SCHACK ® PRODUCTS FOR THE CARBON BLACK INDUSTR INDUSTRY Y
Alstom Power Energy Recovery
ALSTOM Power Energy Recovery GmbH
The Company
produCTs and serviCes
Carbon blaCk
Alstom Power Energy Recovery GmbH was created by the amalgamation o the two traditional companies Schmidt’sche Heissdamp-Gesellschat mbH, Kassel, and Rekuperator Schack KG, Düsseldor.
The exceptional technical understanding and know-how o the two ounder companies orm the main basis o today’s Alstom Power Energy Recovery GmbH products and solutions.
Technical carbon black is produced by subjecting hydrocarbon eedstock to extremely high temperatures in a careully controlled combustion process. Carbon black is used as a high perormance reinorcing component in technical rubber products and as a color pigment. It is a quality determining component and denes the characteristics o the nal product.
Alstom Power Energy Recovery GmbH is a solution provider in the eld o process heat transer and supplies relevant components or plants in the chemical, petrochemical, metallurgical and glass-smelting industries. Due to the broad experience gained in many dierent types o processes Alstom can make use o proven solutions and transer such concepts to similar process requirements.
Alstom Power Energy Recovery GmbH, Düsseldor, is leading in hightemperature technology. The proven competence stems rom experience gained since 1931 in the elds o recuperators or industrial high-temperature application, steam superheaters and red heaters or process media.
In the predominant abrication process – the urnace carbon black process – carbon black is produced when heavy residual oil eedstock is injected into the hot zone o a fame, in excess o stoichiometric quantities. Rapid cooling by water quenching to approx. 1500 °C stops the carbon black ormation process and denes particle shape, size and quality. The heat contained in the mixture o process gas and carbon black can be returned to the process by means o heat exchangers or can be used externally by a waste heat boiler to generate steam. Ater separation o the carbon black a combustible waste gas remains. Incineration o this tailgas in a combustion chamber enables the recovery o energy or the carbon black dryer or steam generation.
Schack® APH 800/144, APH 800/80 and APH 900/144 at Alstom’s workshop in Kassel CARBON BLACK INDUSTRY 2
® SCHACK Products or the Carbon Black Industry
Schack® products in carbon black processes
Alstom’s Schack® products or the carbon black industry are integral process components or energy recovery and thereby serve to optimize the eciency o the carbon black process and reduce cost. Already in 1957 Rekuperator Schack, predecessor o Alstom Power Energy Recovery GmbH, developed, abricated and supplied its rst air preheater or the carbon black industry. Since then continuous research and development on air preheater and other Schack® products or the carbon black industry enabled Alstom to reach the position o a world leading supplier.
The Schack® Air Preheater and the Oil Preheater convey heat rom the process gas directly back to the reactor; thus energy is saved. Schack® Quench Boilers and Reactor Boilers generate steam or turbine drives and external use. Schack® Tailgas red Boilers also produce steam or turbine drive and power generation. The Schack® Rotary Dryers dry the carbon black pellets by using the heat rom tailgas red combustors.
Schack® APH 800/108 and 900/90 under erection CARBON BLACK INDUSTRY 3
® Schack Air Preheater
Air preheaters in the urnace carbon black process preheat combustion air or the reactors. Process gas heat is regained and provides positive eects to the operation cost by reduction in uel consumption increase in eedstock fow/rise in carbon black production reduction in quench water consumption ·
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sChaCk® air preheaTer For the carbon black process Schack® Air Preheaters (APH) are designed according to the principle “fue gas through the tubes”. The combustion air in the APH shell is directed around the tubes by means o bafes. Most Schack® Air Preheater types have cooled inlet tubesheets (double bottom tubesheets – DBTS). The cooling air or the DBTS is branched o rom the process air fow and directly conducted to the DBTS.
Air preheating increases proftability o carbon black process
Schack® APHs are o standardized design rom which they are selected according to the requested process parameters.
Load range o APH types
Alstom’s continuous R&D endeavours to urther increase product and plant eciency led to gradual raising o the air preheating temperature. Current level is 900 °C. In parallel design details were optimised and material selected and tested to meet increased operation parameters.
Increased air preheating temperature supports these positive eects and also reduces CO2 emissions o the process.
