. The pipe hydraulic test is performed by water pressure unit. After successful pressure test, pipe is released from the sealing plates by hydraulic cylinder. PHTM is complete with electric power box and is completely wired.
PHTM area and height required:
Width = 5 m
Length = 20 m
Height = 5 m
Requirement for the concrete water reservoir under the machine (inside dim.):
Width = 3,5m
Length = 15,5 m
Height = 3,1 m
Utilities requirements:
Max. Power Consumption = 50 Kw
Max. Water Supply = 100 l/h
Machine Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
Main characteristics of the PHTM machine:
Max. test pipe length: 12000 mm
Test pipe diameter: 300-2600/4000 mm
Max. end trust load: 640/1100/1600 tons
TESTING CAPACITY
The testing capacity of the PHTM Machine is fully in line with the capacity of CFW Machine, the 100% pipe testing can be achieved.
PHTM Machine is fully automated machine. All operations of pipe sealing and pipe filling are automatic. The testing pressure and time can be easily checked on the measurement equipment, which is also part of the machine.
... |
SHTM Machine
Sleeve couplings are tested on SHTM MACHINE. Sleeve is inserted by the support trolley and is closed by the upper and lower sealing ring which are mounted on the support plate. Sealing plates are fixed on upper and lower frame. Lower frame is fixed in the basement with anchor bolts, upper frame is moved by hydraulic cylinder during pressure test, support plates are closed by clamps, mounted on the periphery of upper frame. Sleeve is sealed with standard sealing gaskets. Pressure is applied by water pressure unit. After successful pressure test, sleeve is extracted by hydraulic cylinder. Each SHTM is complete with electric power box and is completely wired.
SHTM Machine is fully automated machine. All operations of sleeve sealing and filling are automatic. The testing pressure and time can be easily checked on the measurement equipment.
SHTM area and height required:
Width = 4 m
Length = 7 m
Height = 4 m
Utilities requirements:
Max. Power Consumption = 20 kW
Water Supply = 10 l/h
Machine Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
TESTING CAPACITY
The testing capacity of the SHTM Machine is fully in line with the production capacity of our CFW Machine
... |
SJM Machine
Sleeves are assembled-joined with pipe on sleeve joining machine.
Sleeve joining machine should be placed near pipe hydro-testing machine, because according to customer requirements pipes are assembled with sleeve joint.
Pipe transport and movement between machines is foreseen by means of pipe transport trolleys and support beams for pipe rolling.
OGM is foreseen for pipe cutting and grinding operations off line. Off line cutting and grinding is needed when shorter pipes, pipes for fittings or some repair work are required.
The pipe is supported by support wheels. Equipment is complete with electric power box and is completely wired. During cutting and grinding, dust is a side product. Grinding and cutting tool are connected by flexible tubes with suction line and dust filter.
SJM area and height required:
Width = 3 m
Length = 17 m
Height = 3,5 m
Utilities requirements:
Max. Power Consumption = 5 kW
Main characteristics of the SJM machine:
Pipe length: up to 12000 mm
Pipe diameter: 300-2600 mm for SJM2600 and 300-4000 for SJM4000
SJM Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
OGM area and height required:
Width = 7 m
Length = 14 m
Height = 2,5 m
Utilities requirements:
Max. Power Consumption = 40 kW
OGM Operators Requirement:
(workers per shift)
1 machine operator
... |
SGM Machine
SGM is foreseen for sleeve grooving and cutting operation. Sleeves are made from a pipe, which is produced on CFW machine. For an easier pipe manipulation, the pipe has to be cut on 4m lenght. The pipe is supported by the support wheels which are driven by the gear box. Drive motor, belt system and grooving tool set are mounted on hinged support plate connected to the pneumatic cylinder. When grooving is finished, pipe cutting operation starts, while the pipe is still rotating. After sleeve removal, the rest of pipe is moved forward with hydraulic supports toward the correct position for new sleeve production. Equipment is completed with electric power box and is completely wired. During sleeve coupling manufacturing, due to grinding and cuttitng operations, dust is a side product. Grinding and cutting tool are connected by flexible tubes with suction line and dust filter.
SGM area and height required:
Width = 3 m
Length = 5 m
Height = 3 m
Utilities requirements:
Max. Power Consumption = 40 kW
Machine Operators Requirement:
(workers per shift)
1 machine captain
1 machine operator
... |
Laboratory
Technobell equipment for the GRP pipe production includes also laboratory and testing equipment.
Pos.
Description
I.
Mechanical Tests Laboratory
II.
Chemical Tests Laboratory
III.
Laboratory Archive and Library
IV.
Laboratory testing Area
Pos.
Description
1
SD2600 Split Disk Testing Machine
2
CK2800 Stiffness Testing Machine
3
UTM Universal Testing Machine
4
Desk for PC
Pos.
