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Plant Types: Chemical and Specialty Chemical
Subtypes: Phthalic Anhydride
Capacity: 35 ktpa
Raw Materials: Orthoxylene
The plant has a production capacity of 35 000 tons Phthalic Anhydride (PA) per year on a continuous seven days per week basis.
Raw material orthoxylene (o-Xylene, 1,2-dimethylbenzene) is mainly imported by ship to the tank storage at the jetty. Orthoxylene is pumped by pipeline to the site. The reaction is strongly exothermic and the reaction heat is recovered generating steam in an integrated WHB (Waste Heat Boiler). The tail gases from the processes are incinerated in a catalytic incinerator (Catox) where complete combustion takes place leaving only effluent CO2 and water.
The exothermic reaction develops substantial amounts of excess heat. Surplus heat is cooled off with a liquidized salt mix made up by potassium nitrate and sodium nitrate, which in turn is cooled with water and hence no thermal oils is present in the WHB. Reaction occurs in potentially explosive areas in all process steps.
The plant handles hydrocarbons at elevated temperatures and pressures and has the potential for pool fires, explosion and gas jet fires. There is however not sufficient quantity of light hydrocarbons to give rise to the inherent potential for a vapor cloud explosions. There is generally a good standard of remote isolation valves provided in the raw material supply as well as in process units.
Plant Types: Chemical and Specialty Chemical, Petrochemical
Subtypes: Formaldehyde Plant
Capacity: 105mm lbs/yr at 40%-45% (capable of 37-51%)
Raw Materials: Methanol, Oxygen
Formaldehyde Plant (Reichhold Design using metal oxide catalyst).
Available for operation in-place (Allentown, PA USA) or relocation globally.
Process Description:
The Formaldehyde plant (P501) is designed to produce formaldehyde by the catalytic conversion of methanol and oxygen controlled recycle gas. Formaldehyde is produced by the direct oxidation of methanol from the Methanol Storage Tank and Piping (P502). Emissions from the methanol storage tank and piping, during truck unloading, are captured by the Methanol Vapor Recovery System (C502). Emissions not captured by the vapor recovery system are fugitive emissions (Z550). The catalytic conversion reaction is carried out with the aid of a catalyst, which consists of molybdenum and iron oxides. The process gas is passed through the catalyst, contained in a multiple tube unit called the converter. It both heats the air-methanol mixture to the reaction temperature in the upper part of the catalyst tube and removes the heat of the reaction in the lower part. The formalin gases, which leave the converter, are cooled in an after-cooler where low-pressure steam is produced. The cooled gases enter an absorber where the formaldehyde is absorbed into water to produce up to a 53.0% Formaldehyde solution. In order to reach desired production rates, it is necessary to operate the plant under recycle conditions. Part of the gas mixture leaving the absorber stack is returned to a recycle tank where it is mixed with fresh air, at a controlled rate, to maintain oxygen content of 10 — 10.5% by volume. The remaining unused gas mixture goes to the Natural Gas fired (FML541) Catalytic Oxidizer (C501) where it is preheated and oxidized, in the presence of a catalyst, to harmless byproducts. These byproducts are released to the atmosphere through the Formaldehyde Incinerator Stack (5501).
Notes: Shut down in 2024. Documentation is incomplete.
Plant Types: Chemical and Specialty Chemical
Subtypes: Sodium Meta Bi-Sulfite Plant
Capacity: 15000 metric tons/yr
Raw Materials: Sulfur, Soda Ash
NEW From Cancelled Project!
Using “excess air + solid sulfur” incineration process, the obtained sulfur dioxide gas concentration is about 12%~15%. Control the reasonable sulfur incineration temperature to ensure complete combustion of sulfur.
Using our proprietary technology for solid sulfur feed system, so that the sulfur incinerator temperature is stable, the sublimation sulfur is less in the flue gas. The plant is designed with negative pressure air blowing system, which has good operating environment, and sulfur yield is high.
Using automatic continuous discharging centrifuge, which is a continuous automatic operation, is safe and reliable, saving manpower.
The low concentration sulfuric acid waste liquid is used for production of Magnesium Sulfate products, so the plant has no waste liquid effluent discharge.
Perfect design of exhaust gas treatment. In the waste gas, SO2 concentration is less than 50mg/Nm3（SO2≤50mg/Nm3）.