FEM analysis o APH inlet tubesheet (DBTS)
Schack® APH with internal cooling air discharge
In the APH the cooling air is returned into the process air fow. An external cooling air discharge is not necessary. Schack® APH in hard black and sot black lines CARBON BLACK INDUSTRY 4
Advanced calculation and computer simulation methods combined with data gained rom customer eedback o hundreds o APHs in service in carbon black plants around the world made this possible. For all steps in design, dimensioning, abrication and inspection the strict Schack quality standards are applied.
Outlet cone
Return bend or APH
Saw tooth expansion joints or APH
aCCessories APHs or carbon black processes are complemented by Schack® accessories. The inlet box serves or approach fow o the APH with carbon black gas and supports the APH. Downstream o the APH, the outlet cone and the return bend orm the connection to the carbon black plant. APH upper tubesheet in workshop
DBTS reractory lining
APH 900/144
APH 800 °C with accessories
To compensate the thermal expansions between APH and carbon black gas ducting Alstom has developed a special type o expansion joint. Thanks to the shape o the Schack® Saw Tooth Expansion Joint blocking by product deposits is eciently avoided. Additionally Alstom oers tube cleaning systems or APHs which clean the tubes by means o steam impulses during operation.
APH 900/192 ready or shipment CARBON BLACK INDUSTRY 5
Tailgas Combustion
The tailgas generated in great amounts during carbon black production has a high energy content due to its proportion o combustible elements. For environmental reasons it is required to treat the gas in a thermal oxidizer process to minimize the quantity o hazardous substances. It is protable to make use o this thermal energy to produce steam or electricity. CFD-Modelling o tailgas combustion chambers
sChaCk® Tailgas boiler
Inside view o a combustion chamber in operation
Alstom‘s experience in combustion o CO gas combined with sophisticated testing and examination methods permit optimization o the equipment, observing all requirements to CO and NOX emissions. Furthermore by energy recovery in the Schack ® Tailgas Boiler, a reduction in CO2 emissions o the carbon black plant is achieved as well. The specic conditions o the carbon black actory as well as environmental regulations are considered and are complied with by Alstom.
Schack® Tailgas Boilers have proven themselves in practice in the carbon black industry all over the globe. Combined with Schack® Tailgas Combustion a system results which particularly meets the high requirements o the carbon black industry in availability, maintainability, eciency and environmental protection.
Advanced tailgas boilers are o modular designs, taking into account individual requirements. Basis is the Schack ® Combustion Chamber and the Heat Recovery Boiler. The tailgas boiler can be amended by: ·
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Modular Schack® Tailgas Boiler CARBON BLACK INDUSTRY 6
Available steam capacity and electrical power or typical steam parameters o a tailgas boiler
Tailgas booster an Multi uel auxiliary burner SNCR reaction zone Induced draught an Stack
Auxiliary burner or natural gas with instruments Schack® Tailgas Boiler with 49 t/h steam capacity
Depending on the required steam parameters tailgas boilers are available in re tube or water tube design. Besides the boilers Alstom Power Energy Recovery GmbH supplies all auxiliary equipment required or boiler plants.
Schack® Tailgas Boiler or 75,000 Nm 3/h tailgas during erection on site
Tailgas boiler or 41 t/h steam at 45 bar / 400 °C
Typical tailgas boiler arrangement
The scope o supply provided by Alstom Power Energy Recovery GmbH is not limited to hardware supply – it also comprises services.
Field erection, commissioning, maintenance and repair as well as training o operator personnel is available to customers all over the globe.
Partial view on a tailgas combustion chamber during erection CARBON BLACK INDUSTRY 7
Carbon Black Process Heat Recovery
In addition to the air preheaters quench boilers, reactor boilers and oil preheaters are integrated in the carbon black process. Also these Alstom Schack® products serve to recover energy. The reduction in carbon black gas temperature by energy recovery saves quench water, which otherwise would be used to cool the gas beore entering the process lter. As less moisture is contained in the carbon black gas the volume fow to the process lter is reduced.
Schack® products in carbon black processes
This results in lower pressure drop, reduced energy cost or the blower and longer service lie o lter bags.
sChaCk® reaCTor boiler The Schack® Reactor Boiler in the carbon black process is a waste heat boiler that generates process steam. Carbon black gas is typically cooled down rom 600 °C to 400 °C.
The reactor boiler is based on the principle o the shell-and-tube-boiler where the fue gas passes through the tubes and the steam space is integrated in the shell. Design and process data are harmonized so that there is no tendency to ouling which would aect the operation. Reerences prove the high reliability o Schack® Reactor Boilers in service or many years.