Description
5
Laboratory Furnace
6
Water Bath
7
Magnetic Stirrer
8
Analytical Balance
9
Laboratory Balance
10
Drying and Heating Oven
11
Digital Viscometer
12
Equalising Cupboard
13
Fresh water
14
Wardrobe
15
Desk for PC
16
Desk for PC
17
Books / Standards Archive
18
Desk for Copy Machine and Printer
Technobell suggests and in case assists to obtain quality assurance certificate in accordance with EN ISO 9001.
Technobell Quality Control and Inspection Plan incorporates full traceability of materials according EN 10204 3.1.b.
Detailed Description of Quality Control Activities
QUALITY CONTROL ON RAW MATERIALS
QUALITY CONTROL DURING PRODUCTION PHASE
QUALITY CONTROL ON FINISHED PRODUCTS
PROCESS AUDIT
FINAL DOCUMENTATION
QUALITY CONTROL ON RAW MATERIALS
QUALITY CONTROL ON RESIN
Density (ASTM D 792)
Viscosity (ASTM D 2393)
Gel time (ASTM D 2471)
Peak temperature (ASTM D 2471)
Monomer content (DIN 16945)
Acid number (ASTM D 1639)
Volumetric shrinkage (ASMT D 2566)
Elongation at failure (ASTM D 638)
QUALITY CONTROL ON GLASS
Mass control (ISO 3374)
Moisture content (ISO 3344)
Organic content (ISO 1887)
QUALITY CONTROL DURING PRODUCTION PHASE
DIMENSIONAL CHECK
According Construction Specification
WALL THICKNESS
According Construction Specification
MATERIAL TRACEABILITY
for raw materials
for GRP components
for other components
for finished product
PROCESS AUDIT & FINAL DOCUMENTATION
Ultimate Tensile Strength, Unit Modulus and Shear Strength
According BS 4994
Visual inspection of cut out pieces
According ASTM D 2563 II
Resin / Glass Percentage
According ASTM D 2584
Final Thickness and Dimension Measurement
According Construction Specification
Stiffness test
According BS5480
Barcol Hardness
According BS 2782 or ASTM D 2583
Pressure hydro-test
According BS 5480 and client requirements
Testing machines are supplied with computer software programs. All testing data are immediately shown on the computer screen and stored in the computer database.
... |
Factory CFW2600
Machines in the factory can be disposed according to the factory building or special client requirements. Layout drawing shows typical factory arrangement.
Pos. Description
1 Tools Cleaning Room
2 Resin Mixing Room
3 Dosing Pump Room
4 Bridge Crane – 10 tons
5 CFW2600 Machine
6 Resin Storage 4 x 50m3
7 Vapours Suction Ventilator
8 Dust Filter
9 Pipe Transport Equipment
10 OGM2600 Offline Grinding Machine
11 SGM2600 Sleeve Grooving Machine
12 SHTM2600 Sleeve Hydrotesting Machine
13 SJM2600 Sleeve Joining Machine
14 PHTM2600/640 Pipe Hydrotesting Machine
15 Laboratory
16 Air Compressor
17 Main Power Panel
18 Main Control Console
19 Diesel Electric Generator
20 Electro Station
21 Fittings Production Area
22 Pipe Testing Area
23 Catalyst Storage Area
24 Accelerator Storage Area
Factory covered area and height required:
Width = 36m
Length = 78m
Height = 7,5 (under crane hook)
Factory outside uncovered area required:
Area = 25000 m2
Utilities requirements:
Power Supply = 3 x 400V / 50 Hz
Production Line Installed Power =App. 400 kW
Max. Compressed Air Consumption = 8 bar - 6 m3/min
Emergency Diesel Generator = 240 kW
The complete CFW production factory requires approximately 60 employees for the production in 3 shifts (24h per day). They are divided in the following positions:
1 production manager
4 machine captains on CFW machine
16 machine operators on CFW machine
4 machine operators on the SGM machine
4 machine operators on the SHTM machine
6 machine operators on the PHTM machine
2 machine operators on the SJM machine
1 quality control manager
4 quality control operators
4 mechanical and electrical maintenance workers
4 store keepers
10 workers in the fitting manufacturing shop
... |
| Maleic Anhydride (MAn) |
Process description
Our system based on Maleic Anhydride (MAn) unit consists of fixed bed reactor(s), continuous gas cooling, continuous product recovery systems by partial condensation and absorption, batch dehydrating and distillation system (or continuous dehydrating and batch refining system) and a continuous incinerator unit.
Maleic anhydride is produced by the partial oxidation of butane with air over a vanadium/phosphorus catalyst. Low concentrations (PPM range) of a stabilizer (SAS) are added to the feed gas stream to stabilize catalyst activity and selectivity. Water (in the form of steam) is also added under some conditions to modify catalyst performance.
