Flowserve Pump Application Manual

Applications Manual Volume 1Table of Contents Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Corn Wet Milling and Refining Applications Chlor-Alkali Industries Applications Mineral Acids Applications PTA Applications Titanium Dioxide Hydrocracking Applications Delayed Coker Applications Combined Cycle Unit Applications Corn Wet Milling and Refining Applications Table of Contents Page Number 1. Introduction 1.1 1.2 1.3 Rationale and Methodology Raw Materials and Derivatives Corn Wet Milling and Refining Process 1-1 1-2 1-4 2. Market Profile 2.1 2.2 Market Drivers and Growth Competition 2-1 2-2 3. Flowserve Experience 3.1 3.2 3.3 3.4 3.5 Flowserve Sales Decision Makers Competitive Advantages of Durco Process Pumps Guidelines for Seals Plant and Pump Details 3-1 3-3 3-4 3-5 3-5 4. Pump Recommendations 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Steep House Mill House Germ Plant Feed House Modification (Mod) House Syrup Refinery Auxiliary Pumps Profile of End-Users OEMS and Engineering Contractors Master List of Pump Applications Conversion Factors: Alloys, Volumes and Temperatures 4-3 4-8 4 - 15 4 - 20 4 - 23 4 - 24 4 - 31 A- 1 B-1 C-1 D-1 Appendix A Appendix B Appendix C Appendix D i Corn Wet Milling and Refining Applications Exhibits Page Number 1. 2. 3. 4. 5. 6. Components of a Corn Kernel Derivatives of Corn Other Raw Materials Used in Milling and Refining Upstream Processes in Corn Milling and Refining Corn Derivatives in the United States Flowserve Sales of Durco Process Pumps in Corn Wet Milling and Refining Flowserve Customers Plant Organizational Chart Typical Plant Layout Pumps Used in Corn Wet Milling and Refining Pump Applications List: Corn Wet Milling and Refining Pump Applications List: Steep House Pump Applications List: Mill House Pump Applications List: Germ Plant Pump Applications List: Feed House Pump Applications List: Syrup Refinery Pump Applications List: Auxiliary Pumps Alloy Conversions Volume Conversions Temperature Conversions 1-2 1-2 1-3 1-4 2-1 3-1 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. D.1 D.2 D.3 3-2 3-3 3-6 3-7 4-2 4-3 4-8 4 - 15 4 - 20 4 - 25 4 - 31 D-1 D-1 D-1 ii ) important ingredients for processed foods and beverages.Corn Wet Milling and Refining Applications 1. other starchy grains. and the textbook Technology of Corn Wet Milling. East Europe and Latin America Consolidate and share Flowserve’s modular pump experience in this market so that all sales personnel can offer proven pump solutions. 2 Flowserve RED 06/98 1-1 . Although technically part of the food and beverage segment. Elsevier Science Publishers BV. 1992. the industry requires chemical process pumps for abrasive corn slurries and numerous other applications. as it is known in North America. notably soft drinks. Driving this market today are the corn syrups produced from corn starch. DC USA).) economical sugar substitutes. Whereas many small local producers once existed. Flowserve’s Durco Process Pump business has developed a leading presence in the corn1 wet milling and refining industry. Resources for further information include Corn Refiners Association (Washington. a handful of large producers are emerging. and are now expanding via acquisitions and joint ventures in developing regions. Belgium). Demand has been on the rise around the world because these corn syrups are 1. Amsterdam. The Netherlands. a global consolidation is underway in corn wet milling and refining. Given Flowserve’s experience serving corn wet millers in developed regions. In addition to corn. is referred to as maize wet milling in Europe and other parts of the world.2 1 Corn wet milling. The purpose of the manual is therefore twofold: Introduce Flowserve sales personnel to the market as a preparation to pursue new pump business. and 2. as well as this new growth potential in developing areas. especially in Asia Pacific. the Association Des Amidonnieries De Cereales De L’UE (Brussels. Most have well established operations in North America and West Europe.1 Introduction Rationale and Methodology Over the last twenty years. 1. In response to increasing opportunities around the world. fruits and vegetables are wet milled. Paul Harwood Blanchard. it seemed logical to create an applications manual specifically for the wet milling and refining processes. This manual represents the collective work of numerous Flowserve sales engineers and other personnel who have knowledge of the industry. Technology of Corn Wet Milling. EXHIBIT 2 Derivatives of Corn Flowserve RED 06/98 1-2 .) germ. Water is used throughout the milling process to soften and transport the corn.Corn Wet Milling and Refining Applications 1. a fibrous material 3. a protein 4. they are refined to make value-added products. After the four components have been milled. Exhibit 2 illustrates the types of products which can be made from corn.2 Raw Materials and Derivatives Each corn kernel is composed of four materials: 1.) gluten. the kernels are broken down and the four component parts separated. hence the term “wet” milling.) hull. where oil is found 2.) starch EXHIBIT 1 Components of a Corn Kernel By wet milling corn. such as Method of milling (dry and wet) Number and nature of separation steps Hardness of raw material (abrasion concern) For example. but unlike the slurries in corn wet milling. more abrasive than corn Other raw materials are used in parts of the world where corn is less abundant or more expensive. the separation is difficult because the specific gravity of burned and unburned starch is similar. similar to corn Also called cassava (see above) Cereal grass. but there can be differences. seed contains starch. Flowserve RED 06/98 1-3 . The milling process is generally the same. root contains starch Tropical plant. the suction pressures at the inlet of the pump tend to be higher. In the dry process. wheat milling involves dry and wet processes. similar to cassava Primarily milled in Europe Cereal grass. seed contains starch Palm plant. This is done via a wetted centrifugal separation. seed contains starch Tropical plant. pith contains starch Tropical grass. root contains starch Cereal grass. To adjust for this. primarily milled in Europe. some starch burns and must be removed from the rest of the starch.Corn Wet Milling and Refining Applications In addition to corn. numerous other agricultural products are wet milled and refined into similar value-added products. EXHIBIT 3 Other Raw Materials Used in Milling and Refining OTHER RAW MATERIALS Arrowroot Barley Cassava Manioc Potato Rice Sago Sorghum Tapioca Wheat COMMENTS Tropical American plant. most plants include the facilities and upstream processes highlighted in Exhibit 4: EXHIBIT 4 Upstream Processes in Corn Wet Milling and Refining For recommended pump specifications used in these upstream processes.Lactic Acid .Citric Acid . Although not covered in detail in this manual.Sorbitol 3 Most plants include both milling and refining processes.Erythritol . chemicals.” corn is separated into its four components (germ.Ethanol Fuel . fuels. or by one of its customers which uses corn derivatives as feedstock. see Section 4. gluten. These facilities may be owned by the corn wet miller. starch).3 A corn wet milling and refining plant will consist of numerous sub-plants.Vitamin E . The components are then “refined” into any number of derivatives (food ingredients.Polyol .Itaconic Acid .Lysine . During “milling.Mono Sodium Glutamate .Corn Wet Milling and Refining Applications 1. but are often referred to jointly as simply “corn wet milling.).3 Corn Wet Milling and Refining Process “Corn wet milling and refining” is a term used to describe numerous processes involved in converting corn into value-added products. etc. Pump Recommendations.” Flowserve RED 06/98 1-4 . A corn wet milling and refining plant can include various other downstream processing facilities which also require large numbers of process pumps. a few examples of downstream facilities and/or products are: . hull. At a minimum. yet their production has been limited.1 Market Drivers and Growth The corn wet milling market is driven by demand for its derivatives. Despite this there are still significant expansion and upgrade projects in progress today. Corn syrup production has historically been more significant in North America than in other parts of the world. Representing about 20% of the world sweeteners market. Seventy-nine percent of this market is found in developing regions of the world. shows that corn syrups are the largest derivative: EXHIBIT 5 Corn Derivatives in the United States Corn syrups are part of the 5. In Europe. As standards of living increase around the world. so economic development there drives much of the demand for sweeteners.3 billion bushel (135 million tonnes) per year sweeteners market. Market Profile 2. Corn syrups are an expanding part of the world sweeteners market. with even greater potential expected soon as trade barriers are relaxed and economic development proceeds. Higher growth is anticipated in the longer term as economic development and population growth rates accelerate. the sweetener market is set to expand 2%. Smaller corn wet milling and refining facilities do exist. so too has demand for these food products and the corn syrups used to make them. The situation in the United States.Corn Wet Milling and Refining Applications 2. corn syrups are found predominantly in processed foods and beverages. Asia Pacific and Latin America. where the industry is well developed. With moderate economic growth expected during 1998. Flowserve RED 06/98 2-1 . protected sugar industries have supplied most of the sweetener requirements. Durco Process Pumps are very competitive in corn wet milling and refining because of numerous unique features and benefits. pharmaceuticals and biodegradable plastics are all made from corn syrup. IDP. Galigher. Based on what is known of the Asia Pacific and Latin American markets. there is a mixture of domestic producers and those global players mentioned above serving the industry. In Europe. is a product opportunity still in its infancy. One important example comes for the soft drink industry. Increasing worldwide demand means that as companies like Coca Cola® and Pepsi Cola® expand production facilities. The latter.3. High fructose corn syrup (HFCS 55) is increasingly used in place of sugar in soft drinks. upgrading and constructing corn syrup production capacity around the world to support their customers. Mission and Peerless are involved in the industry as well. KSB. 2. Ethanol. Moret and IDP are the main competitors. “pulling” their suppliers along to ensure global product uniformity. ITT Goulds is often the main competition. ITT Allis Chalmers. but one which may yield considerable demand for corn wet milling and refining in the future. Sulzer. biodegradable plastics. animal feed additives. although to a lesser extent. Rubber-lined and high chrome iron pumps often found in mining may also be used in some highly erosive applications. an environmentally friendly fuel. basic chemicals such as citiric and lactic acid.Corn Wet Milling and Refining Applications One reason the outlook for global corn syrup consumption is so promising: Processed food producers are expanding around the world. corn wet millers are purchasing. These are highlighted in Section 3. Flowserve RED 06/98 2-2 . In the United States.2 Competition Competitors in corn wet milling are mostly the same as those found in chemicals processing. Other products which are made from corn syrups impact corn syrup demand. Durco Process Pumps are becoming a standard around the world for corn wet milling applications. but as corn wet millers expand around the globe. Sales have been historically concentrated in developed regions. Flowserve Experience 3. EXHIBIT 6 Flowserve Sales of Durco Process Pumps in Corn Wet Milling and Refining Many major corn wet millers use Durco Process Pumps.1 Flowserve Sales With sales in the tens of millions of US dollars. Some of Flowserve RED’s customers in corn wet milling include: Flowserve RED 06/98 3-1 . so too have sales of Durco Process Pumps.Corn Wet Milling and Refining Applications 3. three of them are amongst the largest forty customers for Durco Process Pumps. Flowserve RED 06/98 3-2 . Industria de Maiz. Examples by region are: Asia Pacific Europe Latin America USA/Canada Asia Modified Starch. Grupo Xacur. Grain Processors. Penford Detailed profiles of these and other producers are found in Appendix A. Thai Roun. Arancia. Alimodones Y Glocosa. Delmaiz. ADM. Molinos ADM. Corn India. Remy Amido Glucose. Amylum (Belgium) AFFILIATES HOME BASE South Korea USA USA France USA France South Korea South Korea UK MARKETS Asia Pacific Global Global Global Europe. Agrana Staerke. North America Europe. These too represent considerable potential and should be targeted as new customer opportunities. Raisio. There are numerous other companies in the industry with which Flowserve has no or limited experience. Doosan Food.Corn Wet Milling and Refining Applications EXHIBIT 7 Flowserve Customers COMPANY Bang Il Industry Cargill Corn Products International Cerestar formerly CPC Corn Products Eridania Beghin Say (parent) National Starch & ICI (parent) Chemical Roquette Samyang Genex Sewon Tate & Lyle (parent) AE Staley (USA). Maffessoni Comercio e Industria. Aranal Comercial. Shin Dong Bang ABR Foods. Midwest Grain. Avebe. Crespel & Dieters. North America Asia Pacific Asia Pacific Global Some of the best opportunities to sell Durco pumps will come from leveraging these existing relationships with customers who are expanding in new markets. Profile of End-Users. Minnesota Grain Processing. the purchasing office is an important contact as the gateway to those in the plant. steep house. The team is often headed up by the plant engineering manager and consists of project engineers and/or an outside engineering firm.Corn Wet Milling and Refining Applications 3.2 Decision Makers The parties with decision making responsibilities will differ depending on the type of business. When a project is approved. including project work. etc. The plant engineering manager (or team leader) makes the final decision on all major equipment purchases based on information assimilated from the team. Flowserve RED 06/98 3-3 . but he is also usually consulted prior to any major equipment purchases.g. area maintenance managers and area mangers. a project team is formed. When equipment is needed. Within each main processing area in the plant (e. the plant engineering manager often has the final say. new project or MRO For new projects.) there is usually one engineer responsible for maintenance activities there. mill house. So for MRO sales it is important to establish relations with the plant maintenance manager. EXHIBIT 8 Plant Organizational Chart While these individuals are usually the decision makers. For MRO business. the area maintenance engineer seeks approval from either the area manager or the plant maintenance manager. Not only does the plant maintenance manager oversee MRO purchases. the decision is dominated by the plant maintenance manager. but others are involved in the process. Another benefit is the ability to set the impeller clearance and mechanical seal without the casing. The Sealmatic pump option is promoted for many continuous services found in corn wet milling and refining. Flowserve’s CD4M material. more single seals can be used in place of double seals. features unique to the Durco Process Pumps are particularly well suited to handle the erosion and sealing issues involved in corn wet milling and refining.Corn Wet Milling and Refining Applications 3. Reinforced baseplate types B (Polybase Polymer Concrete). Whereas much of the competition promotes CF-8M (cast 316) wet-end material and double seals with forced-air circulation. With the FML. This is beneficial since all flush water must be removed. and D (Medium Duty Reinforced) are preferred because of rigidity. The ability to remachine a rear cover versus buying new wet-end parts is an added cost advantage. Flowserve RED 06/98 3-4 . The SealSentry FML seal chamber provides customer cost savings. This means there are fewer external flush requirements (seal pots) and less water entering the process. so limiting wear to the rear cover extends the life of the casing. the less water added. C (Reinforced. Stilt-mounted). it prolongs the life of wet-end parts significantly with little additional cost. also brings advantages. the greater the savings. Corn wet milling and refining customers standardize almost exclusively on CD4M given numerous corrosive and erosive services in the plant. More erosionresistant than stainless steel. a duplex stainless steel.3 Competitive Advantages of Durco Process Pumps Flowserve is especially competitive in corn wet milling and refining because of features designed to prolong pump life and maximize Mean Time Between Planned Maintenance. The dynamically sealing repeller eliminates the need for conventional mechanical seals. Stilt mounting is well accepted because costly grout is not needed and alignment to piping is made simple. C and D) The reverse vane impeller is particulary well suited to corn wet milling applications. Many services contain solids. and is advantageous in corn milling where sealing is difficult and flush undesirable. ease of stocking one metallurgy and Flowserve’s ability to support with quick deliveries. Some of the highly competitive features of Durco Process Pumps include: Reverse vane impeller CD4M material SealSentry FML seal chamber Sealmatic option Reinforced baseplates (types B. use SealSentry FML seal chamber to purge heat and solids (i. The pump application numbers in Exhibit 10 correspond to those found throughout Section 4.e.Corn Wet Milling and Refining Applications 3. 3. FML might completely replace flush arrangements) .5 Plant and Pump Details A broad overview of a corn wet milling and refining plant is illustrated in Exhibit 9 on the next page. Pump Recommendations.Use hard seal faces as recommended in Section 4. Pump Recommendations.4 Guidelines for Seals Many of the fluids found in corn wet milling and refining contain solids and/or have a high viscosity. locate seal faces beyond seal gland and in process fluid .For all single seals.For single seal quench. so it can be difficult to keep the seal clean and intact. use clean water instead of dirty process water . use in tandem execution if contamination is a concern. which adds cost to the process.. Flowserve RED 06/98 3-5 . A more detailed view of select subplants and pump applications follows in Exhibit 10. the following guidelines can contribute to improved seal life: . any water added to the process via the seal support system must be removed. Based on Flowserve experience.Where double seals are specified in Secion 4. Yet.For single and double seals. Pump Recommendations . Corn Wet Milling and Refining Applications Flowserve RED 06/98 3-6 . Corn Wet Milling and Refining Applications Flowserve RED 06/98 3-7 . They are based on specifications which have performed well in the field. and are intended to raise awareness of issues associated with particular applications. Other specifications not addressed in this manual may be equally or more acceptable. A qualified pump engineer must still be involved in the specification of any pump. Flowserve RED 06/98 4-1 . and manufacturers of components/accessories are to be consulted for detailed specifications as well. These guidelines should not take the place of any manufacturer’s recommended specification for a given application.Corn Wet Milling and Refining Applications 4. depending on variables associated with the application. Pump Recommendations The recommendations that follow are general guidelines. Plants in Europe have an average grind of 55.15 4 . which represents an average-sized plant in the USA.24 4 .20 4 .000 bushels (4300 tonnes) per day.31 -- An alphabetical list of pumps found in these upstream processes is found in Appendix C. 4 Based on a grind rate of 170.23 4 .Corn Wet Milling and Refining Applications EXHIBIT 11 Pump Applications List: Corn Wet Milling and Refining FACILITY STEEP HOUSE MILL HOUSE GERM PLANT FEED HOUSE MODIFICATION (MOD) HOUSE SYRUP REFINERY AUXILIARY TOTAL PROCESS PUMPS PROCESS PUMP QUANTITY4 SEE PAGE 22-26 62-65 20 11 30-40 128-130 46-56 320-350 4-3 4-8 4 . Master List of Pump Applications.000 bushels (1400 tonnes) per day . 4-2 Flowserve RED 06/98 . A sulphuric acid solution (0.1 STEEP HOUSE Objective Description Soften clean. where it is deposited into large steep tanks. Plants in Europe have an average grind of 55.Corn Wet Milling and Refining Applications 4. which represents an average-sized plant in the USA. Flowserve RED 06/98 4-3 . EXHIBIT 12 Pump Applications List: Steep House APPLICATION NUMBER SH1 SH2 SH3 SH4 PUMP APPLICATION PROCESS PUMP QUANTITY5 2 16-20 2 2 22-26 SEE PAGE 4-4 4-5 4-6 4-7 -- Presteep Corn Pump Steep Water Recirculation Pump Light Steep Water Pump Sluice Pump TOTAL PROCESS PUMPS 5 Based on a grind rate of 170.000 bushels (4300 tonnes) per day. The steep is complete when the corn kernel is sufficiently broken down to be milled.000 bushels (1400 tonnes) per day.2% concentration) is added and the corn soaks in this “steep water” for up to 48 hours. hard corn in preparation for further processing. Clean corn is transported from storage to the steep house. the water may be heated to preheat the corn. CONDITIONS Fluid Temperature Clean corn slurry (abrasive with 60% solids) 120-127°F (49-53°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single seal FML seal chamber and flush High-chrome iron†. Since corn is steeped at 120-127°F (49-53°C). High-chrome iron is preferable. Flowserve RED 06/98 4-4 . In some cases corn is conveyed dry from storage to steep house. Contact Flowserve RED Marketing regarding availability. CD-4MCu with hard coating Front vane open Recessed impeller pump COMMENTS * † Application is suitable for process pump only if corn transported as a slurry.