Schack® Reactor Boiler inlet tubesheet CARBON BLACK INDUSTRY 8
Schack® Reactor Boiler in operation
sChaCk® oil preheaTer Schack® Oil Preheaters recover the energy rom the carbon black gas to preheat the eedstock. They are designed as tube coils and arranged in the fue gas duct downstream o the air preheaters. Steam superheaters can be designed in the same way oering a technical solution or steam drying and slight superheating.
Schack® Quench Boiler at Alstom workshop in Kassel
Quench boiler ready or shipment
Quench boiler
Schack® Air Preheater and Quench Boiler
Double tube design o quench boiler
The heat recovered rom the carbon black gas is used by the Schack® Quench Boiler to generate saturated steam. The boiler operates in natural circulation mode. Due to the unique double tube design quench boilers are resistant against extremely high thermal loads.
In service the Schack® Quench Boiler has shown only very low tendency to ouling and proven outstanding reliability.
sChaCk® QuenCh boiler Schack® Quench Boilers are positioned within the carbon black process directly downstream o the process quench o the carbon black reactor. Typically, at an inlet temperature o about 1300 °C they cool the carbon black gas to 1000 °C. The cooling temperature window is adjusted to the inlet temperatures o the air preheater connected downstream. When the process air preheating temperature shall be less than 800 °C, quench boiler outlet temperatures below 1000 °C can be achieved by installing quench boilers with longer dimensions. Thus, higher steam generation in the quench boiler is obtained.
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Carbon Black Drying
sChaCk® roTary dryer Besides the described thermal systems Alstom also provides Schack® Rotary Dryers, an important link in the chain o process components o a carbon black production plant. Alstom’s experience in the eld o drum-type dryers is based on Rekuperator Schack know-how and complemented by the experience o Raymond® and Bartlett-Snow™ rom the company Alstom Power Inc., USA.
Rotary dryer, 9‘ diameter, 80‘ long, during abrication in the shop
Inside view o a 9‘ dryer drum Rotary dryer with accessories
Rotary dryer during erection on site CARBON BLACK INDUSTRY 10
Lower section o urnace shell or a 10‘ Schack® Rotary Dryer
Excellence in Manuacture due to own Workshops, Erection, Commissioning, Customer Service
exCellenCe in design, researCh & developmenT Alstom Power Energy Recovery GmbH’s activities in the eld o heat recovery equipment and boiler engineering require a very broad engineering knowledge. Relying on the latest computer technology and rened engineering sotware systems, our R&D department analyses and solves a wide range o very intricate tasks related to process and boiler dynamics, non-linear mechanics, vibration theory, thermodynamics, etc. From the combination o experimental results and theoretical investigations, new designs and solutions to specic engineering challenges are developed.
Main ofce and workshop in Kassel, Germany
exCellenCe in manufaCTure
exCellenCe in QualiTy managemenT
In order to meet our customers’ quality requirements as well as our own stringent standards, we are committed to running our own production acilities in Kassel and Mannheim, Germany. This constitutes the link between our excellence in design, research & development, and our customers’ expectations in terms o the outstanding perormance o our products.
Quality management in our opinion means more than simply complying with standards and meeting the demanding requirements o our customers.
The latest manuacturing techniques, sophisticated production and testing machinery combined with highly qualied, annually certied manuacturing personnel, ensure the creation o top-quality products. Alstom perorms NDT with its own personnel and equipment in accordance with EN 473 and SNT-TC-1a, level II and III or the procedures o RT, UT, MT, PT, VT and LT.
Alstom is certied according to ISO 9001, Pressure Equipment Directive 97/23/EGI, ASME U, U2, S, PP, R-Stamp, Saety Quality Licence or Import Boiler and Pressure Vessels to the People’s Republic o China, “Großer Eignungsnachweis” according to DIN 18800 part 7, UDT o Poland, EN 729-2 and AD-HP, TRD and other international standards. Excellence in Alstom’s quality management again is documented by saety management SCC-certicate.
CARBON BLACK INDUSTRY 11
at pw e rc gh
Ellenbacher Strasse 10 D-34123 Kassel, Germany Phone +49-561-9527-0 in
[email protected] www.shg-schack.com
at pw e rc gh
Parsevalstrasse 9A y r T s u d n i k C a l b n o b r a C 9 0 0 2 / 4 0
D-40468 Düsseldor, Germany Phone +49-211-4726-0 in
[email protected] www.shg-schack.com