Reactor off-gas from the fixed bed reactor flows through a gas cooling system and then min. 50% of the maleic anhydride is condensed in the partial condenser, the other cc. 45-50% feeds to the scrubber and forms Maleic Acid (MAc) solution by reaction with treated Boiler Feed Water.
The molten pure Maleic Anhydride (product) is recovered from the condensed (called: crude) Maleic Anhydride and Maleic Acid solution in a semi-automatic 7-steps dehydrating-refining procedure. Solvent for the dehydration is xylene. In case of higher capacity requirement the system is divided to continuous dehydrating and batch refining systems.
Recovered heat of the exothermic reaction and back-cooling of the reaction gases are used for steam generation. If the customer requires, the system can produce high pressure (HHP) steam, which can be used for operation of the air compressor steam-turbine driver(s) or to produce electric energy.
The off-gas coming from top of the scrubber contains flammable, environmental polluter materials. This environmental damage can be eliminated by burning away the flammable components of off-gases while the generated heat can be used for steam producing.
Process scheme – WITH BATCH DEHYDRATOR/REFINER COLUMN
Process scheme – WITH CONTINUOUS DEHYDRATOR AND BATCH REFINER COLUMN
... |
Chemistry
Main reaction
Main reaction
C4H10 + 3.5
O2 ® C4H2O3
+
4 H2O
∆H
= -1236 kJ/mol (-295.4
kcal/mol)
Burning
C4H10 + 6.5
O2 ® 4 CO2
+ 5 H2O
∆H = -2656
kJ/mol (-634.8 kcal/mol)
C4H10 + 4.5
O2 ® 4 CO +
5 H2O
∆H = -1521 kJ/mol (-363.5 kcal/mol)
Beside this
there are several minor reactions forming by- products like acetic or acrylic
acids:
C4H10
+ 2.5 O2 ® 2 CH3COOH + H2O
C4H10
+ 2.5 O2 ® 4/3 CH2CHCOOH
+ 7/3 H2O
The reaction
takes place on catalyst which is basically a vanadium/phosphorus type.
Typical
temperatures of reaction are between :
Reactor (Salt)
temperature: 400 - 430°C.
Catalyst
temperature (Hot Spot): 430 - 460°C
... |
Yield, Selectivity and conversion
This parameters
depends on the catalyst used but generally they turn around the following
numbers:
Due to the
nature of catalyst selectivity and so yield is higher during Start-of-Run and
lower during End-of-Run conditions.
SOR
EOR
Conversion
(mol%)
80-85
80-85
Selectivity
(mol%)
70-75
60-65
Yield (m/m%)
102-105
85-90
Loss on
Absorption (m/m%)
0,2-0,4
0,2-0,4
Loss on
Distillation (m/m%)
2-3
2,5-3,5
Overall plant Yield (m/m%)
99-102
81,5-86,5
Ton/ton
of n-butane Commercial products
The
catalyst can be regularly on line for 4 to 5 years.
... |
Properties
DESCRIPTION: Product
Maleic Anhydride (C4H2O3)
PROPERTIES:
Unit
Expected
Value
Guaranteed Value
Colour in
molten form:
Hazen
10-15
max. 20
Melting
Point:
°C
52,5-52,7
min. 52,3
Maleic
Anh. Content:
m/m%
99,7-99,8
min. 99,5
Maleic Acid Content:
m/m%
0,05-0,15
max. 0,3
Ash
Content:
m/m%
0,0005
0,002
Iron
Content:
m/m%
< 1,0 ppm
max. 3,0
ppm
Colour Stability
(150°C,
1,5 hours)
Hazen
40-60
max. 100
Appearance:
white solid or colourless molten material
white
solid or colourless molten material
Boiling Point:
°C
202
Density (70 °C):
t/m3
1,384
In solid form
t/m3
1,43
Relative
Vapor Density (air=1)
3,38
Ignition
Point (closed area):
°C
102
Self-Ignition
Point:
°C
477
... |
Advantages
High concentration – High pressure feed to reactor block.
Our technology nowadays allows operating with inlet pressures to reactor of 3 bar(a). This has enormous advantages compared to low and medium pressures operating systems. The n-Butane concentration can reach 2 mol% in feed stream. This data is MUCH HIGHER compared to low pressure systems. As a consequence our 20.000 tube reactor can produce almost 25.000 tons of MAn/ year.
High percentage of condensed crude MAn in condensing section.
As a consequence of high inlet pressure, but not only, the percentage of condensed MAn in condensing section COULD REACH 55 % of MAn contained in reactor off-gases. This is an important advantage compared to common systems, when the percentage of efficiency in this section is usually 45 % and sometimes can reach 50 % of MAn contained in the reactor off-gases. With this advantage the heat consumption in the recovery systems has been decreased with 12-15% compared with elder aqueous technologies.