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Steep House Presteep Corn Pump* SH1 2 DESCRIPTION Clean corn is transported in water through pipelines to one tank in the steep tank battery. Tanks are filled one at a time and it takes about 2 hours to fill each tank. where it is reused. with each tank requiring one pump. The pumps recirculate steep water within one tank. the pumps transport the steep water to the next tank. Flowserve RED 06/98 4-5 . As steeping is completed. CONDITIONS Fluid Temperature Steep water (abrasive with 25-30% solids) 120-127°F (49-53°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Sealmatic pump and single static seal* FML seal chamber CD-4MCu Reverse Vane Durco Power Monitor (model KW941) † COMMENTS * † With high suction pressures. A battery cosists of 8-10 tanks. use single seal with FML seal chamber.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Steep House Steep Water Recirculation Pump SH2 16-20 DESCRIPTION The steep house consists of batteries of steep tanks. Application where pump runs dry as fluid in steep tank empties. Flowserve RED 06/98 4-6 .02%) and about 5% solids. CONDITIONS Fluid Temperature Light steep water 120-127°F (49-53°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 (B) Single seal FML seal chamber CD-4MCu Reverse vane Durco Power Monitor (model KW941) COMMENTS * A Sealmatic pump can be considered for this application. Some of the light steep water is evaporated (FH1). the remaining steep water contains little acid (0. concentrating the solids for use in feed products. Some of this “light” steep water is transported to a holding tank (SH3) where it is combined with other surplus process water and prepared for use as steep acid once again.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Steep House Light Steep Water Pump SH3 2 DESCRIPTION As the steep process is completed. Group 3 (C) Single seal FML seal chamber and flush High-chrome iron*. Contact Flowserve RED Marketing regarding availability. it operates continuously.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Steep House Sluice Pump SH4 2 DESCRIPTION After the steep water is drawn off. CD-4MCu with hard coating Reverse vane or front vane open Durco Power Monitor (model KW941) Flowserve RED 06/98 4-7 . softened corn exits through the bottom of the tank. The corn slurry gathers in a trough or pipeline. and pumped to the mill house. is gravity fed into a sluice pump. Because each sluice pump handles the corn from one steep tank battery (8-10 tanks). CONDITIONS Fluid Temperature Corn slurry (abrasive with 30-35% solids) 120-127°F (49-53°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous COMMENTS * High-chrome iron is preferable. although newer plants are larger.) gluten removal. and 3. which represents an average-sized plant in the USA. gluten (protein) and starch. EXHIBIT 13 Pump Applications List: Mill House APPLICATION NUMBER MH1 MH2 MH3 MH4 MH5 MH6 PUMP APPLICATION Corn Slurry Pump Fiber Slurry Pump Millstream Slurry Pump Gluten Wash Pump Gluten Pump Hydroclone Pump PUMP QUANTITY6 24 11 9-11 6 1-2 11 62-65 SEE PAGE 4-9 4 .2 MILL HOUSE Objective Separate softened corn kernel into component parts.12 4 . and separating processes. including germ (oil). A starch slurry remains.14 -- Description TOTAL PROCESS PUMPS 6 Based on a grind rate of 170. hull (fiber).11 4 . grinding.) hull removal. Flowserve RED 06/98 4-8 . In the mill house.Corn Wet Milling and Refining Applications 4.10 4 .13 4 . Plants in Europe have an average grind of 32. There are three distinct separation processes in the mill house: 1) germ removal.000 bushels (800 tonnes) per day. 2. All four components are transported to other process units for further processing.000 bushels (4300 tonnes) per day. the corn slurry passes through a series of dewatering. CONDITIONS Fluid Temperature Corn slurry (20-30% solids) 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single seal with hard faces FML seal chamber CD-4MCu Reverse vane COMMENTS Flowserve RED 06/98 4-9 . passes over a screen to open the kernel. and is gravity-fed into the first grind mill. In a 170. there can be four sets of first and second grind mills.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS DESCRIPTION Mill House Corn Slurry Pump MH1 24 Corn slurry is dewatered. The entire process is repeated in a second grind mill to ensure all germ is removed. The ground corn slurry falls in a tank and is then pumped into each of two cyclones for germ removal. Each set requires approximately 6 pumps. each processing a quarter of the corn slurry.000 bushel per day plant. The ground slurry (“fiber slurry”) falls into one of three tanks and is pumped to a series of six to eight fiber wash screens. Flowserve RED 06/98 4-10 . the corn slurry enters the third grind mill.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Mill House Fiber Wash Pump MH2 11 DESCRIPTION With germ removed. Each fiber wash screen consists of a screen (to remove gluten and protein). a tank (to collect remaining fiber slurry) and a pump (to transport fiber slurry to next screen). CONDITIONS Fluid Temperature Fiber slurry (20-30% solids) 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single seal FML seal chamber High-chrome iron*. CD-4MCu with hard coating Reverse vane COMMENTS * High-chrome iron is preferable. Contact Flowserve RED Marketing regarding availability. CONDITIONS Fluid Temperature Millstream slurry 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single seal FML seal chamber High-chrome iron*. There may be four sets of hydrocyclones.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Mill House Millstream Slurry Pump MH3 9-11 DESCRIPTION Millstream slurry consists of a gluten and starch slurry coming from the fiber wash screens. CD-4MCu with hard coating Reverse vane COMMENTS * High-chrome iron is preferable. the gluten and starch are separated. Flowserve RED 06/98 4-11 . Here. The germ and hull have been removed. Contact Flowserve RED Marketing regarding availability. Pumps carry the millstream from three holding tanks to a set of two hydrocyclones. a holding tank and a pump. each gluten wash screen consists of a screen. double seal if >30% solids Quench if single CD-4MCu Reverse vane COMMENTS * Solids may be referred to as “dry substance” or DS. Like the fiber wash screens. CONDITIONS Fluid Temperature Gluten slurry (20-30% solids) 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 and 3 (B and C) Single seal if <30% solids.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Mill House Gluten Wash Pump MH4 6 DESCRIPTION Gluten is washed in a series of six screens to remove any traces of starch. Flowserve RED 06/98 4-12 . Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Mill House Gluten Pump MH5 1-2 DESCRIPTION Gluten slurry is pumped from the gluten thickener. CONDITIONS Fluid Temperature Gluten slurry (>30% solids) 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 (B) Double seal FML seal chamber CD-4MCu Reverse vane COMMENTS Flowserve RED 06/98 4-13 . Some competitive pumps (KSB. etc.) have wear rings. A pump feeds each hydrocyclone and to transport clean starch slurry to a holding tank. fluid is > 28% solids. or DS.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Mill House Hydrocyclone Pump MH6 11 DESCRIPTION After millstream separation. CONDITIONS Fluid Temperature Starch slurry* 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single (if < 28% DS). In a 170. seal pot and API plan 52 (if > 28% DS)† CD-4MCu Reverse vane ◊ COMMENTS * † ◊ Fluid passing through the first two-thirds of battery will have < 28% solids or dry substance. As hydrocyclones operate most efficiently at high pressures. double (if > 28% DS) FML seal chamber and quench (if < 28% DS). there is one bank of 10 hydroclyclones. which become worn in high DS applications. Flowserve RED 06/98 4-14 . This alters flow rates and the battery may clog.000 bushel per day plant. Pressures and flows throughout the starch washing hydrocyclone battery must be identical. the starch slurry collects in a holding tank and is then pumped to starch washing hydrocyclones to remove any remaining gluten or other impurities. Sulzer. stuffing box pressure will be high. in the last third of battery. Crude oil is sold to an oil refinery. which represents an average-sized plant in the USA. Exhibit 14 Pump Applications List: Germ Plant APPLICATION NUMBER GP1 GP2 GP3 GP4 PUMP APPLICATION Hexane Pump Extractor Pump Finishing Pump Agitator Pump PUMP QUANTITY7 3 6 10 1 20 SEE PAGE 4 .000 bushels (800 tonnes) per day.000 bushels (4300 tonnes) per day.16 4 .3 Germ Plant Objective Description Extract oil from the germ Germ separated from the corn slurry during milling is sent to the germ plant for further processing. Flowserve RED 06/98 4-15 .17 4 . it may not be economical to process the small quantities of germ into oil. although newer plants are larger.18 4 .Corn Wet Milling and Refining Applications 4. Therefore.19 -- TOTAL PROCESS PUMPS 7 Based on a grind rate of 170. Plants in Europe have an average grind of 32. the oil is removed from the germ. At smaller corn wet milling facilities. some producers sell germ to larger extraction plants. Using hexane extraction. A Guardian magnetic drive pump is a secondary option. Flowserve RED 06/98 4-16 . OEMs and Engineering Contractors. See Appendix B. CONDITIONS Fluid Temperature Hexane (explosive) 190°F (88°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 (B) Single seal† CBL seal chamber.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Germ Plant Hexane Pump* GP1 3 DESCRIPTION Hexane is pumped to and from a holding tank in the germ plant. ANSI flush plan 11 DCI† Reverse vane COMMENTS * † Pumps may be sourced as part of an OEM system. OEMs and Engineering Contractors. This fluid is pumped to the top. See Appendix B. CD-4MCu may be specified for plant standardization and better wear life. Flowserve RED 06/98 4-17 . This continues until the mixture consists of about 80% oil.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Germ Plant Oil Extractor Pump* GP2 6 DESCRIPTION Germ is conveyed to extractor in the germ plant. CONDITIONS Fluid Temperature Corn oil and hexane 190°F (88°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 (B) Single seal with hard faces FML seal chamber DCI† Reverse vane◊ COMMMENTS * † ◊ Pumps may be sourced as part of an OEM system. A 90% hexane/10% oil fluid collects in the bottom of the extractor. where it again passes over germ to yield 50% hexane/50% oil mixture. where it is showered with hexane. CD-4MCu impeller is preferable. Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Germ Plant Finishing Pump GP3 10 DESCRIPTION After hexane is boiled off. Flowserve RED 06/98 4-18 . CONDITIONS Fluid Temperature Corn oil 190°F (88°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 (B) Single seal FML seal chamber DCI* Reverse vane † COMMENTS * † CD-4MCu may be specified for plant standardization and better wear life. CD-4MCu impeller is preferable. the 100% corn oil is finished. Flowserve RED 06/98 4-19 .Corn Wet Milling and Refining Applications PUMP LOCAT ION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Germ Plant Agitator Pump* GP4 1 DESCRIPTION Finished corn oil is stored in a holding tank. One pump agitates the stored oil continuously. CONDITIONS Fluid Temperature Corn oil 150°F (66°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single seal FML seal chamber DCI Reverse vane COMMENTS * Pumps may be sourced as part of an OEM system. OEMs and Engineering Contractors. See Appendix B. The high-protein gluten meal commands a higher selling price than the mediumprotein gluten feed. Exhibit 15 Pump Applications List: Feed House APPLICATION NUMBER FH1 FH2 PUMP APPLICATION Evaporator Pump Condensate Pump PROCESS PUMP QUANTITY8 8 3 11 SEE PAGE 4 . hulls and gluten are dried by mechanical and/or thermal means.Corn Wet Milling and Refining Applications 4. but it is the gluten feed that is usually produced in large volumes. The germ.21 4 . Two feed ingredients include gluten meal (mainly gluten) and gluten feed (mainly hulls with germ and gluten).000 bushels (4300 tonnes) per day. and sold as extracts or processed into feed ingredients. Plants in Europe have an average grind of 32.000 bushels (800 tonnes) per day.22 -- Description TOTAL PROCESS PUMPS 8 Based on a grind rate of 170. although newer plants are larger.4 Feed House Objective Process deoiled germ. which represents an average-sized plant in the USA. Flowserve RED 06/98 4-20 . hulls and gluten into by-products such as animal feeds. Flowserve RED 06/98 4-21 . CONDITIONS Fluid Temperature Light steep water 170-230°F (77-110°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) or larger* Double seal FML seal chamber CD-4MCu Reverse vane COMMENTS * If larger capacity required. concentrating the solids for use in feed products. Two four-effect evaporators each process half the steep sent to the evaporators. Ahlstrom alliance pumps can be quoted. The output is a slurry of 50% solids.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Feed House Evaporator Pump FH1 8 DESCRIPTION Light steep water is evaporated. one each for germ. Flowserve RED 06/98 4-22 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Feed House Condensate Pump FH2 3 DESCRIPTION There are three driers in the feed house. which is transported to the power house. fiber and gluten drying. CONDITIONS Fluid Temperature Condensate 210°F (99°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 1 (A) and 2 (B) Single seal with hard faces ANSI flush plan 11 CF-8M (Cast 316)* Reverse vane COMMENTS * CD-4MCu may be specified for plant standardization. A steam trap converts the steam to condensate. Corn Wet Milling and Refining Applications 4.5 Modification (Mod) House Objective Description Process starch slurry into starch products Two types of starch products are produced in the mod house: unmodified and modified. Unmodified starch involves a dry process, whereas modified starch is refined in a wet process. Mod house processes tend to be more proprietary than those in milling, so process details can vary widely. A 170,000 bushel (4300 tonnes) per day corn mill which processes about 50% of the slurry into starch requires 30-40 chemical process pumps for various centrifuging, drying and chemical applications. Not all corn wet milling plants produce starch. Some will use all starch to produce corn syrups and derivatives. Other plants will do little syrup refining, and concentrate on starch production. Flowserve RED 06/98 4-23 Corn Wet Milling and Refining Applications 4.6 Syrup Refinery Objective Convert stach slurry to various types of sweeteners, including corn syrups, dextrose and fructose. Corn syrups are an important food ingredient, found in products such as ice creams and processed meats. Dextrose, another syrup, is widely used as a feedstock in the pharmaceutical industry and for fructose. There are four types of fructose. Three are high fructose corn syrups: 1.) HFCS 42, used in baking and other foods for mild sweetening, 2.) HFCS 55, used in soft drinks, and 3.) HFCS 90, used in reduced calorie foods. The fourth type is crystalline fructose, used in dry foods. Starch-to-syrup conversion involves acid and enzyme reactions. Most corn syrups and dextrose can be produced using either or both reactions, but fructose production requires a specific enzyme reaction. Acid conversion takes place in a reactor at about 175°-195°F (80°90°C). Enzyme conversion involves numerous additional steps, such as liquefaction, dextrinization and saccharification. Corn syrups and dextrose are then purified, cooled and stored. In fructose production, a similar process is used up to purification. At that point, the dextrose syrup is isomerized, yielding a fructose syrup which has about twice the sweetness of dextrose. A syrup refinery may have one multipurpose corn syrup/dextrose process sequence and one fructose process sequence. Description Flowserve RED 06/98 4-24 Corn Wet Milling and Refining Applications EXHIBIT 16 Pump Applications List: Syrup Refinery APPLICATION NUMBER SR1 SR2 SR3 SR4 SR5 PUMP APPLICATION Hydrochloric Acid Pump Soda Ash Pump Corn Syrup Pump Carbon Slurry Pump Microfiltration Pump PROCESS PUMP QUANTITY9 2 4-6 100 6 16 128-130 SEE PAGE 4 - 26 4 - 27 4 - 28 4 - 29 4 - 30 -- TOTAL PROCESS PUMPS 9 Based on a grind rate of 170,000 bushels (4300 tonnes) per day, which represents an average-sized plant in the USA. Plants in Europe have an average grind of 32,000 bushels (800 tonnes) per day, although newer plants are larger. Flowserve RED 06/98 4-25 Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Syrup Refinery Hydrochloric Acid Pump SR1 2 DESCRIPTION In acid coversion process, a hydrochloric acid solution is added to starch slurry before it enters the hydrolysis reactor. CONDITIONS Fluid Temperature Hydrochloric acid solution (33%) Ambient PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 Single seal CBS seal chamber and external flush if F-Pump FRP (D730) Open F-Pump or unlined L-Pump (group 2 only)* COMMENTS * Unlined L-Pump is preferable; if customer desires sealless pump, contact RED Marketing regarding non-metallic magnetic-drive pumps. Flowserve RED 06/98 4-26 FML seal chamber and quench. A recirculation line from repeller chamber to suction and a DurcoShield are recommended. wet soda ash is added to the syrup to neutralize any acids. A less expensive option is a standard Mark III pump with single seal.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Syrup Refinery Soda Ash Pump SR2 4-6 DESCRIPTION After syrup conversion. Specified for material standardization. CONDITIONS Fluid Temperature Soda Ash (35%) 140°F (60°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous COMMENTS * † Group 2 (B) Sealmatic with single static seal *. Flowserve RED 06/98 4-27 . † FML seal chamber and quench CD-4MCu Reverse vane Packing can be considered instead of a single static seal. and a clean water flush may be needed. Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Syrup Refinery Corn Syrup Pump SR3 100 DESCRIPTION Corn syrup pumps are used throughout the refinery to transport syrups.2 bar on top CD-4MCu Reverse vane 1800 rpm † COMMENTS * † Sealmatic pumps or single seals with quench and drain may be suitable for certain corn syrup services. Flowserve RED 06/98 4-28 . The syrups vary from simpler corn syrups (dextrose) to more refined products (high fructose corn syrup). CONDITIONS Fluid Temperature Corn syrup 180-230°F (82-110°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous All. frequent practice is to increase plant capacity by speeding motors to 3600 rpm to the detriment of equipment. 1800 rpm is recommended to maximize life of the power end. mainly Group 2 (B) Double seal* FML seal chamber. seal pot with approximately 1. CONDITIONS Fluid Temperature Carbon slurry 80-100°F (27-38°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Single Group 2 (B) Single seal FML seal chamber High-chrome iron*. Flowserve RED 06/98 4-29 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Syrup Refinery Carbon Slurry Pump SR4 6 DESCRIPTION Corn syrups pass through carbon columns to be purified and to remove any color. CD-4MCu with hard coating Recessed impeller† COMMENTS * † High-chrome iron is preferable. Three process pumps transport carbon slurry to and from each of two columns. Contact Flowserve RED Marketing regarding availability. Reverse vane impeller may be suitable if carbon slurry is very fine. 000 bushel (4300 tonnes) per day plant utilizes eight filters and 16 pumps. making it foodgrade quality. See Appendix B. Reverse osmosis is a newer filtration technology which may require high pressure pumps. Flowserve RED 06/98 4-30 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Syrup Refinery Microfiltration Pump* SR5 16 DESCRIPTION Microfiltration† removes small particulate from high fructose corn syrup. CONDITIONS Fluid Temperature Corn syrup 200°F (93°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Double FML seal chamber and API plan 52 CD-4MCu Reverse vane COMMENTS * † Pumps may be sourced as part of an OEM system. The microfiltration system consists of a series of filters with two pumps per filter. Microfiltration may also be referred to as ultrafiltration. OEMs and Engineering Contractors. A 170. 