The air is filtration by air filter, and then is feed into air compressor, the air is compressed by air compressor and is feed into sulfur incinerator, the air burning with solid sulfur and obtain sulfur dioxide gas (SO2).
The solid sulfur is fed into sulfur incinerator by solid sulfur feeder, the solid sulfur is mixed with air and burning in the sulfur incinerator, and obtain sulfur dioxide gas (SO2), and release a lot of heat at the same time.
S + O2 = SO2 + Q
A part of sulfur dioxide reaction with oxygen and get sulfur trioxide.
2SO2 + O2 = 2SO3 -Q
After burning, the hot flue gas is enter the flue gas buffer tank, and then is enter the cooling pipe, using circulating water to cooling the flue gas, the flue gas is cooling to 50~60℃ and then is feed into flue gas scrubber, through bubble washing to remove SO3 of flue gas. After the flue gas scrubber, using stage of separator to separation and removal of entrained droplets of flue gas. The scrubbing obtained dilute sulfuric acid is collected and used to produce Magnesium Sulfate by-product. The purified sulfur dioxide gas is sent (through pipeline) to sodium Metabisulfite synthesis section.
SO3 + H2O = H2SO4
Put solid soda ash (Na2CO3) into the soda ash batching kettle of sodium Metabisulfite synthesis section, add water and mother liquor (the filter liquor) of sodium Metabisulfite centrifuge and mixed into suspension, and then pumping the suspension into sodium Metabisulfite synthesis reactors, and feeds clean sulfur dioxide gas successively into the first stage, second stage and third stage synthesis reactors, after synthesis reaction, get sodium Metabisulfite suspension in the first stage synthesis reactor. The reaction tail gas is discharged from the third stage synthesis reactor, and is lead into the scrubbing tower for treatment.
Na2CO3 + 2SO2 = Na2S2O5 + CO2
The Sodium Metabisulfite suspension is discharged from the first stage synthesis reactor and stored into slurry tank, and then from the slurry tank feed into centrifugal, through centrifugal separation and get wet solid Sodium Metabisulfite, which is content 3~5% water, feed the wet Sodium Metabisulfite into hot air dryer (airflow drier), and through cyclone separators, get Sodium Metabisulfite products. The filtrate is collected into the acid mother liquor tank, reused for soda ash solution batching kettle. The drying use hot air comes from the waste heat recovery jacket of sulfur incinerator. After drying, the tail gas is send into tail gas absorption column.
The tail gas countercurrent contact with soda ash solution, the sulfur dioxide gas in the tail gas was absorbed by soda ash solution, the tail gas was cleaned and emptying **(SO2≤50mg/Nm3)**. The absorption solution reused for soda ash solution batching.
In the flue gas scrubber of sulfite dioxide purification section, the sulfite trioxide is absorbed by water and get concentration of 50~60% dilute sulfuric acid liquid waste, which is used to produce Magnesium sulfate heptahydrate by-products.
MgO + H2SO4 + 6H2O = MgSO4·7H2O
Plant Types: Chemical and Specialty Chemical
Subtypes: Fermentation Plant
Capacity: 40 mmgpy
Solid Separations:
Saccharified mash is then sent to the sugar clarification system. Paddle screens and centrifuges are used to filter out spent grain solids and wash sugar from the spent grains in a 3-stage counter current wash. Liquid sugar is pumped to 121,000-gallon SS storage tanks and solids are sent to rotary drum dyer for final drying.
Fermentation begins with bacterial propagation through a sanitary seed train consisting of two 44 gallon seed tanks, two 2000 gallon seed tanks and finally a 28,500 gallon seed tank before being mixed with liquid sugar in four 285,000 gallon fermenters. During fermentation broth is continuously stripped from the fermenters and passed through an Alfa Laval ultra filtration skid separating the biologics from the fermentation broth which are sent back to fermenter. Filtrate is pumped to the distillation unit where Butanol and Acetone are distilled off through a series of distillation columns and passed through a 3-effect evaporation system before heading to final product storage
Other notable features include an on-site wastewater treatment facility rated for 157,000 gallons per day and full product testing and microbiological laboratory.
Other potential uses included: high protein feed products, renewable biochemicals, single cell proteins, sustainable aviation fuel, food grade organic acids and industrial/GNS alcohols.