Cleaning of Partial Condenser without any shutdown requirement
Careful and inventive process design allows Technobell to avoid quick plugging of the Partial Condenser. The Condenser can be operated continuously for min. 10 days then washed out during a few hours WITHOUT shutdown of the unit. After the cleaning procedure in (without any maintenance cost) the Condenser can be switched back and used for another min. 10 days. Using our own procedures the Condenser can be used continuously during the catalyst life-cycle.
Technology allows the use of any suitable – commercially available oxidation catalyst.
Technobell is not binding any client to use recommended catalyst. This can be chosen from the market by the client.
Basically batch or semi continuous distillation with use of xylene as dehydration solvent is proposed.
Technobell is in original design proposing the batch distillation unit with xylene as a solvent in the azeotropic dehydration phase. This reliable, well proven and simple refining method allows obtaining very good quality of pure product with low solvent losses. Generally both Maleic Acid dehydration and product refining can be solved in one common dehydrator/refiner column. Distribution of these process steps is recommended in case of expansion an old unit (higher capacity demand) or capacity requirement over 20,000 MTPA of MAn.
Energy, Utilities and Environment care
Technobell applies a three level steam system:
High pressure steam (can be exported or used for electric energy production);
Medium pressure steam (can be exported or used for electric energy production);
Low pressure steam level.
The environment is protected with two sub systems:
Incinerator for waste-gases and heavy-ends,
Waste water treatment unit.
... |
| GRP Pipes |
GRP pipes
Glass Reinforced Polyester pipes are manufactured with polyester resins and fibrous glass reinforcements and depend on the type with inorganic filler. The design philosophy of GRP pipes is to provide products with suitable properties and the required margin of safety that will enable the pipe to work satisfactory after an extended period of operation (50 years) under typical service conditions.
They represent the ideal solution for conveying any kind of water and most of the chemicals, because they combine the advantage of corrosion resistance, which is typical of plastics, and high mechanical strength, typical of steel.
GRP pipes can be produced with continuous (CFW) and discontinuous (DFW) manufacturing process.
GRP pipes are joined with:
GRP Sleeve
GRP Bell & Spigot
GRP Flanges
GRP Lamination - welding
Available are all standard fittings, which are:
Elbows of any degree
Fix, loose, blind flanges
Equal, reduced, lateral tees
Concentric, eccentric reducers
End caps
Fittings and special items are manufactured using the hand lay-up technique. The chemical barrier and the top coat of fittings are equal to the one of the pipe; the structural wall is made with alternated layers of mat and woven roving.
... |
Advantages
Typical properties that result in advantages in GRP pipes application can be summarised as follows:
High mechanical resistance due to the glass reinforcement.
Corrosion resistance, both the external wall and internal wall in contact with the conveyed fluid. No protections such as coating, painting or cathode are needed. GRP pipes are resistant to nearly all chemicals.
Smoothness of the internal wall minimizes the head losses and avoids the formation of deposits. In contrast to steel, cast iron and concrete, GRP pipe maintains initial smoothness through all exploitation period
Very long life, virtually infinite, of the material, which does not need maintenance.
Absolute impermeability of pipes and joints both from internal to external and vice-versa.
Low weight of pipes which allows the use of light laying and transport equipment.
Long pipe sections, longer than pipes made with other materials, resulting in fast installation and less joints.
Workability of the material on site with the use of simple tools. It is possible to make any kind of shapes (tees, elbows…), joints and connections.
Possibility of nesting, different diameters of pipe can be nested during transport, allowing additional saving in transport operations.
... |
Fields of application
Water distribution
Water transmission
Potable water
Geothermal water
Desalination plantsv
Seawater intake and outfalls
Sanitary sewersv
Storm sewers Irrigation
Oil fields
Ships
Chemical process
Power plant cooling and raw water supply
... |
Pipe Wall
The GRP pipe wall consists of three layers perfectly adherent with one another, each having different characteristics and properties in relation to their function. The properties of chemical resistance and impermeableness are, anyway, equivalent for the three layers which are namely:
Liner:
It is in direct contact with the conveyed fluid and guarantees the maximum resistance to the chemical attack from the fluid itself. Moreover, the liner presents an internal surface particularly smooth. The liner is composed of glass veil and chopped glass (glass mat).
Mechanical resistant layer:
Its function is to render the pipe wall resistant to the stresses due to the design conditions (stresses due to the internal and/or external pressure, flexural strength due to the external loads). The thickness of the filament depends on the design conditions. The mechanical layer is composed of continuous glass filament roving, chopped glass and filler if necessary.
Top coat or external layer:
It has a thickness of about 0.2 mm and consists of pure resin with or without glass reinforcement. It guarantees the complete impregnation of the peripheral fibers, thus yielding the external pipe surface completely free of protruding fibers and well finished.
... |
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