32 4 .000 bushels (800 tonnes) per day.) Are not found in the main process units described in this manual or 2.Corn Wet Milling and Refining Applications 4. Plants in Europe have an average grind of 32. although newer plants are larger. Flowserve RED 06/98 4-31 .33 4 .000 bushels (4300 tonnes) per day.36 4 .39 -- TOTAL PROCESS PUMPS 10 Based on a grind rate of 170.38 4 .34 4 . which represents an average-sized plant in the USA.) Are found in more than one of these process units.37 4 .7 Auxiliary Pumps Description This section covers pump applications which: 1.35 4 . EXHIBIT 17 Pump Applications List: Auxiliary Pumps APPLICATION NUMBER AU1 AU2 AU3 AU4 AU5 AU6 AU7 AU8 PUMP APPLICATION Cooling Tower Pump Syrup Load Out Pump Lime Slurry Pump Soda Ash Pump Sodium Hydroxide Pump Starch Tank Farm Pump Sulphuric Acid Pump Waste Water Pump PROCESS PUMP QUANTITY10 12 4 2 2 2 4 2+ 20-30 48-58 SEE PAGE 4 . CF-8M (Cast 316) and CD-4MCu are specified to standardize plant. Ahlstrom alliance pumps can be quoted. CD-4MCu for standardization Allows for flexibility as cooling capacity varies Flowserve RED 06/98 4-32 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump (Cooling Tower) Cooling Tower Pump AU1 12 DESCRIPTION CONDITIONS Fluid Temperature Water Ambient PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) or larger* Single seal FML seal chamber DCI† Reverse vane in CD-4MCu◊ Variable speed driver § COMMENTS * † ◊ § If larger capacity required. DCI is sufficient. Horizontal split case and vertical turbine pumps are also acceptable for this application. There are about four large storage tanks. each requiring one pump for load-out. CONDITIONS Fluid Temperature Corn Syrup 130°F (54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Double seal FML seal chamber CD-4MCu Reverse vane COMMENTS Flowserve RED 06/98 4-33 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Syrup Load Out Pump AU2 4 DESCRIPTION Pumps transport finished high fructose corn syrups into trucks or railcars. Contact Flowserve RED Marketing for availability. Flowserve RED 06/98 4-34 . CONDITIONS Fluid Temperature Lime Slurry Ambient PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 1 (A) Double seal FML seal chamber High-chrome iron*. Application is in waste water treatment facility.Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Lime Slurry Pump AU3 2 DESCRIPTION Lime slurry is added to process water for pH control. CD-4MCu with hard coating Open High head application COMMENTS * High-chrome iron is preferable. Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Soda Ash Pump AU4 2 DESCRIPTION Soda ash is used to control pH levels in process water. Application is in waste water treatment facility. CONDITIONS Fluid Temperature Soda Ash Ambient PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 1 (A) or 2 (B) Sealmatic with double lip seal FML seal chamber CD-4MCu Reverse vane COMMENTS Flowserve RED 06/98 4-35 . Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Sodium Hydroxide AU5 2 DESCRIPTION Caustic solutions are used to clean lines and filters throughout the plant. CONDITIONS Fluid Temperature Sodium Hydroxide 140°F (60°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous COMMENTS Group 2 (B) Double seal FML seal chamber CD-4MCu Reverse vane Flowserve RED 06/98 4-36 . CONDITIONS Fluid Temperature Liquid Starch 120-130°F (49-54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 3 (C) Single seal FML seal chamber CD-4MCu Reverse vane COMMENTS Flowserve RED 06/98 4-37 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Starch Tank Farm Pump AU6 4 DESCRIPTION Pumps transport liquid starch from tanks into the refinery for processing. especially when sulphuric acid prices are high. Non-metallic magnetic-drive pumps are another option. and to refinery processes to speed reactions and control pH. Contact RED Marketing regarding availability. CONDITIONS Fluid Temperature Sulphuric acid* 80-105°F (27-41°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 1 (A) Not applicable Not applicable CN-7M† Reverse vane Sealless magnetic drive pump COMMENTS * † Sodium bisulfide may be used in lieu of sulphuric acid. Flowserve RED 06/98 4-38 .Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Sulphuric Acid Pump AU7 2+ DESCRIPTION These pumps deliver sulphuric acid to steep water to sanitize and reduce corn. Corn Wet Milling and Refining Applications PUMP LOCATION PUMP APPLICATION APPLICATION NUMBER QUANTITY OF PUMPS Auxiliary Pump Waste Water Pump AU8 20-30 DESCRIPTION Sumps collect process waste water throughout facility. From here water is pumped to waste water facility to be treated or back into the process. CONDITIONS Fluid Temperature Waste water (abrasive) 80-130°F (27-54°C) PUMP RECOMMENDATION Pump Size Seal Seal Support Materials Impeller Miscellaneous Group 2 (B) Single seal FML seal chamber CD-4MCu Open Self-priming pump COMMENTS Flowserve RED 06/98 4-39 . Montezuma Agrana Staerke Austria (five plants) Germany Netherlands Amido Glucose SA Industria E Comercio Alimodones Y Glocosa Mive SA de CV Aranal comercial SA de CV Aracia CA Brazil-Estancia Mexico-Zapopan Mexico-Guadalajara Mexico-Guadalajara (two plants) Mexico-San Juan del Rio Arancia-Colibri JV with Corn Products International Former Corn Products International partner 54000b/ 1350 mt Asia Modified Starch Co Ltd. Clinton 200000 b/ 5000 mt USA-New York. Cedar Rapids USA-Iowa. Thailand-Nokomatchasi Avebe France-Haussimont Netherlands-Nijmegem Bang Il Industry South Korea-Inchun 25610 b/ 650 mt Cargill BV Cargill Foods Corn Milling Netherlands-Bergen op Zoom Flowserve RED 06/98 A-1 .Corn Wet Milling and Refining Applications APPENDIX A Profile of End-Users COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) 7880 b/ 200 mt ADM minor interest in Minnesota Grain Processing and Tate & Lyle European plants 250000b/ 6250 mt ABR Foods Ltd UK-Northhamptonshire ADM Food Processing USA-Illinois. Decatur USA-Iowa. Cedar Rapids 100000 b/ 2500 mt 320000 b/ 8000 mt 185000 b/ 4625 mt American Crystal Sugar Co. Eddyville USA-Nebraska.Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) Milling Poland Russia Turkey USA-Iowa. Dayton USA-Tennessee. Memphis UK-Essex Cerestar Belgium-Brussels China Denmark-Holte Cerestar Scandinavia A/S France-Haurbourdin France-Neuilly-sur-Seine Germany-Krefeld Cerestar France SA Cerestar Deutschland GmbH Cereol Hungary Italy-Castelmassa Italy-Milano Netherlands-Sas Van Gent Cerestar Benelux BV Cerestar Iberica SA Spain-Martorell Flowserve RED 06/98 A-2 . Cargill operates 100000 b/ 2500 mt 200000 b/ 5000 mt Cargill Plc JV with Ulker Group JV with JIFA 32388 b/ 822 mt USA-Iowa. Wahpeton USA-Ohio.. Blair USA-North Dakota. Minn-Dak Farmers Cooperative and Golden Growers own. Decatur USA-Indiana. Dimmit Crespel & Dieters Companhia Portuguese de Amidos SARL Corn India Ltd Corn Products International (CPI) Inc Germany-Ibbenbueren Portugal-Savacem India Argentina-Baradero Refineries de Mais SAICF Goodman Fielder Mills. Brasil Ltd Refinacoes de Milho. Brasil Ltd CASCO Inc 16000 b/ 400 mt 12000 b/ 300 mt 100000 b/ 2500 mt 47280 b/ 1200 mt 34000 b/ 850 mt 31520 b/ 800 mt 8000 b/ 200 mt 5000 b/ 125 mt CPI technology license 33000 b/ 825 mt Australia. Cardinal Canada-Ontario. Ltd Refinacoes de Milho. Brasil Ltd Refinacoes de Milho. Maizena SA Columbia-Barranquilla Flowserve RED 06/98 A-3 .Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) Turkey UK-Manchester USA-Alabama. London CASCO Inc Canada-Ontario. Hammond 85000 b/ 2125 mt Cerestar UK Ltd USA-Texas. Lane Cove Brazil-Anastacio Brazil-Balsa Nova Brazil-Cabo Brazil-Mogi Guacu Canada-Ontario. Port Colborne CASCO Inc Chile-Llay-Llay Industrias de Mais y Alimentos SA Industrias de Maiz SA. Brasil Ltd Refinacoes de Milho. . CNT CPI major interest Columbia-Medellin India-Bombay Japan-Tokyo CPI minor interest Japan Kenya-Eldoret CPI and NSK JV CPI and local government interest 5000 b/ 125 mt Malaysia-Petaling Jaya Stamford Food Industries Sdn Berhad CPI 100% interest Mexico-see Arancia New Zealand-Onebunga New Zealand Starch Products Rafhan Maize Products CPI technology license CPI majority interest 32000 b/ 800 mt 60000 b/ 1500 mt 230000 b/ 5750 mt 80000 b/ 2000 mt Alfonzo Rivas Co.Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) 18000 b/ 450 mt Columbia-Cali Industrias de Maiz SA. Turmero Alfonzo Rivas Co. Maizena SA Industrias de Maiz SA. Maizena SA Corn Products Co (India) Ltd.Stockton USA-Illinois. Agua Viva Venezuela. Nihon Shokuhin Kako (NSK) Co.. Ltd. WinstonSalem Venezuela. CA CPI technology/ management agreement CPI technology/ management agreement Pakistan-Faisalabad USA-California.. CA (technology management agreement with CPI) IPOK Yugoslavia-Zrenjanin Delmaiz SA Argentina-Buenos Aires CPI JV Flowserve RED 06/98 A-4 . Summit-Argo USA-North Carolina. Perkin Minnesota Grain Processing USA-Minnesota. Atchison 85000 b/ 2125 mt 85000 b/ 2125 ADM minor interest 230000 b/ 5750 mt 230000 b/ 5750 mt USA-Illinois. Muscatine 120000 b/ 3000 mt Mexico-Merida Argentina-Chacabuco AE Staley technology agreement 21670 b/ 550 mt Brazil Chile Jaeckering Kroener Maffessoni Conercio e Industria Midwest Grain Germany-Hamm Germany-Ibbenbueren Brazil-Centro Cacador USA-Kansas.Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) 21670 b/ 550 mt Doosan Food Co Ltd South Korea-Inchun Former CPI partner Emsland Staerke Finnsugar Ltd Cultor Gastaldi Hermanos Saicfei Grain Processors Inc. Grupo Xacur SA de CV Industrias de Maiz SA (IMASA) Germany-Emlichheim Finland-Kantvik Argentina-Cordoba USA-Iowa. Columbus Molinos Canuelas SA Molinos y Establecimientos Harineros Bruning SA National Starch & Chemicals Argentina-Buenos Aires Argentina-Sante Fe Germany-Neustadt National Starch & Chemicals GmbH ICI acquisition Flowserve RED 06/98 A-5 . Marshall USA-Nebraska. Keokuk Samyang Genex Co. Idaho Falls USA-Iowa. South Korea-Kimpo Flowserve RED 06/98 A-6 . South Korea-Inchon South Korea-Ulsan Sewon Ltd. USA-Idaho. Kansas City Oriental Brewery Co. Cedar Rapids Pfiefer & Langen Primalko Raisio Group Remy Industries Roquette Germany-Koeln Finland-Koskenkorva Finland-Raisio Belgium-Wijgmaal-Leuven France-Benheim France-Lestrem France-Lille Roquette Freres Owns plant in Romania France-Vacquemont Italy-Cassano Spinola Spain-Barcelona Romania Owned by Roquette Freres 150000 b/ 3750 mt 39400 b/ 1000 mt 23640 b/ 600 mt Former CPI partner 47280 b/ 1200 mt USA-Iowa.Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) UK-Manchester UK-Tilbury USA-Indiana. Ltd. South Korea-Lee Chun 19700 b/ 500 mt 85000 b/ 2125 mt 100000 b/ 2500 mt Penford Products Co. Hammond USA-Missouri. ADM interest AE Staley JV 98500 b/ 2500 t Bulgaria Amylum Bulgaria AD China-Guangzhou Amylum China Egypt-Cairo National Company for Maize Products France-Bordeaux Amylum Aquitaine France-Nesle Amylum France SA 86680 b/ 2200 t Greece Thessaloniki Amylum Hellas SA Hungary Hungrana kft India (3 plants) Israel Italy Bharat Starch Amylum Israel Sedamyl SpA Tate & Lyle. ADM minor interest Norway Flowserve RED 06/98 A-7 . Amylum minor interest Tate & Lyle major interest Tate & Lyle major. ADM minor interest Tate & Lyle major interest Government major. ADM minor interest Agrana. ADM minority interest Tate & Lyle major. Tate & Lyle.Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) 39400 b/ 1000 mt 27580 b/ 700 mt South Korea-Pusan Former CPI partner Shin Dong Bang South Korea-Ansan SOC Industrial Teofilo Grob SA Tai Roun Product Co Ltd Chile-La Union Taiwan-Yunlin Former CPI partner Tate & Lyle Belgium-Aalst Amylum Belgium NV Tate & Lyle majority. ADM minor interest Morocco Netherlands Amylum Megheeb Amylum Nederland BV Amylum Norway Tate & Lyle. ADM minor interest Tate & Lyle major. Lafayette AE Staley Tate & Lyle.Corn Wet Milling and Refining Applications COMPANY PLANT LOCATION PLANT NAME AFFILIATIONS GRIND RATE (bushel/ metric tonne per day) Romania-Tirgusecuiesc Slovakia Amidex Amylum Slovakia spol Amylum Iberica SA Tate & Lyle. Decatur USA-Indiana. Loudon Vietnam AE Staley Amylum Vietnam Tate & Lyle. ADM Flowserve RED 06/98 A-8 . ADM Tate & Lyle. Lafayette AE Staley AE Staley USA-Indiana. ADM minor interest Tate & Lyle major. ADM minor interest Tate & Lyle. USA-Illinois. ADM 210000 b/ 5250 t 175000 b/ 4375 t Spain-Zaragoza Turkey Amylum Nisasta UK-Greenwich Amylum UK Ltd. ADM minor interest Tate & Lyle minor interest Tate & Lyle major. ADM 65000 b/ 1625 t USA-Tennessee. Inc. HPD (Wheelabrator) Koch Membrane Systems Centrifuges. VA) USA (Greenville. French Oil Graver Separations. Inc. CA) USA (Northvale. Inc. Coppee Delta T Corporation Fluor Daniel USA (Hutchinson. IL) France (Miribel) USA (Palm Desert. IL) USA (Springfield. hydrocyclones PRODUCT Fluid-Quip Inc. MA) Martech Niro Inc. Belgium (Brussels) USA (Columbia. IL) Netherlands (Amsterdam) USA (Milford. DE) USA (Naperville. Inc Broadbent Centrifugals Crown Iron Works Dedert Corporation Dorr-Oliver Inc. microfiltration Feed dryers Microfiltration Feed dryers Centrifuge Oil extractor Evaporator. USA (Lisle. IL) USA (Fort Worth. TX) USA (Minneapolis. microfiltration Centrifuges. IL) USA (Rosemont. SC) Ethanol Corn wet milling. hydrocyclones Oil Extractor Microfiltration Evaporator Microfiltration Flowserve RED 06/98 B-1 . CT) USA (Oak Brook. OH) USA (Newark. OH) Cyclone USA (Harvey. KS) Belgium (Brussels) USA (Williamsburg. PikTek. IL) USA (Oakbrook Terrace. IL) Germany USA (Wilmington. Inc. Swenson Process Equipment Tech Sep Groupe US Filter Westfalia Separator. APV Crepaco. NJ) ENGINEERING CONTRACTORS AMG Borton. hydrocyclones Evaporator. Inc. Inc. MD) USA (Troy. MN) USA (Olympia Fields. Barr-Rosin.Corn Wet Milling and Refining Applications APPENDIX B OEMS AND ENGINEERING CONTRACTORS COMPANY LOCATION ORIGINAL EQUIPMENT MANUFACTURERS ABB Air Preheater. OH) USA (Cincinnati. citric acid Centrifuge Evaporator Centrifuges. food-grade alcohol Ethanol Corn wet milling. Inc.Corn Wet Milling and Refining Applications Infilco Degremont Belgium (Brussels) USA (Richmond. Raytheon Engineers & Constructors. VA) PSI Process Systems. Inc. Starcosa Technip Vogelbusch USA (Memphis. itaconic acid Biodegradable plastics. TX) Ethanol. MN) USA (Muscatine. syrup refining Corn wet milling. TN) USA (Downers Grove. refining Waste Treatment Plant Flowserve RED 06/98 B-2 . citric acid. IA) Germany France (Paris) USA (Houston. IL) USA (Minneapolis. Simons Stanley Consultants. refining. vitamin E Corn wet milling. Inc. 34 4 .28 4 .Corn Wet Milling and Refining Applications APPENDIX C MASTER LIST OF PUMP APPLICATIONS Below is an alphabetical list of pump applications found upstream in a corn wet milling and refining plant.12 4 .000 bushels (4300 tonnes) per day.29 4 . PUMP APPLICATION APPLICATION NUMBER PROCESS PUMP QUANTITY11 SEE PAGE Agitator Pump Carbon Slurry Pump Condensate Pump Cooling Tower Pump Corn Slurry Pump Corn Syrup Pump Evaporator Pump Extractor Pump Fiber Slurry Pump Finishing Pump Gluten Pump Gluten Wash Pump Hydrochloric Acid Pump Hexane Pump Hydroclone Pump Light Steep Water Pump Lime Slurry Pump Microfiltration Pump Millstream Slurry Pump Mod House Pump GP4 SR4 FH2 AU1 MH1 SR3 FH1 GP2 MH2 GP3 MH5 MH4 SR1 GP1 MH6 SH3 AU3 SR5 MH3 -- 1 6 3 12 24 100 8 6 11 10 1-2 6 2 3 11 2 2 16 9-11 30-40 4 .26 4 .19 4 .23 11 Based on a grind rate of 170.13 4 . The facilities covered include the feed house (FH). which represents an average-sized plant in the USA. C-1 Flowserve RED 06/98 . although newer plants are larger.22 4 .17 4 .11 4 .16 4 .32 4-9 4 .000 bushels (800 tonnes) per day. germ plant (GP).10 4 . steep house (SH) and syrup refinery (SR). mill house (MH).21 4 . Auxiliary pumps (AU) are also included.18 4 .14 4-6 4 . Plants in Europe have an average grind of 32.30 4 . 37 4-5 4 .38 4 .Corn Wet Milling and Refining Applications Presteep Corn Pump Sluice Pump Soda Ash Pump — Auxiliary Pump Soda Ash Pump — Syrup Refinery Sodium Hydroxide Pump Starch Tank Farm Pump Steep Water Recirculation Pump Sulphuric Acid Pump Waste Water Pump PROCESS PUMP TOTAL SH1 SH4 AU4 SR2 AU5 AU6 SH2 AU7 AU8 2 2 2 4-6 2 4 16-20 2+ 20-30 321-350 4-4 4-7 4 .36 4 .39 Flowserve RED 06/98 C-2 .35 4 .27 4 . Fahrenheit into Celsius degrees C= (degrees F-32) 5/9 CD-4MCu designation has changed to CD-4MCuN to indicate presence of nitrogen.2 Volume Conversions MULTIPLY bushels bushels kilograms metric tonnes metric tonnes pounds BY 56 . A744 DIN (WN) DESIGNATIONS NAME DIN 1693.4 1000 .018 TO OBTAIN pounds metric tonnes metric tonnes bushels kilograms bushels EXHIBIT D.Corn Wet Milling and Refining Applications APPENDIX D Conversion Factors: Alloys. Volumes and Temperatures EXHIBIT D.001 39.4500 Ductile Iron Durco CF-8M Durcomet 100 Durimet 20 DCI D4 CD-4M D20 SYMBOL Contact Flowserve RED Marketing for availability of high-chrome iron. Durcomet 100 meets the CD-4MCuN specification. D-1 Flowserve RED 06/98 .4408 1. A395 CF-8M.025 . A890 CN-7M. 0.3 Temperature Conversions 1. Celsius into Fahrenheit degrees F = 32+9/5 degrees C 12 2. A744 CD-4MCu12. 1.7043 DIN 17445. EXHIBIT D.4463 1.1 Alloy Conversions DURCO PROCESS PUMP DESIGNATIONS ASTM (Cast) DESIGNATIONS 60-40-18. . 1 4.5 Flowserve Sales Decision Makers Competitive Advantage of Flowserve Chemical Process Pumps Guidelines for Mechanical Seals Plant and Pump Details 3-1 3-2 3-2 3-3 3-4 4.4 3.3 4.1 2. Market Profile 2.2 4.2 Market Drivers and Growth Competition 2-1 2-2 3.5 Brine Handling Electrolysis Caustic Handling Chlorine Handling Hydrogen Handling Profile of End Users Conversion Factors: Alloys. Temperature Other Pump Applications 4-2 4-3 4-4 4-5 4-6 A-1 B-1 C-1 Appendix A Appendix B Appendix C Flowserve RED 10/98 i .1 1.1 3.Chlor-Alkali Industries Applications Table of Contents Page Number 1-1 1-2 1.2 Rationale and Methodology The Chlor-Alkali Process 2. Flowserve Experience 3.3 3.2 3. Introduction 1.4 4. Pump Recommendations 4. 2. Flow Diagram of Manufacturing Processes Global Chlor-Alkali Production 1-3 3-1 Flowserve RED 10/98 ii .Chlor-Alkali Industries Applications Exhibits Page Number 1. because of the broad range of application possibilities for Flowserve chemical process pumps. Durimet 20 met many of the corrosion-resistant needs. The Duriron Company. Inc. and later Durichlor. This manual will explain the basic chlor-alkali manufacturing process and will enumerate the corrosion challenges faced by plant operating personnel. Some of the smaller plants are actually captive operations producing caustic soda and chlorine for use as basic raw materials for other products. The chlor-alkali industries have needed. ferric chloride (FeCl3). the chlor-alkali industries are using these and other materials including CD-4MCu. sodium hypochlorite (NaOCl. the broad range of corrosion-resistant materials and the materials application expertise offered by the Flowserve Corporation to solve their severe corrosion problems. Due to the extreme service conditions encountered. soda ash). and Elf Atochem just to name a few. Finally. Later. in addition to being able to offer solutions to corrosion problems. 1 a. this manual will focus on these two critical chemicals. Because of the company’s long involvement with this very basic activity and because of the inherent materials requirements and corrosive nature of the processes. in fact. Pioneer. = also known as Flowserve RED 10/98 1-1 .k. 1. sodium hydroxide and chlorine are the most common and. there has always been a need for corrosion resistant materials.k. more importantly. titanium. it seemed appropriate to create an applications manual. Ashai. a. sodium carbonate (Na2CO3. The chlor-alkali industries exist worldwide and the plants vary in size from quite small to very large. found widespread use. Of these. OxyChem. bleach). Solvay. It will further make available the company’s experience in confronting the challenges with its broad range of materials.a.Chlor-Alkali Industries Applications 1. The material Duriron. Enterprises involved in the chlor-alkali industries are some of the most recognized global companies including Dow. Because of the widespread use of chlorine and sodium hydroxide and. Bayer.k. Flowserve Corporation has been involved with the chlor-alkali industries almost from the inception of one of its predecessors. but not limited to.a.a. chlorine (Cl2). a. hydrochloric acid (HCl). calcium chloride (CaCl2). a. Formosa Plastics. lye). Olin. sodium hydroxide (NaOH.a. Presently. and hydrogen (H2). and will continue to need. rank close to sulfuric acid and ammonia in magnitude of dollar value of use. PPG. 1 caustic soda. There are hardly any consumer products that are not dependent on chlorine and sodium hydroxide at some stage in their manufacture. and non-metallics. the Flowserve line of chemical process pumps possess features that can improve overall pumping performance in these difficult services and these features will be highlighted.k. sodium bicarbonate (NaHCO3). ICI. sodium chlorite (NaClO 2).1 Introduction Rationale and Methodology The chlor-alkali industries produce some of the most basic and widely used inorganic chemicals including. electrolysis. and liquefaction. or used to enhance the calorific value of the plant fuel gases. drying. anodes. and magnesium. UHDE. The mercury cell process produces the purest caustic. The caustic handling area of the plant concentrates the sodium hydroxide through evaporators and removes the impurities by precipitation and filtration. but extreme controls are required to avoid environmental problems. this technology also has drawbacks. That portion of the brine not decomposed is sent back to brine purification and recycled. the neutral brine is not very corrosive. and hydrogen handling. Mercury cells are practically extinct in the U. The resulting charged ions migrate to the anode and cathode where the ions combine to form sodium hydroxide.S and are actually outlawed in Japan.Chlor-Alkali Industries Applications 1. “packaged” for sale. The sodium hydroxide exiting the electrolysis area is impure and. Each of these is discussed below. At this stage. however. for diaphragm and membrane cell plants. Chlorine Engineers (Mitsui). Brine preparation and purification are critical steps to avoid problems during electrolysis. There are also many variations of these basic cell designs involving special cathodes. The sodium hydroxide is directed to evaporators and separators for concentrating and purification. iron. diaphragms. membranes. Diaphragm cell technology replaced the mercury cells but because the diaphragm was made of asbestos. Regardless of the cell design or variations. These variations. There are five basic areas in these plants: brine handling. the goal is to keep the anodic and cathodic areas separated. The chlorine is sent on for cooling. Exhibit 1 is a simplified schematic showing the three types of chlor-alkali plants.2 The Chlor-Alkali Process The basis for the chlor-alkali process is the following simple chemical equation: energy NaCl (salt) + H2O (water) ------→ NaOH (caustic soda) + ½ H2 (hydrogen) + ½ Cl2 (chlorine) The chemical reaction takes place in an electrolytic cell. diaphragm. Ashai. The brine solution is treated with various chemicals to remove compounds of calcium. The major contaminant is sodium chloride (salt) and this is precipitated and returned Flowserve RED 10/98 1-2 . Dow. The different types of chlor-alkali plants are characterized by the electrolysis cell design used. Electrolysis is the heart of the process. it is neutralized with hydrochloric acid. the basic reaction involved is the same. chlorine. are referred to by the name of process developer and some of the common names are OxyTech. etc. and hydrogen. There are basically three cell designs used: mercury. and Oronzio De Nora. the brine is used to cool the chlorine gas stream and the resulting hot. chlorinated brine is quite corrosive. and caustic soda and hydrogen form at the cathode while chlorine forms at the anode. caustic handling. Electrical energy is applied across the cell and a portion of the brine is eletrolytically decomposed. saturated brine is fed into the electrolytic cell on the anode side. many times. The hydrogen can be flared. Membrane cells comprise the current approach in electrolytic cell technology. The potential environmental problems plus advancements in the other technologies have resulted in movement away from mercury cell plants. Purified. chlorine handling. in some plant designs. of a low concentration (typically 12-16% for diaphragm cells and 3035% for membrane cell plants). and membrane. After the brine is treated to remove contaminants. Regardless of the cell technology. Chlor-Alkali Industries Applications Flowserve RED 10/98 1-3 . The sodium chlorate and any remaining salt are removed by treating the caustic with ammonia. In a few plants. the gas is captured. being hygroscopic. For some applications. the gas is scrubbed and added to the fuel gases in the plant to enhance the calorific value. Chlor-alkali plants are not major sources of commercial hydrogen gas. the gas is compressed and liquefied. Finally. and quite corrosive. the tail gases from the drying and liquefaction steps must be captured and treated. After drying. In many plants. and sold. The gas is first cooled (sometimes using the feed brine) and this removes some of the moisture by condensation. Since chlorine gas is toxic. This results in a very corrosive scrubber liquid. then it is sent to drying towers. packaged. scrubbed. this gas is flared off. In some plants. Sodium hydroxide is generally sold in concentration of about 50%. Flowserve RED 10/98 1-4 . The gaseous chlorine is exposed to sulfuric acid and the acid. adsorbs the water vapor and dries the chlorine. Some of the sodium hydroxide produced is used to scrub the tail gases. Other contaminants include iron and sodium chlorate. it goes through an additional evaporator step and is concentrated to about 75%. flake form. The liquid chlorine is stored and shipped in pressurized cylinders and tank cars.Chlor-Alkali Industries Applications to the brine preparation area. wet. there is the hydrogen gas. The reaction of caustic with chlorine produces sodium hypochlorite (bleach). It is supplied both as a liquid solution and in dry. Iron is removed by treating the caustic with calcium carbonate and filtering the mixture. The chlorine gas exiting from the electrolysis area is hot. Because these chemicals are used in so many processes. The by-products from these operations are judged to be quite environmentally unsavory and other bleaching agents such as hydrogen peroxide are gaining favor.4% globally through 2002. Therefore.Chlor-Alkali Industries Applications 2.. and has. the growth in demand is expected to be fairly steady and forecast at an annual rate of about 2. due primarily to the problems in Asia. increased demand for one can.g. and Latin America. however.1 units of sodium hydroxide. No new capacity is expected in Western Europe. low cost electricity. Asia. Below are the major users for these chemicals: Chlorine Plastics (e. availability of salt and abundant. of these chemicals sometime during their manufacture.0 unit of chlorine to 1. The chlor-alkali industries are somewhat fragmented with regard to manufacturing considerations (supply) and product users (demand). The chlor-alkali process produces these chemicals in the ratio of 1. New construction is anticipated in North America (a major exporter of these chemicals). Plant location (supply) is influenced most heavily by two factors.S. there has not been a similar decline in demand for caustic so its supply has tightened. One area of significant. decline in the use of chlorine is as a bleaching agent particularly in pulp and paper processing.1 Market Drivers and Growth Chlor-alkali production is driven by demand for sodium hydroxide and chlorine. and probably permanent.7% for the U. vinyls (e. Market Profile 2. The demand for vinyls has lagged recently.g. PVC pipe) consume about 25% of the chlorine used. the demands for the two chemicals do not necessarily grow together. However. the Mideast. and production of chlorine has been curtailed. – vinyls) Water purification Solvents Pulp and paper Pharmaceuticals Bleaching Pesticides/herbicides Refrigerants Sodium Hydroxide Pulp and paper Metallurgical processes Soaps/detergents Pharmaceuticals Foods Dyes Synthetic fibers Petroleum refining Rubber Textiles Chemicals Glass There are hardly any products or industries that do not use one. For instance. This ratio is relatively fixed. and 3. or both. These two factors do not weigh heavily in locating plants that use sodium hydroxide and chlorine Flowserve RED 10/98 2-1 . resulted in oversupply of the other. Regardless of where the chlor-alkali plants are located. 2. Sulzer. the technology employed is limited to that discussed above. Also. Durco Process Pumps have a long and distinguished history in chlor-alkali production. IDP. basic chemical processing. Competitive advantages will be highlighted in Section 3. and Ebara. Flowserve’s design engineering developments in those areas that enhance pump reliability improve the company’s competitive position. therefore. chlor-alkali operations will be in the vicinity. It is reasonable to assume. Flowserve RED 10/98 2-2 . Flowserve’s historical strengths in materials development and materials application expertise have served the company well in this market. So.3. that very large consumers of these chemicals can justify their own captive operations close by or that traditional chlor-alkali producers will be relatively close to their major customers. where there are PCV producers or pulp and paper operations. Peerless). the major players are ITT-Goulds.Chlor-Alkali Industries Applications (demand). all manufacturers of chemical processing pumps are competitors. though. Finally. Of course. there is one unifying factor and that is the chlor-alkali technology.2 Competition Chlor-alkali production is traditional. and KSB with occasional competition from the Sterling Group (Labour. These 10 producers account for about 43% of the worldwide production. Exhibit 2 below shows the global distribution of the output.1 Flowserve Experience Flowserve Sales Chlor-alkali production is a global business and it is estimated that 40 million metric tons of chlorine and 44 million metric tons (t) of sodium hydroxide are produced annually. EXHIBIT 2 Global Chlor-Alkali Production Latin America 6% Asia Pacific 37% North America 33% Europe 24% Flowserve Chemical Process pumps are used worldwide in chlor-alkali plants. Below is a list of the top 10 chlor-alkali producers and their estimated 1997 output (does not reflect China. thousand t 5700 2750 1550 1300 1095 1070 1060 955 950 900 Sodium hydroxide. Four of these 10 are among the top 20 worldwide customers for Flowserve Chemical Process pumps. and India).Top 20 customer Chlorine. 3.Chlor-Alkali Industries Applications 3. Company Dow Chemical * OxyChem * PPG Formosa Plastics * Solvay Elf Atochem ICI Bayer * Pioneer Olin * . Russia. thousand t 6270 3025 1705 1430 1205 1177 1166 1050 1045 990 Flowserve RED 10/98 3-1 . and. Finally. operations Flowserve RED 10/98 3-2 . some plants are designed around licensed technology and the licensor may have key input on equipment purchases.2 Decision Makers New plants and major expansions are often handled by an engineering firm and the project manager and rotating equipment expert are key individuals. For MRO2 purchases. they give a good representation of the companies involved in chlor-alkali production and their geographic distribution. can be offered and the company has the materials application knowledge to assist in selecting the best material for the very difficult services found in chlor-alkali operations. in fact.Chlor-Alkali Industries Applications In Appendix A. one can never overlook the purchasing function at the plant level. there are tables for the four regions shown in Exhibit 2 listing the major chloralkali producers.3 Competitive Advantage of Flowserve Chemical Process Pumps The principle competitive advantage is the company’s materials expertise. there may be a materials or corrosion engineering group that will have input particularly regarding the materials of construction. The listings of companies are not exhaustive as there are many small producers and many captive operations. Also. The data for North America and Europe are fairly complete and specific regarding individual producers and levels of output. Also. however. Many times. Also. some plants receive guidance from a corporate materials group relating to corrosion problems and contact with these individuals can be beneficial. end-user personnel are part of the project team and final authority for equipment purchases may fall with the senior end-user person. plant materials personnel can be influential particularly if the plant has experienced corrosion problems. the plant engineering manager will be a key individual. Again. Other Flowserve Chemical Process pump features that offer advantages to chlor-alkali producers include: • • • • • 2 Mark III reverse vane impeller ANSI 3A power end SealSentry FML seal chamber Sealmatic option Polybase baseplates MRO = maintenance. however. The strengths in this area are unmatched by any of Flowserve’s competitors. 3. both metallic and nonmetallic. repair. 3. There are no readily available data for the former Soviet block countries. plant maintenance is a key area. The data for the Asia Pacific region are very incomplete and sketchy so this table shows some output by country only. The principal Flowserve alloys used in Chlor-alkali processes are listed in Appendix B along with their ASTM designations and DIN equivalents. may require the use of specific equipment to maintain the technology guarantee. For in-house projects. A broad range of corrosion resistant materials. For some services. optimal pump performance can be restored easily with a simple impeller clearance adjustment. This should eliminate the need for an external flush and. chloride and caustic induced cracking must be avoided. or steam. Some services in chlor-alkali plants contain solids. Also. costly mechanical seals are sometimes needed. the Sealmatic option is an ideal choice. 3-3 • • • • Flowserve RED 10/98 . there will be some material removal through corrosion. Services can contain solids. Corrosion of carbon steel baseplates can be a serious problem and the Polybase design offers a very economical alternative to stainless steel baseplates. locate seal faces beyond the seal gland and in the process liquid. Since no flush is required. prevent erosion damage. Because of the severe nature of many chlor-alkali services. For services where environmental concerns are present. use hard faces as recommended. For all single seals in sodium hydroxide service. quench. 3. use a clean water. In addition. The SealSentry FML seal chamber provides protection for the mechanical seal and permits the use of single seals without an external flushing system. use the SealSentry FML seal chamber. The ANSI 3A power end seals the bearings and bearing lubricant from these potentially harmful vapors thus prolonging bearing life. below are some general guidelines for improved seal life: • For those services where single seals are suitable.Chlor-Alkali Industries Applications The Mark III reverse vane impeller offers significant operational benefits. no additional water is added to the caustic thus enhancing the evaporation process. consider dual seal arrangements. For all single seals. In the caustic handling area of a chlor-alkali plant. general corrosion attack must be confronted. because of the severe corrosive nature of some of the services. if solids are present. Because there is only one critical setting for the impeller.4 Guidelines for Mechanical Seals The demands on mechanical seals in chlor-alkali plants can be severe. the reverse vane design reduces NPSHR and cavitation problems resulting in much longer pump and mechanical seal life cycles. Based on Flowserve experience. Sodium hydroxide presents difficulties for a mechanical seal because of crystallization on the seal faces. one of the operations being performed is evaporation to increase the concentration of the caustic. and elastomer suitability must be considered. The atmospheric conditions in some areas of a chlor-alkali plant can be less than ideal due to the presence of chlorine and salt brine vapors. Also. The Polybase baseplate is an ideal choice for the potentially corrosive environment sometimes found in chlor-alkali plants. Section 4. Flowserve RED 10/98 3-4 .5 Plant and Pump Details Exhibit 1 is a general schematic for a typical chlor-alkali plant. will present a general overview of the types of applications for chemical process pumps found in chlor-alkali operations. 3. Pump Recommendations. Because of the wide range in plant sizes and operational variations. there is no definitive list of pump quantities and designations. Applications for other types of pumps are shown in Appendix C. Because of the severe nature of many chlor-alkali services. the input of a Flowserve FSD sealing specialist is recommended.Chlor-Alkali Industries Applications • Check all seal elastomers for suitability. Chlor-Alkali Industries Applications 4. and are intended to raise awareness of issues associated with particular applications. A qualified pump engineer must still be involved in the specification of any pump. depending on variables associated with the application. Other specifications not addressed in this manual may be equally or more acceptable. Pump Recommendations The recommendations that follow are general guidelines. They are based on specifications which have performed well in the field. Flowserve RED 10/98 4-1 . These guidelines should not take the place of any manufacturer’s recommended specification for a given application. and manufacturers of components/accessories are to be consulted for detailed specifications as well. 1 Brine Handling 4.1.1 Objective This area of the plant is involved in preparation. Seals: Single or dual (seal material selection critical). sodium carbonate (Na2CO3). hard faces are recommended particularly for single seals) Seal Support: FML seal chamber for metallic pumps. calcium chloride (CaCl3). • Brine Pumps – acidic brines + + + + + Conditions: Acidic brine. CD-4MCu is an excellent selection for neutral/alkaline brines. recycling.). flush system for dual seals. Materials: CF-8M. Flowserve RED 10/98 4-2 . It has excellent corrosion resistance in this service and offers better performance if solids present. Materials: Titanium. The purified brine is stored and circulated to the electrolytic cells as required. magnesium. and if solids are present. 100-160°F (38-70°C) Materials: DCI/WCB (to 120°F [50°C] max. Not all the brine that goes through the cells is decomposed. Seal Support: FML seal chamber. 120-200°F (60-95°C). the brine must be purified. clarification. flush system for dual seals. FRP (D730) Seals: Single or dual (some brine solutions contain solids.2 Description Common salt (sodium chloride. CF-8M. called depleted or spent brine. purification. CD-4MCu. and sodium hydroxide (NaOH).1. is recycled. sulfates) that are detrimental to the electrolytic cells. Seals: Single or dual. and filtration. Purification operations include precipitation. flush system for dual seals. NaCl) is dissolved in water to form a saturated brine solution. temperatures less than 120°F (50°C).Chlor-Alkali Industries Applications 4. Durichlor (D51M). This depleted brine must also be purified before it can be returned to the storage area. Palladium stabilized titanium (TiPd). Comments: TiPd recommended above 180°F (82°C) • + + + + Reagent Pumps Conditions: Typical reagents include sodium sulfite (Na 2SO3). This brine.1. Because common salt contains many contaminants (primarily calcium. storing. barium. Comments: FRP not recommended if solids present. and delivering brine to the electrolysis area. 4. Seal Support: FML seal chamber. 4. DCI/WCB may not be acceptable because of concern over iron contamination.3 • Pump Application Guidelines Brine Pumps – neutral and alkaline brines + + + + + Conditions: Neutral or alkaline brine. 175-200°F (80-95°C) Materials: CD-4MCu. Seals: Single or dual (seal material selection critical) Seal Support: FML seal chamber. 95°F (35°C) max.2.1 Objective This area of the plant is involved in the electrolytic decomposition of the brine and the formation of sodium hydroxide. and hydrogen. CN-7M. chlorine. FRP (D730) Seals: Single Seal Support: FML seal chamber (metallic pumps) 4.2.3 • Pump Application Guidelines Cell Liquor Pumps (diaphragm cell) + + + + • Conditions: 10-12% NaOH.2. Teflon (PFA)-lined. Purified (demineralized) water + + + + Conditions: High purity water. Flowserve RED 10/98 4-3 . 175-210°F (80-100°C) Material: CF-8M (less than 200°F [93°C]). Seals: Single or dual (seal material selection critical) Seal Support: Flush system for dual seals. Seals: Single or dual (seal material selection critical) Seal Support: FML seal chamber. water or steam quench for single seals. ambient temperature Materials: CF-8M. Electrical energy is applied across the cell and the brine is electrolytically decomposed.Chlor-Alkali Industries Applications • Hydrochloric Acid Pumps + + + + • Conditions: 32% hydrochloric acid. Materials: FRP (D730). CD-4MCu. Membrane Cell Caustic + + + + Conditions: 30-35% NaOH. 15-17% NaCl. Sodium hydroxide and hydrogen gas are formed at the cathode and chlorine gas is formed at the anode. 4.2 Electrolysis 4. flush system for dual seals.2 Description Saturated sodium chloride brine is fed into the anode side of an electrolytic cell. flush system for dual seals. 4. water or steam quench for single seals. Membrane cell caustic is 30-32% sodium hydroxide. Material: Titanium (Ti). water or steam quench for single seals. 4. CN-7M (suitable to 300°F [150°C]).3. Depleted Brine + + + + + Conditions: 16-22% NaCl and chlorine. and increasing the concentration of the sodium hydroxide solution coming from the electrolytic cells.3. 15-17% sodium chloride. Comments: TiPd recommended above 180°F (82°C). Diaphragm cell caustic is 10-12% sodium hydroxide. Note: This can be a good application for Guardian or Chemstar MD pumps because of the potential for problems with mechanical seals. Material: DCI/WCB. Mercury cell caustic is at 50% strength from the cell.2 • Pump Application Guidelines Caustic Pumps + + + + + Conditions: 50% NaOH. plus other impurities.3. CZ-100 (cast nickel). CD-4MCu. precipitation of impurities. water or steam quench for single seals. possible iron contamination). Seals: Single or dual (seal material selection critical). CN-7M. 4. Seal Support: FML seal chamber. is also of high purity. 175-210°F (80-100°C) Material: CF-8M (less than 200°F [93°C]). offer better resistance than CF-8M to solids). CF-8M (suitable to 200°F [95°C]).1 Objective This area of the plant is involved in reducing impurities. CD-4MCu (suitable to 250°F [120°C]. 4-4 + Flowserve RED 10/98 . flush system for dual seals. Palladium stabilized titanium (TiPd).3 Caustic Handling 4. 4. Seal Support: FML seal chamber. and only requires some filtration. and requires simple evaporation to reach 50% concentration. Seals: Single or dual (seal material selection critical). flush system for dual seals. ambient-210°F (ambient-100°C). excellent for maintaining high product purity). and anhydrous sodium hydroxide. CN-7M. flush system for dual seals. CZ-100 (suitable to boiling point.Chlor-Alkali Industries Applications • Mercury Cell Caustic + + + + • Conditions: 50% NaOH. is of high purity. Comments: DCI/WCB (suitable to 120°F [50°C]. a 73% solution. 175-212°F (80-100°C). CF-8M. Sealmatic option should be considered for continuous duty service. and filtration to reach a commercial 50% solution.2 Description Standard commercial grades of caustic are a 50% water-based solution of sodium hydroxide. It requires triple effect evaporation. CD-4MCu. Seals: Single or dual (seal material selection critical) Seal Support: FML seal chamber. Material: DCI/WCB.4 Chlorine Handling 4. Sealmatic option should be considered for continuous duty service. CN-7M.4. Seal Support: FML for DCI/WCB and Durimet 20. Durichlor (D51M). 100-125°F (38-52°C) Material: Durimet 20. drying. 2% chlorine. Seals: Single or dual (seal material selection critical). by-pass flush for single seal in D51M pump. Seal Support: FML seal chamber. water or steam quench for single seals. 4. by-pass flush for single seal in D51M pump. temperatures above 100°F (38°C) can cause accelerated corrosion. The gas is cooled in one or two stage heat exchangers to around 50°F (18°C).Chlor-Alkali Industries Applications • Caustic Pumps + + + + + Conditions: 73% NaOH. CZ-100 (suitable to boiling point. excellent for maintaining high product purity). flush system for dual seals. 150-300°F (65-150°C) Material: CD-4MCu. 4. CN-7M (suitable to 300°F [150°C]).4.2 Description The chlorine gas produced by all the cell types is saturated with water vapor. jacketed seal chamber to avoid solidification of caustic during pump shutdown. offer better resistance than CF-8M to solids). The tail gases from the liquefaction process are scrubbed with a caustic solution. ambient temperature. The cool. dry gas can be sent to pipelines for transport or it can be liquefied by compression. Seals: Single or dual. Sulfuric Acid Recirculating Pump + + + + Conditions: 96% sulfuric acid. Comments: 73% NaOH solidifies at about 150°F (65°C). Comments: Caution is recommended with DCI/WCB. Durimet 20.4. The gas is then dried in counter-current drying towers using concentrated sulfuric acid (H2SO4). Flowserve RED 10/98 4-5 . and liquefying the gaseous chlorine. 4.3 • Pump Application Guidelines Sulfuric Acid Unloading Pump + + + + + • Conditions: 98% sulfuric acid. flush system for dual seals. Durichlor (D51M) Seals: Single or dual Seal Support: FML for Durimet 20. flush system for dual seals. CZ-100 (cast nickel).1 Objective This area of the plant is involved in cooling. CD-4MCu (suitable to 250°F [120°C]. 5 Hydrogen Handling 4. Seals: Single or dual Seal Support: FML for CW-6M and Titanium pumps. CW-6M. CF-8M Seals: Single Seal Support: FML seal chamber. 50-60°F (10-15°C) Material: DCI/WCB. flush system for dual seals.3 • Pump Application Guidelines Chilled Water Circulating Pump + + + + Conditions: Water. CF-8M Seals: Single Seal Support: FML seal chamber. 4.Chlor-Alkali Industries Applications • Sulfuric Acid Recirculating Pump + + + + • Conditions: 78% sulfuric acid.5. • Chilled Water Circulating Pump + + + + Conditions: Water. sodium hypochlorite. 100-125°F (38-52°C) Material: Durichlor (D51M). Scrubber Pump + + + + Conditions: Sodium chloride.5. Flowserve RED 10/98 4-6 . any traces of oxygen must also be removed. Durichlor (D51M). Titanium. 100-125°F (38-52°C) Material: Titanium. 4. sodium hydroxide. by-pass flush for single seal in D51M pump. For some special uses. by-pass flush for single seal in D51M pump.5. flush system for dual seals.1 Objective This area of the plant is involved with cooling and compressing the gaseous hydrogen. 1% chlorine. 50-60°F (10-15°C) Material: DCI/WCB. Seals: Single or dual Seal Support: FML for Titanium pumps. 4.2 Description The hydrogen gas produced by any of the cell types is very pure and requires only cooling. Alabama Convent. Louisiana Port Edwards. Alabama Muscles Shoals. Tennessee McIntosh. Texas Delaware City. Oregon Baton Rouge.Chlor-Alkali Industries Applications Appendix A Profile of Major End-Users North America OUTPUT (chlorine/ sodium hydroxide. Louisiana Becancour. Delaware LaPorte. Texas Deer Park. thousand tons [metric]) 368/405 235/258 2362/2598 1244/1368 171/188 161/177 500/550 407/447 243/267 47/51 180/198 216/237 96/106 223/246 346/380 284/312 425/468 354/389 128/141 489/538 42/46 135/148 298/328 199/219 592/651 230/253 352/387 1104/1215 349/383 243/267 69/76 238/262 135/148 COMPANY Dow Canada Dow Chemical Elf Atochem Formosa Plastics Georgia Gulf ICI Canada LaRoche Industries Niachlor Olin Corporation OxyChem Pioneer PPG Industries Vulcan Materials Weyerhaeuser PLANT LOCATION Fort Saskatchewan. Ontario Gramercy. West Virginia Geismar. New York Augusta. Nevada St. Wisconsin Wichita. Texas Plaquemine. Louisiana Lake Charles. Quebec Cornwall. Louisiana Point Comfort. Louisiana Portland. Kansas Longview. Ontario Freeport. Texas Mobile. Louisiana Henderson. Washington Taft. Texas Plaquemine. Louisiana Natrium. Georgia Charleston. Louisiana Corpus Christi. Washington Flowserve RED 10/98 A-1 . Alberta Sarnia.Louisiana Niagara Falls. New York Tacoma. Alabama Niagara Falls. Gabriel. United Kingdom Wilton. Germany Brunsbuttel. Germany Dormagen. Italy Gela. Italy Flix.e Ind. Italy Priola. United Kingdom Flowserve RED 10/98 A-2 . Italy Porto Marghera. thousand tons [metric]) 130/143 70/77 240/264 90/99 260/286 41/45 233/256 162/179 224/246 1100/1210 122/134 292/321 365/401 122/134 80/88 15/17 130/143 80/88 115/126 129/142 185/204 90/99 170/187 35/39 42/47 145/160 80/88 58/64 320/352 90/99 75/83 720/792 170/187 40/44 220/242 52/57 COMPANY Akzo Salt Akzo Salt Akzo Salt BASF BASF Bayer Bayer Bayer Bayer Dow Stade Elf Atochem Elf Atochem Elf Atochem Elf Atochem Eng. France Saint Auban. Germany Leverkusen. Germany Fleetwood. Finland Marl. France Le Pont de Claix. Spain Assemini. United Kingdom Northwich. Italy Porto Torres. France Jarrie. The Netherlands Rotterdam-Botlek. Aragoneas Enichem Enichem Enichem Enichem Enichem Enichem Enichem Enichem ERKIMIA Finnish Chemicals Finnish Chemicals Huls ICI ICI ICI ICI Rhone-Poulenc Rhone-Poulenc Rhone-Poulenc PLANT LOCATION Delfzijl. The Netherlands Antwerpen. Germany Krefeld 11. Germany Stade. Spain Joutseno.Italy Sant’Eufemia. France Chesterfield. Spain Vilaseca.e Ind. United Kingdom La Madeleine. The Netherlands Henglo. Spain Sabinanigo. Aragoneas Eng. Aragoneas Eng. Belgium Ludwigshafen. Finland Kuusankoski. France Lavera. France Palos de la Frontera. United Kingdom Runcorn.e Ind. Italy Pieve -Vergonte.Chlor-Alkali Industries Applications Appendix A Europe Profile of Major End-Users OUTPUT (chlorine/ sodium hydroxide. Germany Fos sur Mer. Italy Mantova. Belgium Tavaux. Germany Rosignano. Italy Herten.Chlor-Alkali Industries Applications Appendix A Europe Profile of Major End-Users Solvay Solvay Solvay Solvay Solvay Solvay Solvay Solvay Solvay Solvay Tessenderlo Chemie Hallein. France Rheinberg. Spain Torrelavega. Austria Antwerpen. Spain Zurzach. Belgium 50/55 190/209 120/132 325/357 210/231 135/148 135/148 180/198 62/68 50/55 210/231 Flowserve RED 10/98 A-3 . Belgium Jemeppe sur Sambre. The Netherlands Martorell. Switzerland Tessenderlo. Indonesia Ichihara.Chlor-Alkali Industries Applications Appendix A Profile of Major End-Users Asia Pacific OUTPUT (chlorine/ sodium hydroxide. Taiwan Jenwu City. Japan Nagoya. Mitsui Toatsu Japan. Hanyang Chem. Japan Ulsan. Ashai Glass Japan. Mitsui Toatsu Japan. Ashai Glass Japan. Korea Lin Hai City. Japan Takaishi. Taiwan. Formosa Plastics Thailand. South Korea. South Korea. Hanyang Chem. Japan. Japan Nagoya. Indochlor Indonesia. other Japan. Japan Kashima. other Indonesia. China Petro. Japan Tokuyama. Taogosei Chem. Taogosei Chem. other PLANT LOCATION Serang. Taiwan Flowserve RED 10/98 A-4 . Japan Kashima. thousand tons [metric] ) 4900/5390 2500/2750 120/132 110/121 570/627 191/210 182/200 280/308 70/77 71/78 59/65 2185/2404 85/94 160/176 315/347 440/484 85/94 200/220 400/440 300/330 180/198 300/330 350/385 COUNTRY/ COMPANY China. Japan Tokushima. other Japan. Japan. Mitsui Toatsu Japan. Tosoh South Korea. Indonesia Serang. Japan Yokkaichi. other India. Korea Yochon. Kashima Chlorine Japan. Japan Omuta. Asahimas Indonesia. other Taiwan. Tosoh Japan. Japan Shin-Nanyo. Tokuyama Soda Japan. Dow Brazil. Mexico Lima. other Mexico. Brazil Salvador. Chloro de Tahanutepec Mexico. other Mexico. other PLANT LOCATION San Antonio del Oeste. del Istmo Peru. Quimpac Venezuela.Chlor-Alkali Industries Applications Appendix A Profile of Major End-Users Latin America OUTPUT (chlorine/ sodium hydroxide. other Colombia. other Brazil. Carbochloro Brazil. Brazil Tlalnepantla. Salgama Chile. Peru Flowserve RED 10/98 A-5 . thousand tons [metric]) 100/110 235/259 400/440 270/297 400/440 60/66 35/39 288/317 69/76 129/142 100/110 120/132 COUNTRY/ COMPANY Argentina. Argentina Cubatao. Alcalis de la Patagonia Brazil. Mexico Monterrey. Quimica Ind. Fahrenheit to Celsius ° C = (°F – 32) ÷ 1.2 Temperature Conversions 1. GGG 40. 3.8 X ° C) + 32 2. 0. A494 CW-6M. B367 DIN (WN) DESIGNATIONS DIN 1693.4500.4408. GSC-25N N/A DIN 17445. G-Ni95 2.7032 DURCO PROCESS PUMP DESIGNATIONS NAME SYMBOL Ductile Iron Carbon Steel Durichlor Durco CF-8M Durcomet 100 Durimet 20 Cast Nickel Chlorimet 3 Titanium Palladium Stabilized Ti DCI DS D51M D4 CD4M D20 DNI DC3 Ti TiPd EXHIBIT B. 10619. A494 Grade C3.3 DIN 17245. G-X6CrNiMo 24-8-2 1.7031 DIN 17850. Temperatures EXHIBIT B.7043. A744 CD-4MCu.4883 DIN 17850. A395 WCB. A890 CN-7M.1 Alloy Conversions ASTM (Cast) DESIGNATIONS 60-40-18. A216 Grade 2. 2. 1. Celsius to Fahrenheit ° F = (1.4463. A744 CZ-100.4170. G-XcrNiMo1810 1. G-X7CrNiMoCuNb2520 DIN 17730. B367 Grade 8A. A518 CF-8M.Chlor-Alkali Industries Applications Appendix B Conversion Factors: Alloys. 3.8 ° Flowserve RED 10/98 B-1 . Flowserve RED 10/98 C-1 . Large vertical turbine pumps are used the handle the large volume of condensate produced by the evaporators. In the hydrogen area. However. Finally. there are requirements for other types of Flowserve pumps particularly in larger plants. high volume vertical turbine or double suction pumps are used. The wastewater system to handle rainwater and runoff water also requires large vertical turbine pumps. in plants that use the ammonia process for desalting.Chlor-Alkali Industries Applications Appendix C Other Pump Applications The focus of this manual is on the application of Flowserve chemical process pumps in chlor-alkali operations. the operation is high pressure and API pumps are used. . 1 Market Drivers and Growth 2.Mineral Acids Applications Table of Contents Page Number 1.5 Plant and Pump Details Pump and Material Recommendations 4.3 Competitive Advantage of Flowserve Chemical Process Pumps 3. 4.1 Rationale and Methodology 1.4 Guidelines for Mechanical Seals 3.1 Sulfuric Acid 4.2 Competition Flowserve Experience 3.4 Hydrochloric Acid Major Sulfuric Acid Producers Major Phosphoric Acid Producers Major Nitric Acid Producers Major Hydrochloric Acid Producers Conversion Factors: Alloys. 3. Temperatures Other Pump Applications 1-1 1-2 2-1 2-2 3-1 3-1 3-1 3-2 3-3 4-2 4-4 4-5 4-8 A-1 B-1 C-1 D-1 E-1 F-1 2.1 Flowserve Sales 3.3 Nitric Acid 4.2 Phosphoric Acid 4.2 Processes Market Profile 2.2 Decision Makers 3. Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Flowserve RED 2/99 i . Introduction 1. Mineral Acids Applications Exhibits Page Number 1. 2. 3. 4. Sulfuric Acid Isocorrosion Chart Phosphoric Acid Isocorrosion Chart Nitric Acid Isocorrosion Chart Hydrochloric Acid Isocorrosion Chart 4-3 4-6 4-7 4-10 Flowserve RED 2/99 ii . Durimet 20 was introduced. This alloy was particularly well suited to handle the highly oxidizing conditions presented by nitric acid services plus it offered enhanced erosion/corrosion properties needed to produce wet-process phosphoric acid. Flowserve Corporation through one of its predecessors. and derived from. The manufacture and use of mineral acids are truly global activities. These acids are used in. has been supplying equipment to handle mineral acids since its inception. it is safe to say that the mineral acids have been major driving forces behind many of the materials developments introduced over the years and form a large part of the basis for the materials application expertise possessed by Flowserve. the material Duriron (durable cast iron). Plant sizes vary from extremely large to quite small. was intended initially to handle concentrated sulfuric and nitric acids in the production of explosives. and in conjunction with the Ohio State University.1 Introduction Rationale and Methodology There are four principal mineral (inorganic) acids: sulfuric (H2SO4). phosphoric (H3PO4). During the 1960’s. The real corrosion challenges and the opportunities to solve serious customer problems present themselves more in the use of these acids. Prior to the development of Durimet 20. In 1939. Most of the recognized global chemical companies are involved to some degree with either the manufacture or use of mineral acids. Flowserve RED 2/99 1-1 . developed early this century. Some information is presented on the basic processes used in producing these acids and the materials used in their production. sulfuric acid presented severe corrosion problems for the then available stainless steels. nitric (HNO3). However. machineable alloy became available to handle sulfuric acid. These acids are widely used in a variety of processes and because of the very corrosive nature of these substances. the requirements for chemical process pumps in the actual production of these acids are somewhat limited. a ductile. So. CD-4MCu was introduced.Mineral Acids Applications 1. The Duriron Company. With the development of Durimet 20. 1. and hydrochloric (HCl). castable. the innovative developments introduced with non-metallic materials like fiber-reinforced plastics (FRP) and fluoropolymer (PTFE/PFA) linings were spurred largely by the unique corrosion challenges presented by hydrochloric acid. This is where Flowserve’s materials expertise and unique engineering features can help improve overall pumping performance in these difficult environments and this will be the principal focus of this manual. In fact. Many units are captive operations. the manufacture of an extremely broad range of products. they offer many opportunities for the application of Flowserve chemical process pumps. Finally. This manual was created to bring together the company’s long and successful involvement in providing equipment and materials to handle these very basic chemicals. The sulfur trioxide is dissolved in 98% sulfuric acid and reacts with the 2% water present forming sulfuric acid.Mineral Acids Applications 1. The following chemical reaction is typical 3H2SO4 + Ca(PO4)2 + 6H2O → 2H3PO4 + 3CaSO4•2H2O One important factor not reflected by this equation is the presence of impurities.2. The acid produced by the AOP has a strength of 60-65%. Ammonia (NH3) is catalytically oxidized to produce nitrous oxide (NO 2) and this gas is absorbed in water to produce nitric acid. 1. The electric furnace process produces a purer phosphoric acid. In very basic terms. To produce stronger concentrations requires further processing.3 Nitric Acid Nitric acid is produced by the Ammonia Oxidation Process (AOP). The acid produced by the electric furnace process is quite pure. this process converts elemental sulfur (S) into sulfur dioxide (SO2) and the sulfur dioxide is catalytically oxidized to produce sulfur trioxide (SO3). both of which can contribute to corrosion problems. The elemental phosphorus is oxidized to produce phosphorus pentoxide (P2O5) and this compound is hydrated to produce phosphoric acid. Sulfur dioxide is also formed during the roasting of metal sulfides in smelting operations and during the combustion of hydrogen sulfide. Many times sulfuric acid plants are built adjacent to these sites to make use of the sulfur dioxide by-product. The wet-process is more prevalent and involves treating phosphate rock with sulfuric acid forming phosphoric acid and a sulfate. phosphate rock is processed in a furnace to produce elemental phosphorus (P).2. A typical source is the reaction of chlorine with benzene: C6H6 (benzene) + Cl2 → C6H5Cl (chlorobenzene) + HCl The commercial grade of concentrated acid produced through chlorination is 38% HCl. but it also requires a higher grade of rock. Demand for acid stronger than 60-65% is quite small.1 Processes Sulfuric Acid The contact process is used to produce almost all sulfuric acid.2.2. 1. Flowserve RED 2/99 1-2 .2 1. Most of the phosphate bearing rock contains fluorides and fluosilicates.4 Hydrochloric Acid Hydrochloric acid is obtained almost solely as a by-product of the chlorination of hydrocarbons. In this process. 1.2 Phosphoric Acid Phosphoric acid is produced from phosphate containing rock through either the wet-process or the electric furnace process. it has been said that the per capita use of sulfuric acid is an index of the technical development of a nation. Appendix A lists some of the major global producers of sulfuric acid. this figure is about 30%. electrowinning process. the economies involved in producing byproduct acid will result in closing of some sulfur burning plants. Below are the principal users of sulfuric acid: Agricultural fertilizers Chemical processing Mineral extraction Pigments Metallurgical processes Petroleum refining (alkylation) Soaps and detergents Textiles Explosives Annual global production of sulfuric acid exceeds 100 million metric tons (t). Global demand for sulfuric acid will probably follow overall GDP growth.1. Probably the fastest growing use for sulfuric acid is in copper leaching as part of the solvent extraction. the most widely used industrial chemical.. Also. The demand for fertilizers will generally drive the demand for sulfuric acid. By-product producers are not necessarily located near acid markets (fertilizer producers). This is an area where much of the production is from by-product SO2 created in sulfide ore roasting. 2. Increased production of sulfuric acid from copper smelter generated sulfur dioxide will have a significant influence on the market.1 2. Over 50% of this is produced in North America. about 60% of the acid used goes into these fertilizers while in the U. the principal use of sulfuric acid is in the manufacture of agricultural fertilizers. In the U. but it should be noted that much of the acid is produced in captive operations.1. by far. In fact. 2.Mineral Acids Applications 2.K.S.2 Phosphoric Acid The principal uses of phosphoric acid are: Agricultural fertilizers Soaps and detergents Insecticides Animal feeds Metallurgical processes Sugar refining Flowserve RED 2/99 2-1 . Undeniably.1 Market Profile Market Drivers and Growth Sulfuric Acid Sulfuric acid is. 2. Peerless). Major global producers are listed in Appendix B. plastics.1.4 Hydrochloric Acid The principal uses of hydrochloric acid are: Metal cleaning and pickling Petroleum wells Ore reduction Food processing Cleaning solutions Global production of hydrochloric acid is about 15 million metric tons (t) per year.2 Competition Mineral acid production and handling involve serious corrosion problems. much like sulfuric acid. IDP. but to a lesser degree than sulfuric or phosphoric acids. Because of this.3 Nitric Acid The principal uses of nitric acid are: Agricultural fertilizers Explosives Organic synthesis (fibers. In fact. The principal players are ITT-Goulds. there are some specialty type pumps and materials that come into play Flowserve RED 2/99 2-2 . Fully 80% of all phosphoric acid is used in the manufacture of agricultural fertilizers. Nitric acid production is a mature industry and growth will be minimal. but. Also. Nitric acid usage is dependent on agricultural fertilizer output. Growth in demand should be 24% per year and almost all hydrochloric acid is a by-product of hydrocarbon chlorination. Plant location is based almost solely on the availability of phosphate rock.S. Appendix C lists some of the principal global producers. all manufacturers of chemical process pumps are competitors.Mineral Acids Applications Refractory bonding Pharmaceuticals Annual global production of phosphoric acid is about 40 million metric tons (t). in Western Europe demand has declined due to concern over nitrate levels in the groundwater. and KSB with occasional competition from the Sterling Group (Labour. again. Plant location is dependent on the availability of ammonia. About one-third of this total is produced in the U. demand should grow with the demand for fertilizers.1. a great deal of the production capacity is captive. therefore. elastomers) Metallurgical processes Photoengraving Pharmaceuticals Precious metals extraction Annual global production of nitric acid is about 35 million metric tons (t). 2. 2. Appendix D lists some of the principal global producers. Competitive advantages will be highlighted in Section 3.Mineral Acids Applications here. Also. Flowserve RED 2/99 2-3 . particularly hydrochloric.3. Flowserve’s design engineering innovations can enhance overall pump reliability and improve the customer’s competitive position. Labour claims that its R55 alloy offers some advantages in higher temperature mineral acid services. Wet-process production of phosphoric acid involves the handling of rock slurries and rubber-lined pumps are widely used. Flowserve can offer a long history of applications expertise and materials knowledge to help customers solve their corrosion problems. Durco Process Pumps have been pumping mineral acids for decades and have performed admirably in these very difficult services. so companies like Fybroc will be competitors. Non-metallics are used quite often in these acids. Instead.. Decision makers involved in acquiring chemical process pumps to handle mineral acids in plant operations include operations and engineering managers. operations Flowserve RED 2/99 3-1 . other Flowserve Chemical Process pump features that offer advantages to those handling mineral acids include: 1 MRO = maintenance. Even though these data are not complete.2 Decision Makers Since much mineral acid production is captive and since many of the plants are built in conjunction with other processes to make use of by-product materials. For projects handled by engineering firms. there are over 50 significant producers of sulfuric acid in the U. MRO1 purchasing must not be overlooked. for their own consumption. repair. the plant engineering manager is a critical contact. 3. Of the merchant producers. but there is no list of specific producers. For in-house projects. In plants where corrosion from mineral acids is a constant challenge. Because these are such highly fragmented markets. there is a projected production output of 17 million metric tons of sulfuric acid for China for 1998. Quite likely.S. Europe. they give a good representation of the companies involved with mineral acid production and their geographical distribution. or totally. they will be part of a larger project and it will be necessary to recognize these needs and offer Flowserve’s expertise.1 Flowserve Experience Flowserve Sales Mineral acid production and use are truly global activities and Flowserve chemical process pumps are used worldwide to handle these corrosive liquids. Many of the materials needed to handle mineral acids were developed by Flowserve and the long applications history results in selecting the best materials for these very severe services. but only about half produce for the merchant market. In addition to materials. most of the Chinese production is captive. Appendices A-D show the principal producers for three global regions (North America. 3. Many of the large volume producers of these acids produce mostly.Mineral Acids Applications 3. the production data are sketchy. the Flowserve Materials Engineering Group can assist in assessing in-plant corrosion problems and offering proven solutions to these problems. 3. materials engineering groups. Three of these are by-product producers (Magnum Metals. For instance. For example.3 Competitive Advantage of Flowserve Chemical Process Pumps The principal competitive advantage is the company’s materials expertise. Asia Pacific). In addition. and in many plants. the project manager and rotating equipment expert are key individuals. specific projects just involving acid plants may be rare. materials and corrosion engineers are often assigned to these projects and contact with these individuals can be fruitful. Kennecott) and the other is the global company Rhone Poulenc. There are no readily available data for Latin America. four account for over 50% of the merchant capacity. maintenance personnel. These strengths and capabilities are unmatched by Flowserve’s competitors. Also. Phelps Dodge. the Mark III reverse vane design makes the rear cover/seal chamber the primary wear surface. 3. Because of the severe nature of many mineral acid services. The family of SealSentry seal chambers allows the customer to choose a design to maximize seal life and minimize operating costs. a much less costly part than the casing which is the wear surface for open impeller designs. Flowserve RED 2/99 3-2 . The Flowserve family of sealless pumps can offer solutions for these difficult sealing problems. the reverse vane design reduces NPSHR and cavitation problem resulting in much longer pump and mechanical seal life cycles. there will be some material removal through corrosion. The atmospheric conditions in some areas where mineral acids are being handled can be less than ideal. the recommendations of a Flowserve FSD sealing specialist should be obtained. Services can lead to severe general corrosion attack on 316 stainless steel.4 Guidelines for Mechanical Seals The demands on mechanical seals in mineral acid services are usually severe. The FM (Flow Modifier) series of seal chambers provides protection for the seal and permits the use of single seals without an external flush. This can be a real advantage in very corrosive services because high alloy materials can result in costly seal flush plans. Also. Some mineral acid services require double seals and the CBL design provides better flushing and cooling of the seals resulting in extended seal life. Finally. optimal pump performance can be restored easily with a simple impeller clearance adjustment. and chloride pitting and cracking can be a problem. the new Polychem M series pumps offer the advantages of sealless design with innovative non-metallic materials utilization to handle very corrosive services. In particular. The ANSI 3A power end positively seals the bearings and bearing lubricant from these potentially harmful conditions thus prolonging bearing life. the extreme range of corrosive conditions possible with mineral acids can be handled. Because of the severe nature of mineral acid services. With only one critical setting for the impeller. The Polybase baseplate is an ideal choice for many mineral acid services.Mineral Acids Applications • • • • • Mark III reverse vane impeller ANSI 3A power end SealSentry mechanical seal chambers Polybase baseplates Sealless pump technology The Mark III reverse vane impeller offers significant operational benefits. Many mineral acid applications present some extremely difficult problems for mechanical seals. Also. Therefore. because of the alternate materials available with the Polybase design. careful attention must be given to seal selection and configuration. Corrosion of carbon steel baseplates can be a serious problem and the Polybase design offers a very economical alternative to stainless steel baseplates. there will be pump and material guidelines for the general handling of these acids. Therefore.5 Plant and Pump Details The principal uses of Flowserve chemical process pumps are outside the actual production of mineral acids. there might be only 3-4 chemical process pumps handling sulfuric acid. in addition to pumps and materials used in actual manufacture of mineral acids. in a contact process sulfuric acid plant.Mineral Acids Applications 3. Flowserve RED 2/99 3-3 . For example. in Section 4. Mineral Acids Applications 4. and manufacturers of components/accessories are to be consulted for detailed specifications as well. depending on variables associated with the application. Pump and Material Recommendations The recommendations that follow are general guidelines. A qualified pump engineer must still be involved in the specification of any pump. and are intended to raise awareness of issues associated with particular applications. Flowserve RED 2/99 4-1 . Other specifications not addressed in this manual may be equally or more acceptable. They are based on specifications which have performed well in the field. These guidelines should not take the place of any manufacturer’s recommended specification for a given application. D51M is not suitable. The oxide film that provides protection against corrosion for stainless steels is unstable for CF-8M in dilute sulfuric acid. In that process. a region for CF-8M is shown outlined with a dashed line. a higher alloy stainless steel. oxygen (O2).1. if the concentration of these substances is less than 200 parts per million (ppm). Flowserve RED 2/99 4-2 . When these substances are present above about 200 ppm. Sulfuric acid is somewhat unique in that below about 70% the liquid will be reducing while above 70% it is oxidizing.1. caution should be exercised in depending on these compounds to make an otherwise marginal material suitable. carbon steel and ductile iron are often used. Exhibit 1 is an isocorrosion chart showing suitable materials for handling all concentrations of pure sulfuric acid. Finally. It should be noted that at the very low concentrations. then the materials shown in Exhibit 1 are suitable.2 Materials Recommendations Selecting the appropriate material for handling sulfuric acid presents a broad range of challenges. ferric ion (Fe+3). These substances may be present as contaminants or intentional additions. like CN-7M. Above 200 ppm. Reducing agents are commonly present in sulfuric acid services and these substances are also detrimental to the suitability of the stainless steel alloys. 4.1. or a nickel-base alloy. is required.1 Sulfuric Acid Production of Sulfuric Acid The process for producing sulfuric acid is discussed in Section 1.1 4. Interestingly. chloride and fluoride contaminated sulfuric acid is routinely handled with the fluoropolymers (PTFE/PFA). and compounds containing antimony (Sb) and arsenic (As).2. CW -6M is commonly used. depending on concentration and temperature. There are a few things worth noting about Exhibit 1. and nitric acid (HNO 3). Behavior of CF-8M in dilute sulfuric acid can be erratic and caution is recommended. then CW-6M or PTFE/PFA are normally used. Some common oxidizing agents are copper sulfate (CuSO4). carbon disulfide (CS2). For chlorides only. CD-4MCu is a much better choice for dilute sulfuric acid. Many typical applications involve handling sulfuric acid containing small amounts of other substances. Suitable materials. like CW-6M. at higher concentrations (93-100%). D51M is suitable. there are essentially three chemical process pumps. concentrated sulfuric acid containing dissolved SO3 sometimes expressed as greater than 100% concentration). hydrogen sulfide (H2S). Even though these substances inhibit corrosion of stainless steels in sulfuric acid. Chlorides and fluorides are common contaminants and very small quantities can increase the corrosivity of the acid significantly. but is not suitable if fluorides are present. Two of these pumps handle 98% sulfuric acid and the other handles oleum (fuming sulfuric acid. can range from ductile iron and carbon steel to zirconium. Standard horizontal chemical process pumps are normally used for these services and the material of construction is almost always CN-7M. sodium sulfite (Na 2SO3). Because of this characteristic and particularly in the mid-range concentrations. Oxidizing substances can also be present in sulfuric acid services and these compounds can inhibit corrosion of stainless steels. Some typical reducing agents are sulfur dioxide (SO2). In general.Mineral Acids Applications 4. 0254 mm).Mineral Acids Applications Exhibit 1 SULFURIC ACID ISOCORROSION CHART (20 mpy lines2) Temperature (° F) Percentage of Sulfuric Acid (by wgt) _______________________ 2 Within the temperature-concentration regions where the alloys are shown.001 in = 0. general corrosion rates will be ≤ 20 mils per year (1 mil = 0. Flowserve RED 2/99 4-3 Temperature (° C) . NOTE – See Page E-1 for Alloy cross-references. Viton is normally suitable for all sulfuric acid concentrations within its acceptable performance temperature range. this is an application area where magnetic drive pumps are used. These oxidizing conditions make most carbon seal faces unsuitable and silicon carbide is generally used. Mechanical seal metallic components cannot generally tolerate much corrosion because of thin cross-sections and small size. As mentioned above. careful consideration must be given to the barrier fluid.2 for producing phosphoric acid. but these conditions occur infrequently. For all single seal applications. or no. The electric furnace process produces a high purity acid with little. The presence of fluorides and fluosilicates.2. 4.2. A corrosion rate of 20 mils per year (mpy) may be acceptable for the pump wet-end parts. For dual seals. but Alloy 20 is probably not suitable for the seal components.1.2. the standard black Polybase should be replaced with the special H2SO4 Red material. Hastelloy C is generally used in this concentration range and for all concentrations at higher temperatures.Mineral Acids Applications Another variable influencing material performance in sulfuric acid that merits consideration is liquid velocity. The same precautions Flowserve RED 2/99 4-4 . there are a number of chemical process pumps handling various concentrations of phosphoric acid. This is not a particularly strong acid so most services can be handled with stainless steels. the FM-style seal chamber should be used to provide a more friendly environment for the seal. solids present so CF-8M is most frequently used. the Polybase finds frequent use with pumps handling sulfuric acid. 4. Because costly materials are required for many mechanical seals in sulfuric acid services. Finally. CD-4MCu is widely used. In the wetprocess. Guardian and ChemStar MD models with CN7M/Alloy 20 construction are used and the PolyChem M series will also be suitable for many applications. 4.2 4. This alternative should be considered for many sulfuric acid applications.4 meters per second) is desirable. and temperatures above 200°F (93°C). Limiting liquid velocity to less than 8 feet per second (2.2 Materials Recommendations Exhibit 2 is an isocorrosion chart showing suitable materials for handling pure phosphoric acid. excessive velocity of the sulfuric acid can lead to removal of this film. but this rate would not be acceptable for mechanical seal components. CN-7M is suitable for the pump parts.1 Phosphoric Acid Production of Phosphoric Acid There are two principal processes discussed in Section 1.3 General Guidelines for Mechanical Seals The main consideration in seal selection is corrosion. Because of the highly oxidizing nature of sulfuric acid above 70% concentration. may require the use of CW-6M. This is of particular concern in the range of 65-80% acid. Neither water nor alcohol is suitable since contact between these liquids and the acid can result in very rapid heat generation. The second consideration is the oxidizing nature of sulfuric acid above 70%. Because of the frequent presence of solids. stainless steels depend on a thin oxide film for protection and even in the absence of solids. 1 Nitric Acid Production of Nitric Acid Section 1. the service was converted to a dual seal. However. Viton is a suitable elastomer within its acceptable performance temperature range. fluorides.Mineral Acids Applications enumerated in Section 4. The acid concentration exiting the column is 60-65% and can be handled with CF-8M.2 Materials Recommendations Exhibit 3 is an isocorrosion chart showing suitable materials for handling pure nitric acid. This could be a factor if any welding will be done without subsequent heat treatment. When this problem has been experienced. It should be noted that the phosphate industry has used the Sealmatic pump design for many high solids applications. intergranular corrosion will occur adjacent to welds that have not been heat treated. The presence of solids can influence seal selection. Many specifications will call for the low carbon grades (CF-3.1.3. can be handled with stainless steels except at high concentrations and temperatures. 4. and reducing agents apply to phosphoric acid. 4.3.2 above regarding the presence of chlorides. At temperatures greater than 150°F (64°C). there is no real advantage gained with the low carbon grades over the standard alloys if all parts receive an adequate heat treatment.2. mechanical seal selection is not difficult. Most seals used consist of 316 SS metal parts and carbon/ceramic faces. dual seals with a water barrier fluid are used. when uncontaminated. testing done at Flowserve and data found in the literature show that if there is a difference. This is primarily a gaseous process until the nitrous oxide (NO 2) is passed through the absorption column. CF-3M). Flowserve RED 2/99 4-5 . Both CF-8 and CF-8M are shown as acceptable materials for handling most nitric acid services.3 General Guidelines for Mechanical Seals Because this is not a particularly strong acid.3 discusses the principal process for producing nitric acid. For moderate levels of solids.2. For higher solids loading.3 4. This acid is very strongly oxidizing and. it is so slight as to be insignificant. Because nitric acid is so oxidizing. Some feel that CF-8 is the better alloy for this highly oxidizing service. but many of these services experienced problems with the solids packing the repeller chamber during shutdown. Alloy 20 metal parts are usually required. a single seal with the FM-style seal chamber is suitable. however. 4. NOTE – See Page E-1 for Alloy cross-references.001 in = 0.0254 mm). Flowserve RED 2/99 4-6 Temperature (° C) .Mineral Acids Applications Exhibit 2 PHOSPHORIC ACID ISOCORROSION CHART (20 mpy lines2) Temperature (° F) Percentage of Phosphoric Acid (by wgt) _______________________ 2 Within the temperature-concentration regions where the alloys are shown. general corrosion rates will be ≤ 20 mils per year (1 mil = 0. Flowserve RED 2/99 4-7 Temperature (° C) .Mineral Acids Applications Exhibit 3 NITRIC ACID ISOCORROSION CHART (20 mpy lines2) Temperature (° F) Percentage of Nitric Acid (by wgt) _______________________ 2 Within the temperature-concentration regions where the alloys are shown. NOTE – See Page E-1 for Alloy cross-references.001 in = 0. general corrosion rates will be ≤ 20 mils per year (1 mil = 0.0254 mm). because of the highly oxidizing nature of nitric acid. In both cases. 4. CW-6M is more suitable. This mixture is commonly called a pickling solution and is used to clean metal surfaces. however. In the presence of these ions. Viton is not suitable in nitric acid. The second mixture involves nitric with adipic acid. there is the mixture of nitric with hydrofluoric acid.2. the acid will attack the binders in tungsten carbide. a special grade must be used. These include both the fluoropolymers (PTFE/PFA) and solid fiber reinforced (FRP) epoxy. However. particularly castings. These operations can introduce ferric (Fe+3) and cupric (Cu+2) ions. stainless steels are not suitable for any hydrochloric acid service. N-7M and zirconium (Zr) cannot tolerate the presence of these ions and are unsuitable.1 Hydrochloric Acid Production of Hydrochloric Acid Section 1. by far. This alloy is essentially CF-3 with about 5% silicon. of all the acids and extreme care must be taken in material selection. Flowserve can offer a material called Durcomet 5 (DV) that works very well. the temperature is limited to 150°F (65°C). the fluoropolymers (PTFE/PFA) are widely used.4. selfsintered silicon carbide faces are used. However. but CD-4MCu performs quite well up to about 180°F (82°C). 4. As shown on this chart. For very intermittent services. The most common metallic material used is Hastelloy C.3. CN-7M has given reasonable life.4 discusses the process for producing hydrochloric acid. The acid concentration exiting the column is about 35% and is handled mostly with nickel-base alloys or nonmetallics. 4.2 Materials Recommendations Hydrochloric acid is the most corrosive. nonmetallics find wide acceptance for handling hydrochloric acid.3 General Guidelines for Mechanical Seals Metallic corrosion is the principal concern in mechanical seal selection. This mixture will attack the CF alloys.Mineral Acids Applications Two common mixed services involve nitric acid. 4. The fluoropolymers also find use in nitric/adipic services. Exhibit 4 is an isocorrosion chart for pure hydrochloric acid.3 General Guidelines for Mechanical Seals For most applications. particularly for continuous duty. Either PTFE or Kalrez gasketing and secondary sealing are required. The Flowserve foundry is the only licensed producer of this material in North America. This concentrated acid is very corrosive and is not handled well by any standard alloys. Because of the severe nature of this service. both oxidizing agents. titanium (Ti) is suitable up to about 10% acid while D51M is suitable to about 20% acid. Generally. Cleaning and pickling metals are the predominate uses for hydrochloric acid. This process is gaseous until the hydrogen chloride (HCl) is absorbed in water to form the acid. There is an area on the isocorrosion chart (Exhibit 3) above 95% that is bounded by a dashed line and does not list any materials.4 4. First. titanium (Ti) is suitable.4. The acid will attack most common carbon binders so if a carbon face is required. Also. Above this temperature.4. This is a very corrosive mixture. the metal components of mechanical seals can be made of 316 SS. even this alloy will suffer attack. Because all suitable metallic materials are very costly. Carbon/ceramic faces are usually suitable and Viton is an acceptable Flowserve RED 2/99 4-8 . special consideration must be given to the face and elastomer materials. Mineral Acids Applications elastomer within its performance temperature range. Dual seals are often used with hydrochloric acid to prevent exposing the metallic parts to the acid. Because of the very costly mechanical seals required for hydrochloric acid services, the PolyChem M series will find widespread use here. In fact, hydrochloric acid services are some of the principal applications for nonmetallic magnetic drive pumps. Flowserve RED 2/99 4-9 Mineral Acids Applications Exhibit 4 HYDROCHLORIC ACID ISOCORROSION CHART (20 mpy lines2) Temperature (° F) Percentage of Hydrocholoric Acid (by wgt) _______________________ 2 Within the temperature-concentration regions where the alloys are shown, general corrosion rates will be ≤ 20 mils per year (1 mil = 0.001 in = 0.0254 mm). NOTE – See Page E-1 for Alloy cross-references. Flowserve RED 2/99 4-10 Temperature (° C) Mineral Acids Applications Appendix A Major Sulfuric Acid Producers U.S and Canada Company ASARCO Location East Helena, MT El Paso, TX Hayden, AZ Bartow, FL Riverview, FL Bartow, FL Plant City, FL Timmons, Ontario Falconbridge, Ontario Donaldsonville, LA Mulberry, FL Nichols, FL South Pierce, FL Uncle Sam, LA San Manuel, AZ White Springs, FL Baton Rouge, LA Baytown, TX Carson, CA Hammond, IN Houston, TX Martinez, CA Lathrop, CA Pocatello, ID Aurora, NC Fort Meade, FL Raw Material Lead smelter by-product Copper smelter by-product Copper smelter by-product Elemental S Elemental S Elemental S Elemental S Copper/zinc smelter by-product Copper/zinc smelter by-product Elemental S Elemental S Elemental S Elemental S Elemental S Smelter by-product Elemental S 95% sludge & 5% H2S 100% sludge 100% sludge 40% elemental S & 60% sludge 70% elemental S & 30% sludge 100% sludge Elemental S Elemental S Elemental S Elemental S Remarks Mostly captive Partly captive Partly captive Captive Mostly captive Captive Captive Partly captive Partly captive Captive Captive Mostly captive Captive Mostly captive Partly captive Captive Partly captive Partly captive Partly captive Partly captive Partly captive Partly captive Captive Mostly captive Captive Mostly captive Cargill Fertilizers C.F. Industries Falconbridge, Ltd. IMC-Agrico Magma Metals Occidental Chemical Rhone Poulenc J.R. Simplot Texasgulf U.S. Agri-Chemicals Flowserve RED 2/99 A-1 Mineral Acids Applications Appendix A Major Sulfuric Acid Producers Asia Pacific Country Indonesia Japan Company Petrokimia Gresik Dowa Mining Hibi Kyodo Smelting Mitsubishi Metals Nippon Mining Onahama Smelting Sumitomo Metal Mining Toagosei Chemical Toho Zinc Location Gresik, East Java Kosaka Okayama Tamano Naoshima Akita Saganoseki Onahama Toyo Nagoya Annaka Iwaki Takehara Ulsan Yosu Toufen City Kaohsiung City Maptaput South Korea Taiwan Thailand Dongbu Chemical Korea General Chemical Heng I Chemical Kaohsiung Ammonium Sulfate National Fertilizer Flowserve RED 2/99 A-2 Mineral Acids Applications Appendix A Major Sulfuric Acid Producers Europe Country Belgium Finland Company Bayer Rhone-Poulenc Kemira Agro Kemira TiO2 Location Antwerpen Gent Kokkola Siilinjärvi Pori Chauny La Madeleine Le Grande Quevilly St. Chimiques du Nord EniChem Kemira Pernis Fesa-Enfersa Albright & Wilson ICI Flowserve RED 2/99 A-3 . Ind. smelter gas Pyrite Elemental S Elemental S Elemental S Elemental S Elemental S Copper/lead smelter gas Pyrite Elemental S & pyrite Elemental S Elemental S & pyrite Elemental S Pyrite Pyrite Elemental S Elemental S Elemental S France Rhone-Poulenc Chimie Germany Greece Italy The Netherlands Spain United Kingdom Norddeutsche Affinerie Sachtleben Chemie Ste. Clair du Rhone Hamburg Duisburg-Homberg Thessaloniki Gela Porto Marghera Rotterdam Cartegena Huelva Whitehaven Billingham Runcorn Raw Material Elemental S Elemental S Pyrite. Mineral Acids Applications Appendix B Major Phosphoric Acid Producers U. FL Bartow. FL Aurora. FL Riverview. Industries Farmland Hydro FMC Location Geismar. FL Green River. WY Carteret. LA Redwater. FL Piney Point.S and Canada Company Arcadia Fertilizer Cargill Fertilizer C. Alberta Mulberry. KS Newark. CA Donaldsonville. LA Bartow. Agri-Chemicals Flowserve RED 2/99 B-1 .F. FL Pierce. NC Fort Meade. FL Uncle Sam. FL Process Wet Wet Wet Wet Wet Wet Hydrated P2O5 Furnace Furnace Furnace Wet Wet Wet Wet Wet Wet Wet Wet Wet Wet IMC-Agrico Imperial Oil Mulberry Phosphates Occidental Chemical Texasgulf US. FL Plant City. FL South Pierce. FL Nichols. FL White Springs. NJ Lawernce. LA Mulberry. Ind. Chimiques du Nord Italy Ind. Siciliana Acido Fosforico The Netherlands Hydro Agri Rotterdam Kemira Pernis Spain Fesa-Enfersa United Kingdom Albright & Wilson Engis Wet Siilinjärvi Wet Le Petit et le Grand Quevilly Wet Le Havre Wet Hürth-Knapsack Furnace & wet Thessaloniki Wet Gela Wet Vlaardingen Wet Rotterdam Wet Huelva Wet Oldbury Furnace Whitehaven Wet Flowserve RED 2/99 B-2 . Chimique Prayon-Rupel Kemira Agro Grande Paroisse Hydro Azote Germany Hoechst Greece Ste.Mineral Acids Applications Appendix B Major Phosphoric Acid Producers Europe Country Belgium Finland France Company Location Process Soc. East Java Ube Miyako Niigata-Hidashiko Mitsui Toatsu Chemicals Hikoshima Hokkaido Nippon Phosphoric Acid Kimitsu-gun Dongbu Chemical Ulsan Korea General Chemical Chinhae Yosu Chinese Petroleum Hsiaokang National Fertilizer Maptaput Flowserve RED 2/99 B-3 .Mineral Acids Applications Appendix B Major Phosphoric Acid Producers Asia Pacific Country Indonesia Japan Company Petrokimia Gresik Central Glass Co-op Chemical Location South Korea Taiwan Thailand Gresik. Ontario Nitrochem Maitland. Quebec Carseland. OK Lawrence. TX Victoria. TN Unocal Kennewick. TX Orange. WI Kingsport. LA La Platte. OK U. IN Radford. WY Dupont Beaumont. KS ICI Canada Beloeil. KS Chattanooga.F. IA Geismar. Industries Donaldsonville. LA Coastal Chemical Battle Mountain. CA Ammonium Ammonium Ammonium Ammonium Ammonium nitrate nitrate nitrate nitrate nitrate Captive Captive Captive Captive Captive Captive Captive Captive Captive Ammonium nitrate Explosives Explosives Explosives Explosives Explosives Explosives Nitrate fertilizers Ammonium nitrate Flowserve RED 2/99 C-1 . Alberta Courtright. PA Louisiana. VA Lawrence. Army Baraboo. WA West Sacramento. Ontario Terra Nitrogen Verdigris. AR Farmland Industries Beatrice. KA Enid. NE Dodge City. MO El Dorado Chemical El Dorado.S.S. TN Charleston. NV Cheyenne. and Canada Company Arcadia Fertilizer Location Augusta. GA Remarks Captive Partly captive Partly captive Partly captive Mostly captive Captive Captive Captive Captive Captive Captive Captive Partly captive Mostly captive Captive Mostly captive Captive Mostly captive Use Ammonium nitrate & Caprolactum Ammonium nitrate Ammonium nitrate Ammonium nitrate Ammonium nitrate Ammonium nitrate Ammonium nitrate Ammonium nitrate Nitrobenezene Adipic acid Adipic acid Clinton.Mineral Acids Applications Appendix C Major Nitric Acid Producers U. TX Dyno Nobel Donora. NE Wilmington. NC C. Mineral Acids Applications Appendix C Major Nitric Acid Producers Europe Country Austria Belgium Denmark Finland Company Location France Germany Greece Ireland Italy The Netherlands Norway Spain Sweden United Kingdom Agrolinz Agrarchemikalien Linz BASF Antwerpen Kemira Fredericia Kemira Oulu Siilinjärvi Uusikaupunki Grande Paroisse Le Petit et le Grand Quevilly Mazingarge Monioir de Bretagne Toulouse Hydro Azote Ambés Le Havre Montoir de Bretagne Pardies BASF Ludwigshafen Hoechst Frankfurt Aeval Ptolemais Irish Fertilizer Industries Arklow Agrimont Porto Marghera Enichem Ravenna DSM Meststoffen Gellen Ijmuiden Hydro Agri Sluiskil Sluiskil Norsk Hydro Glomfjord Herøya Rjukan Fesa-Enfersa Avilés Puertollano Sagunto Tablada Hydro Supra Köping Landskrona Hydro Fertilizers Immingham ICI Billingham Severnside Stevenston. Scotland Wilton Kemira Ince Flowserve RED 2/99 C-2 . Mineral Acids Applications Appendix C Major Nitric Acid Producers Asia Pacific Country Indonesia Japan South Korea Taiwan Company Multi Nitrotama Kimia Ashai Chemical Sumitomo Chemical Dongbu Chemical Korea General Chemical Taiwan Fertilizer Location Nobeoka Niihama Ulsan Yosu Haulien Kaohsiung Flowserve RED 2/99 C-3 . chlorination Thermal reaction By-product. GA Charleston. vinyl chloride By-product. WV Deer Park. chlorination By-product. TX La Porte. and Canada Company BASF Borden Chemicals Dow Location Geismar. MD Lake Charles.S. TX Niagra Falls. LA Natrium. chlorination Thermal reaction Thermal reaction Thermal reaction By-product. TX Midland. LA Ingleside. chlorination By-product. vinyl chloride By-product. WI Wichita. LA Geismar. alkybenzenes By-product. vinyl chloride By-product. OH Lake Charles. vinyl chloride Remarks Mostly merchant Captive Captive & merchant Captive Mostly captive Merchant Mostly captive Captive & merchant Captive & merchant Captive Captive Captive Mostly captive Captive & merchant Captive & merchant Captive & merchant Captive Captive Mostly merchant Merchant Merchant Captive Mostly merchant Captive Merchant Merchant Captive Captive Mostly merchant Captive & merchant Captive Dow Canada Formosa Plastics Geon Georgia Gulf ICI Materials Miles Occidental Olin Oxymar PPG Industries Vista Chemical Vulcan Materials Westlake Monomers Flowserve RED 2/99 D-1 . LA Geismar. vinyl chloride Phosgene By-product. isocyanates By-product. CA Plaquemine. LA Geismar. vinyl chloride By-product. WA Augusta. chlorination By-product. MI Oyster Creek. LA Freeport. isocyanates By-product. WV Baltimore. NY Tacoma. Alberta Sarnia. KY Raw Material By-product. chlorination By-product. isocyanates By-product. vinyl chloride By-product. intermediates By-product. TX Barberton. isocyanates By-product. KS Calvert City. LA Baytown. LA Port Edwards. LA Port Comfort. TN Lake Charles.Mineral Acids Applications Appendix D Major Hydrochloric Acid Producers U. chlorination By-product. isocyanates By-product. vinyl chloride By-product. TX Pittsburg. chlorination By-product. chlorination Chemical reaction Chemical reaction & by-product By-product. TX New Martinsville. vinyl chloride By-product. TX Plaquemine. LA Fort Saskatchewan. Ontario Baton Rouge. VCM By-product. VCM By-product. VCM By-product. fluorocarbons By-product. Du Chlorure de Vinyle Solvay BASF Hüls Aktiengesellschaft ICI Solvay Wacker-Chemie Ausimont EVC The Netherlands Norway Spain Sweden United Kingdom ROVIN Norsk-Hydro Aiscondel Viniclor Hydro Plast European Vinyls Flowserve RED 2/99 D-2 . VCM By-product. VCM Direct synthesis By-product. VCM By-product. VCM By-product. isocyanates & VCM By-product. VCM By-product. VCM By-product. VCM By-product. chlorination Potassium chloride Potassium & sodium chloride Potassium chloride By-product. VCM By-product. fluorocarbons By-product. VCM By-product. VCM By-product. VCM By-product. VCM By-product. fluorocarbons By-product. chlorination By-product. VCM By-product. chlorination By-product. VCM By-product.Mineral Acids Applications Appendix D Major Hydrochloric Acid Producers Europe Country Belgium BASF Limburgse Vinyl Maatschappij Solvay Tessenderlo Chemie Company Location Antwertpen Tessenderlo Jemeppe sur Sambre Ham Kwaadmechelen Tessenderlo Vilvoorde Jarrie Lavéra Pierre-Bénite Saint Auban Fas sur Mer Tavaux Ludwigshafen Marl Wilhelmshaven Rheinberg Burghausen Bussi sul Tirino Porto Marghera Spinetta-Marengo Assemini Brindisi Porto Marghera Porto Torres Ravenna Rotterdam-Botlek Herøya Vilaseca Martorell Stenungsund Fleetwood Runcorn Raw Material By-product. VCM France Elf-Atochem Germany Italy Soc. VCM By-product. VCM By-product. VCM By-product. West Java Kashima Ichihara Kita-Kyushu Yodogawa Omi Takasago Mizushima Shibukawa Nagoya Takaoka Tokushima Shin-Nanyo Yokkaichi Tsurumi Yokohama Ulchu Jenwu City Suao City Bangplakod Denki Kagadu Kogyo Kanegafuchi Chemical Kanto Denka Kogyo Toagosei Chemical Tosoh Corp.Mineral Acids Applications Appendix D Major Hydrochloric Acid Producers Asia Pacific Country Indonesia Japan Company Indochlor Perkasa Ashai Denka Kogyo Ashai Glass Location Serang. Tsurumi Soda South Korea Taiwan Thailand Kyunggi Chemical Formosa Plastics South East Soda Thai Asahi Caustic Soda Flowserve RED 2/99 D-3 . G-X6CrNi189 DIN 17445.7043. B367 Grade 702. 1. A744 CF-8M. Fahrenheit to Celsius °C = (°F – 32) ÷ 1. A395 WCB. 0. A890 CN-7M.2 Temperature Conversions 1. GX7CrNiMoCuNb2520 2.4308. GX6CrNiMo 24-8-2 1.3 DIN 17245. A518 CF-8.4882 DIN 17850. 3.4408. A216 Grade 2.7032 N/A DURCO PROCESS PUMP DESIGNATIONS NAME SYMBOL Ductile Iron DCI Carbon Steel DS Durichlor D51M (HSI) Durco CF-8 D2 Durco CF-8M Durcomet 100 Durimet 20 Chlorimet 3 Chlorimet 2 Titanium Palladium Stabilized Ti Zirconium D4 CD-4M D20 DC3 DC2 Ti TiPd Zr EXHIBIT E. 1. B367 Grade 8A.4500.1 Alloy Conversions ASTM (Cast) DESIGNATIONS 60-40-18. A744 CW-6M.4883 2. GGG 40. A494 N-7M.4463.7031 DIN 17850. GXCrNiMo 1810 1. A744 CD-4MCu. 3. 10619. Celsius to Fahrenheit °F = (1. B752 DIN (WN) DESIGNATIONS DIN 1693.Mineral Acids Applications Appendix E Conversion Factors: Alloys. Temperatures EXHIBIT E. GSC-25N N/A DIN 17445. A494 Grade C3.8 Flowserve RED 12/98 E-1 .8 X °C) + 32 2. large axial flow pumps are used with the evaporators. Flowserve RED 2/99 F-1 . Another is large cooling water circulating pumps. there are requirements for other types of Flowserve pumps in the manufacture of these acids. Finally. One typical application is boiler feedwater pumps.Mineral Acids Applications Appendix F Other Pump Applications The focus of this manual is on the use of Flowserve chemical process pumps for handling mineral acids. in the wet-process method for producing phosphoric acid. however. . 3 Competitive Advantages of Flowserve Chemical Process pumps 3. Pump Recommendations 4. Introduction 1.2 Decision Makers 3.1 Introduction to Pump Recommendations 4.2 The PTA Process 2.PTA Applications Table of Contents Page Number 1-1 1-1 1.1 Market Drivers 2. Flowserve Experience 3.1 Flowserve Sales 3.1 Rationale and Methodology 1.2 Common Services 4.4 Guidelines for Mechanical Seals 3.5 Plant and Pump Details 3-1 3-1 3-2 3-3 3-3 4. Market Profiles 2.2 Competition 2-1 2-2 3.3 Specific Applications Appendix A Appendix B Appendix C PTA Producers Alphabetical Listing of Pump Descriptions Other Pump Applications 4-2 4-2 4-6 A-1 B-1 C-1 Flowserve RED 2/99 i . Uses of PTA Global PTA Production 2-1 3-1 Flowserve RED 2/99 ii . 2.PTA Applications Exhibits Page Number 1. Other major players include DuPont. Mitsui. the exact make-up is proprietary information. Flowserve chemical process pumps have enjoyed widespread application in PTA production. in some detail.PTA Applications 1. All the catalyst systems include cobalt and manganese acetates with a bromine-based promoter. Introduction 1. The catalyst used is platinum based Flowserve RED 2/99 1-1 . It will present. Amoco Chemicals is the giant in the field accounting for about 40% of the world’s total capacity. has standardized on Flowserve chemical process pumps. With this presentation will be included the pump configurations that have proven to offer dependable service. the leading global producer of PTA. this manual is offered as a tool to increase familiarity with this key chemical. In fact. The broad range of materials available along with a reputation for reliable. The crude TA is purified through catalytic hydrogenation and crystallization to produce purified terephthalic acid (PTA). This contaminant must be removed by purification because it imparts an undesirable color to the crude TA. These resins are used in a broad range of products ranging from commodity type items to aerospace applications. Eastman. 2. Tuntex Petrochemical. Since significant growth in demand is forecast for PTA. dependable operation and excellent after sales support have lead to wide acceptance for Flowserve chemical process pumps in PTA production. a few major players are dominant. Flowserve chemical process pumps are a standard component in the PTA production process. Special emphasis will be given to those features of the configurations that are unique to Flowserve chemical process pumps and the benefits these features offer to the end-user. The by-product contaminant is removed and the crude TA is purified by catalytic hydrogenation. however. Mitsubishi. The manual will present the basics of the processes for producing PTA. 1. Production of PTA is global with many participants. Para-xylene is oxidized in the presence of a reaction solvent (acetic acid) and a catalyst mixture to produce crude terephthalic acid (TA). 3. Much of the process technology involved in producing PTA is proprietary. the catalyst mixture used in the oxidation phase is a closely guarded variable for most producers. however. therefore. The crude TA is contaminated with 4-carboxyenzaldehyde. Amoco Chemicals. and a group of state-owned units in China.1 Rationale and Methodology Purified terephthalic acid (PTA) is the primary and preferred raw material for production of high-purity polyester resins. Mixed xylenes are converted to para-xylene. Demand for the products that use these resins is growing at a significant rate and.2 The PTA Process There are three principal steps in the production process for PTA: 1. the applications where Flowserve chemical process pumps have been successfully applied. Kohap. the demand for PTA will grow also. a by-product of the oxidation process. For example. Flowserve RED 2/99 1-2 .PTA Applications and. again. is proprietary. The other parts of the process are involved with recycling the acetic acid and with treating the vent gases through scrubbing and incineration. The distribution of use by these groups is shown in Exhibit 1.PTA Applications 2. Exhibit 1 Exhibit 1 1 1 Exhibit Exhibit Uses of PTA PTA Uses of ofof PTA Uses Uses PTA Engineering plastics 3% Polyester films 7% PET bottle resins 15% Polyester fibers 75% Specific applications within the product groups shown above include: • • • • • • • • • • • • • • • • • • Easy-care apparel fabrics Blended apparel fabrics Carpeting Upholstery fabrics Soft drink containers Boil-in-bag food pouches Microwavable food containers Blister packaging Lightweight body armor Automotive body panels X-ray and microfilms Magnetic recording tape Electrical insulation Appliance and power tool housings Lawn furniture Tire belting Sporting goods Aerospace parts Flowserve RED 2/99 2-1 . Market Profile 2.1 Market Drivers and Growth There are four principal product groups that use almost all the PTA produced. With Flowserve’s global presence. in large part. Flowserve RED 2/99 2-2 . These include ITT-Goulds. The competitive advantages will be highlighted in Section 3. most of the planned expansion in PTA production is in the developing regions. by consumer spending. Flowserve chemical process pumps have established a reputation for reliable service in many critical and demanding applications in the PTA production process. Almost all PTA production is captive with Amoco Chemicals being the only significant merchant supplier. 2. but these are becoming active again plus new units are being planned. However. The mid-1990’s saw a dramatic increase in PTA production capacity. This resulted in significant overcapacity and depressed pricing. Test marketing has begun on PET beer bottles. and KSB with the Sterling Group (Labour. The overall growth in global GDP will be the principal factor determining the growth in demand for PTA. it should be noted that the acquisition of Amoco by BP may have an affect on scheduled expansion projects. a growth rate of 6-8% in demand for PTA is projected. at least through 2003. The PTA market is very competitive and Flowserve chemical process pumps offer unique features that will benefit end-users through improved reliability. If this application finds market acceptance. Peerless). Sulzer. indications are that the bottom of the market probably occurred in mid-1997 and pricing has started to recover.3. PET growth will accelerate. IDP. Overall. Several expansion projects were put on hold. The location of PTA plants is usually determined by the location of polyester resin facilities. and Ebara appearing occasionally. One factor that will influence this growth rate is the development of new uses for PET.2 Competition The usual competitors for ANSI/ISO business are factors in PTA projects. Also. However. the company is well positioned to serve this market in those regions of the world where growth is projected.PTA Applications It is evident that the demand for PTA is driven. Flowserve Experience 3. Exhibit 2 below shows the global distribution of the output: Exhibit 2 Exhibit 2 Global PTA Production Global PTA Production Latin America 6% North America 19% Asia Pacific 64% Europe 11% In Appendix A. DuPont has become a major player in PTA production through the purchase of ICI’s polyester business. it should be noted that in the developing regions. Also.PTA Applications 3.7 million metric tons (t). these companies represent some real potential for Flowserve chemical process pumps. For in-house projects. Many times. Amoco and DuPont. there may be a materials or corrosion engineering group that will have input particularly regarding the materials of construction. 3.2 Decision Makers New plants and major expansions are often handled by an engineering firm and the project manager and rotating equipment expert are key individuals. Of these planned expansions. This represents both a significant opportunity and a sizeable challenge. Two companies. As alliance partners. Flowserve RED 2/99 3-1 . the alliances are not rigidly enforced and success will largely depend on local efforts. where much of the expansions will take place. However. enduser personnel are part of the project team and final authority for equipment purchases may fall with the senior end-user person. the plant engineering manager will be a key individual.1 Flowserve Sales PTA production is a global business with estimated annual output of about 14. 50% (excluding Amoco and DuPont) is located in the Asia Pacific region. there are tables for the four regions shown in Exhibit 2 listing the global producers of PTA. The tables in Appendix A show planned expansions totalling 8. possess about 48% of the existing production capacity and represent about 38% of the projected expansions.9 million metric tons (t). 3. a much less costly part than the casing which is the wear surface for open impeller designs. The CBL design offers an oversize chamber which permits excellent access to the seal by an external flush which leads to efficient cooling. One reason is the presence of solids in many of the services. 1 MRO = maintenance. The Flowserve family of sealless pumps can offer operational advantages in many of these services. Finally. the recognized leader in PTA production. Finally. however. to date. Baseline™ PreEngineered Baseplates meets the needs of each customer. For all Amoco PTA plants. operations Flowserve RED 2/99 3-2 . the reverse vane design reduces NPSHR and cavitation problems resulting in much longer pump and mechanical seal life cycles. The ANSI 3A power end positively seals the bearings and bearing lubricant from any potentially harmful conditions existing in the plant thus prolonging bearing life. the Type E heavy-duty baseplate is used to assist in extending MTBPM in these critical applications. Again.PTA Applications For MRO1 purchases. Flowserve chemical process pumps offer some unique features to assist end-users in extending pump life and improving pump performance. However. With only one critical setting for the impeller. The family of SealSentry seal chambers allows the customer to choose a design to maximize seal life and minimize operating costs. These include: • • • • • Mark III reverse vane impeller ANSI 3A power end SealSentry mechanical seal chambers Baseline™ Pre-Engineered Baseplates Sealless pump technology The Mark III reverse vane impeller offers significant operational benefits. the Mark III reverse vane design makes the rear cover/seal chamber the primary wear surface. there are some services where sealless technology would be appropriate. Also. The FM (Flow Modifier) series of seal chambers provides protection for the seal and permits the use of single seals without an external flush. some plants receive guidance from a corporate materials group relating to corrosion problems and contact with these individuals can be beneficial. plant materials personnel can be influential particularly if the plant has experienced corrosion problems. As the primary supplier of chemical process pumps to Amoco. In addition to experience in pump selection and configuration. Baseplate selection is critical to reducing internal pump stress and vibration thus prolonging Mean Time Between Planned Maintenance (MTBPM). Also. valuable experience has been obtained. repair. one can never overlook the purchasing function at the plant level. optimal pump performance can be established with a new installation and is easily restored with a simple impeller clearance adjustment.3 Competitive Advantage of Flowserve Chemical Process Pumps The principal competitive advantage is the company’s in-depth involvement with pump selection and configuration for PTA plants. plant maintenance is a key area. in PTA operations. Sealless pumps have not found widespread acceptance. Pump Recommendations. Flowserve RED 2/99 3-3 . these services will be listed and proven pump configurations will be presented. Many of the liquids will attack Viton and alternate elastomers must be used.PTA Applications 3. In Section 4. Because of the nature of the PTA process. there is a trend toward this type seal in the upstream para-xylene operations and this may be extended to include the PTA operations. Applications for other types of Flowserve pumps will be presented in Appendix B.). Also. 3. Although gas seals have not found widespread use. the recommendations of a Flowserve FSD sealing specialist should be sought. mechanical seals. etc. in PTA plants. flush plans. there is concern about emissions and this must be factored into seal selection. to date.5 Plant and Pump Details There are some common services in all PTA plants that require the same type pump configuration (materials. These seals are normally flushed from an external source.4 Guidelines for Mechanical Seals Many of the services in PTA production involve liquids with solids present. Secondary elastomeric seals must be suitable for the liquids handled. Flowserve RED 2/99 4-1 .PTA Applications 4. and are intended to raise awareness of issues associated with particular applications. These guidelines should not take the place of any manufacturer’s recommended specification for a given application. depending on variables associated with the application. and manufacturers of components/accessories are to be consulted for detailed specifications as well. Pump and Material Recommendations The recommendations that follow are general guidelines. Other specifications not addressed in this manual may be equally or more acceptable. They are based on specifications which have performed well in the field. A qualified pump engineer must still be involved in the specification of any pump. jacketed CBL for higher temperatures. Bearing Housing: ANSI 3A. Pump Material: CF-8M (316 SS). 316 SS or Hastelloy C metal parts). These services are shown below with a listing of the major pump options used in these services. it is not considered abrasive. Seal Flush System: ANSI Plan 7332 (injection of clean. HAC. Baseplate: Type E (reinforced). Flowserve RED 2/99 4-2 . Pump Material: CF-8M (316 SS). cool liquid from external source). casing drain (flanged. Specific TA. however. socket welded with valve).1 Introduction to Pump Recommendations There are a number of common services in all PTA plants. Acetic Acid (HAC). Casing Modifications: Raised face flanges. Mechanical Seal: Single cartridge (carbon/silicon carbide faces. cooling coil added for higher temperatures.2 Terephthalic Acid (TA). Titanium used when temperature exceeds about 270oF (132oC).PTA Applications 4.2. Teflon or Kalrez secondary seals. 4. Also shown are some common pump descriptions used for these services (Appendix B shows an alphabetical listing). Water Comment: This service contains solids (usually catalyst).2 Common Services 4. Water Comment: This service contains solids.1 Terephthalic Acid (TA).2. it is not considered abrasive. Water Services: Pump Description TA Filter Feed TA Filtrate Dry Scrubber Circulation Slurry Return Solvent Stripper Circulation (Ti pump) CRU Centrifuge Feed CRU Mother Liquor CRU Condensate Removal Operating Temperature 197 F (91oC) 156oF (68o) 200-218oF (93-103oC) 197oF (91oC) 273oF (133o) 129-149oF (53-65oC) 129-149oF (53-65oC) 90-122oF (32-50 oC) o 4. After the common services is a listing of some other specific services found in most plants. Seal Chamber: CBL (external flush used). however. Seal Chamber: FML. Baseplate: Type E (reinforced). socket welded with valve). Flowserve RED 2/99 4-3 . Casing Modifications: Raised face flanges. but when present an external flush is used.3 Acetic Acid (HAC). Pump Material: CF-8M (316 SS). Bearing Housing: ANSI 3A. balanced component seal used for high temperature centrifuge feed pumps. Seal Flush System: ANSI Plan 7332 (injection of clean. jacketed for high temperatures. cooling coil added for higher temperatures. Mechanical Seal: Single cartridge (carbon/silicon carbide faces. Teflon or Kalrez secondary seals. Teflon secondary seals. Specific TA. Baseplate: Type E (reinforced). casing drain (flanged. cool liquid from external source). 316 SS or Hastelloy C metal parts). Water Services: Pump Description PTA Solids Filter Feed Filtered Mother Liquor Residue Vent Scrubber Circulation Pressure Centrifuge Feed (jacket seal chamber) PTA Filter Feed Mother Liquor PTA Filtrate Operating Temperature 212oF (100oC) 212oF (100oC) 149-230oF (65-110oC) 212oF (100oC) 305oF (151oC) 192oF (88oC) 212oF (100oC) 165oF (73oC) 4. casing drain (flanged. Seal Chamber: CBL (external flush used). socket welded with valve).2. 316 SS or Hastelloy C metal parts). CBL with ANSI Plan 7332. Seal Flush System: ANSI Plan 7321 (by-pass from discharge through orifice and cooler to seal). Bearing Housing: ANSI 3A. ANSI Plan 7332 when solids present. jacketed CBL for higher temperatures. Water Comment: This service is normally free of solids.PTA Applications Casing Modifications: Raised face flanges. Mechanical Seal: Single cartridge (carbon/silicon carbide faces. Viton secondary seals. socket welded with valve). Seal Chamber: FML. Some of these contain solids and external seal flushes are used. 4. Casing Modifications: Raised face flanges. Seal Chamber: FML. Bearing Housing: ANSI 3A. Bearing Housing: ANSI 3A. cooling coil added for higher temperatures. jacketed for high temperatures. Baseplate: Type E (reinforced). casing drain (flanged.4 Para-xylene Comment: This service is free of solids. Water Services: Pump Description TA Vacuum Seal Fluid Absorber Circulation Mother Liquor Absorber Top Section Solvent Bottoms (jacketed FML) Dehydration Tower Reflux (Plan 7321) Seal Fluid Dehydrated Solvent PX (para-xylene) Decanter Feed PX Stripper Bottoms (Plan 7321) PTA Acetic Acid Feed Operating Temperature 131 F (55oC) 104-111oF (40-43oC) 160F (71oC) 90oF (32oC) 241-277oF (116-136oC) 199oF (92oC) 194oF (90oC) 164-194oF (73-90oC) 90oF (32oC) 217oF (102oC) 98oF (36oC) o 4. CD-4MCuN. casing drain (flanged. Pump Material: CF-8M (316 SS). Pump Material: CF-8M (316 SS). CBL with ANSI Plan 7332.2.PTA Applications Specific HAC. Mechanical Seal: Double cartridge (carbon/silicon carbide faces. but is considered a hazardous fluid. Flowserve RED 2/99 4-4 . 316 SS metal parts). socket welded with valve). Casing Modifications: Raised face flanges.2. Seal Flush System: ANSI Plan 7311 (by-pass from discharge through orifice to seal). This is a potential application for Guardian and ChemStar MD sealless pumps.5 Water Comment: There are many types of water services. Seal Chamber: FML. ANSI Plan 7311 (by-pass from discharge through orifice to seal) used for a few applications. ANSI Plan 7332 when solids present.2. Caustic is used for wastewater treatment and in scrubbing applications. Flowserve RED 2/99 4-5 . casing drain (flanged. flush. 316 SS or Hastelloy C metal parts. Caustic services are potential applications for Guardian. ANSI Plan 7321 (by-pass from discharge through orifice and cooler to seal). Bearing Housing: ANSI 3A. Baseplate: Type E (reinforced). vent & drain glands).6 Caustic (Sodium Hydroxide) Comment: There are a number of caustic services with the sodium hydroxide level within the range 5-50%. Specific Water Services: Pump Description PTA Vacuum Seal Fluid Steam Condensate (CD-4MCuN. Teflon secondary seals. Teflon or EPDM secondary seals. jacketed cover) Condensate Collection Wastewater Booster Wastewater Wastewater Feed Wastewater w/NaOH ESW Wastewater Treated Wastewater Wastewater Treatment Cooling Water Operating Temperature 125oF (51oC) 275oF (135oC) 194-212oF (90-100oC) 126oF (52oC) 80-100oF (26-37 oC) 126-178oF (52-81oC) 110-120oF (43-48oC) 75oF (23oC) 75oF (23oC) 80oF (26oC) 4. all applications should use a quench to avoid solids accumulation on the faces. Baseplate: Type E (reinforced). Casing Modifications: Raised face flanges. Mechanical Seal: Single cartridge (carbon/silicon carbide faces. 316 SS or Hastelloy C metal parts). ChemStar MD and PolyChem sealless pumps. Seal Flush System: Most water services do not use a seal flush system. Pump Material: CF-8M (316 SS). Seal Flush System: Most caustic services do not use a seal flush system. socket welded with valve).PTA Applications Mechanical Seal: Single cartridge (carbon/silicon carbide faces. 4. Teflon secondary seals. 162-183oF (72-83oC). 4. 99oF (37oC). Hastelloy C metal parts). Sodium Bromide.4 Hydrobromic Acid Description: HBr Charge.3 Specific Applications There are a number of specific applications involving only a few pumps. Water Description: Quench Section Recirculation. Below is a listing of these pumps with any significant deviation from the general configuration. Pump Type: Nonmetallic (Fluoropolymer lined). 81oF (27oC). 4. EPDM secondary seals.3.1 Sodium Formate Description: Sodium Formate Transfer. Water Description: Scrubbing Section Recirculation. these pumps are of the general configuration shown above. Hastelloy C metal parts). Mechanical Seal: Single balanced (carbon/silicon carbide faces. In general. Hastelloy C metal parts). Sodium Bromide. Rear cover: FML (no seal flush required). Mechanical Seal: Double (carbon/tungsten carbide faces. Rear cover: FML (no seal flush required). Sodium Bicarbonate. Mechanical Seal: Single cartridge (carbon/silicon carbide faces. Seal Flush System: ANSI Plan 54 (circulation of clean liquid from external source).3. 4. 78oF (25oC) Rear cover: FML (no seal flush required). Water Description: Compressor Area Oily Sewer. EPDM secondary seals. Flowserve RED 2/99 4-6 . Rear cover: FML (no seal flush required). Mechanical Seal: Single balanced (carbon/silicon carbide faces. Alloy 20 metal parts). Mechanical Seal: Single cartridge (carbon/silicon carbide faces.3.2 Sodium Formate.3. EPDM secondary seals.5 Lube Oil.PTA Applications 4. Alloy 20 metal parts). 104oF (40oC) Sodium Formate Charge. 4. 104oF (40oC). Teflon secondary seals.3.3 Sodium Formate. NC Columbia. SC Kingsport.015 545 270 80 90 500 --115 160 -- COMPANY Amoco DuPont Eastman Hoechst (Cape Ind. AL Cape Fear.PTA Applications Appendix A PTA Producers North America OUTPUT (thousands t) Current Expansion 750 1. TN Wilmington. NC Flowserve RED 2/99 A-1 . SC Decatur.) PLANT LOCATION Cooper River. Mexico Paulina.PTA Applications Appendix A PTA Producers Latin America COMPANY Amoco-Petrocel (Temex) Amoco/Rhône-Poulenc (Rhodiaco) Rhône-Poulenc (Rhodia-Ster) Petrocel PLANT LOCATION Cosoleacaque. Brazil Bahia. Brazil Altamira. Mexico OUTPUT (thousands t) Current Expansion 515 130 120 50 90 125 70 -- Flowserve RED 2/99 A-2 . Italy San Roque. Turkey Schwedt. Netherlands Ottana. Germany Yanbu. Quimica Petkim Petro. Saudia Arabia OUTPUT (thousands t) Current Expansion 370 550 -90 200 70 65 350 500 485 290 -150 --350 Flowserve RED 2/99 A-3 . Belgium Wilton.PTA Applications Appendix A PTA Producers Europe COMPANY Amoco Dupont (ICI) Eastman EniChem Int. Und Kraftstoffe Sabic (Ibn Rushd) PLANT LOCATION Geel. UK Rotterdam. Spain Aliaga. ) Amoco-Mitsui Amoco-Samsung ATV Petro.) Amoco (j. Pakistan Kuannyin. Taiwan Map Ta Phut. Thailand OUTPUT (thousands t) Current Expansion 500 1420 --850 120 250 250 --400 450 850 480 270 350 550 -155 225 230 -450 250 250 75 35 -250 420 350 100 -250 350 --250 -250 400 500 250 450 350 ---350 --400 300 -----225 -700 900 Toray Industries Tuntex Petro. Japan Tainan. Korea Tong Yang.v. Taiwan Ulsan. China Yizheng. LG-Caltex (Samnam) Mitsubishi Kagaku Mitsui Sekka Mitsui-Siam Cement Mizushima Aroma Pertamina Reliance Samsung General State owned PLANT LOCATION Kuantan. Korea Utar Pradesh. Japan Rayong.PTA Applications Appendix A PTA Producers Asia Pacific COMPANY Amoco Amoco (Capco j. China Shanghai. India Serang. Malaysia Kaohsiung. Indonesia Patalganga. China Beijing. Korea Nanjiing. Indonesia Ulsan. China Urumiqui. Bakrie Kasei Dae Han ICI DuPont (ICI)-Far East. Taiwan Llan Hsien. Japan Palembang. Flowserve RED 2/99 A-4 . China Merak. Korea Kitakyushu. China Liaoyang. China Tokai. Thailand Mizushima. India Ulsan. Korea Yeochon. Korea Port Quasim. Japan Matsuyama. Textiles Formosa Plastics Kohap Petro. Japan Kuga-gun. Taiwan Zhuhai. Indonesia Pusan.v. Water TA. Water TA. Water TA. Water HAC. HAC. Water TA. Water TA. HAC. Water Water HAC. HAC. Water HAC. Water HAC. Water TA. HAC. Water HAC. Water TA. HAC. Water Water TA. Water TA. HAC. HAC. Water TA. Water TA. Water TA.PTA Applications Appendix B Alphabetical Listing of Pump Descriptions Pump Description Absorber Circulation Absorber Top Section Condensate Collection CRU Centrifuge Feed CRU Condensate Removal CRU Mother Liquor Dehydration Tower Reflux Dry Scrubber Circulation ESW Wastewater Filtered Mother Liquor Mother Liquor Mother Liquor Pressure Centrifuge Feed PTA Acetic Acid Feed PTA Filter Feed PTA Filtrate PTA Solids Filter Feed PTA Vacuum Seal Fluid PX (para-xylene) Decanter Feed PX Stripper Bottoms Residue Slurry Return Solvent Bottoms Solvent Stripper Circulation (Ti pump) Steam Condensate TA Filter Feed TA Filtrate TA Vacuum Seal Fluid Treated Wastewater Vent Scrubber Circulation Wastewater Wastewater Booster Wastewater Feed Wastewater Treatment Cooling Water Wastewater w/NaOH Pump Service HAC. Water HAC. Water TA. Water HAC. HAC. 4-4 4-4 4-5 4-2 4-2 4-2 4-4 4-2 4-5 4-3 4-3 4-4 4-3 4-4 4-3 4-3 4-3 4-5 4-4 4-4 4-3 4-2 4-4 4-2 4-5 4-2 4-2 4-4 4-5 4-3 4-5 4-5 4-5 4-5 4-5 Flowserve RED 2/99 B-1 . Water Water TA. Water Water Water Water Water Water Page No. Water HAC. Water Water TA. Water Water TA. There are also requirements for very large pumps to handle cooling tower. Finally. there are typical utilities applications like boiler feed water services.PTA Applications Appendix C Other Pump Applications The focus of this manual is on the application of Flowserve Chemical Process pumps in PTA operations. However. chiller. Flowserve RED 2/99 C-1 . There are applications like some of those listed for Flowserve Chemical Process pumps but at higher pressures (1250 psi [90 kg/cm2] discharge pressure) and these applications use API pumps. and river water plant feed services. there are potential applications for other types of Flowserve pumps. . 1 Rationale and Methodology 1.1 Flowserve Sales 3. Introduction 1.2 Decision Makers 3.3 Competitive Advantages of Flowserve Chemical Process Pumps 3.1 Market Drivers 2.Titanium Dioxide (TiO 2) Applications Table of Contents Page Number 1.2 The PTA Process 2.5 Plant and Pump Details 4.3 Other Applications Appendix A Appendix B TiO 2 Producers Other Pump Applications 4-2 4-2 4-3 A-1 B-1 3-1 3-1 3-2 3-3 3-3 2-1 2-2 1-1 1-1 Flowserve RED 08/99 i .1 Introduction to Pump Recommendations 4.2 Slurry Applications 4.2 Competition 3. Pump Recommendations 4.4 Guidelines for Mechanical Seals 3. Flowserve Experience 3. Market Profiles 2. Sulfate Process Chloride Process Uses of TiO2 Global Capacity and Demand for TiO2 1-2 1-4 2-1 3-1 Flowserve RED 08/99 ii . 3. 4. 2.Titanium Dioxide (TiO 2) Applications Exhibits Page Number 1. and durability. However. dried.Titanium Dioxide (TiO 2) Applications 1. white powder made from titanium bearing ores that has the power to pigment virtually anything. and this solution is clarified. the processes and services involved in producing TiO 2 result in significant after-market opportunities so this manual is offered as a tool to increase familiarity with this key chemical and its manufacturing technology. and control of emissions. One major disadvantage of the sulfate process is that it produces large quantities of waste materials. The TiO 2 is calcined. Production of TiO 2 is global with many participants. Exhibit 1 is a simplified schematic of the sulfate process. The applications found in a typical TiO 2 plant present a broad range of materials and operational challenges including corrosion. Flowserve chemical process pumps find widespread use in TiO 2 production. features and materials unique to Flowserve chemical process pumps will be highlighted along with the benefits these features provide to end-users.1 Rationale and Methodology Titanium dioxide (TiO 2) is a bright. Kronos (part of NL Industries). however. Flowserve chemical process pumps are standard components in most TiO 2 production facilities. Kemira. six producers account for about 70% of the output. product purity. The reaction mass consists of soluble sulfates of titanium and iron. In this process. and packaged. Below are brief descriptions and discussions of each. and Kerr-McGee. However. Pump configurations that have given dependable service will be given. Growth in demand for TiO 2 is forecast to be about 3% per year over the next five years and there may not be much expansion since there is excess capacity at this time. and the titanium sulfate is hydrolyzed to form TiO 2. 1. ilmenite ore is digested in hot concentrated sulfuric acid. Millenium Inorganic Chemicals (formerly SCM Chemicals). given various aftertreatments to impart specific properties. The properties that make it such a good pigmenting agent include brightness. much effort has been expended to convert some of the Flowserve RED 08/99 1-1 . Flowserve chemical process pumps enjoy widespread use in TiO 2 production. Introduction 1. erosion/corrosion. Because Flowserve can offer such a broad range of materials and because of the applications expertise acquired through close collaboration with the major TiO 2 producers. Tioxide (part of ICI). erosion.2 Production Processes There are two processes used to produce TiO 2: the sulfate process and the chloride process. Crystallization and filtration remove the iron sulfates. ground. These six are: Dupont. opacity. Finally. Titanium Dioxide (TiO 2) Applications Exhibit 2 Chloride Process Ilmenite ore Sulfuric acid Cinder Digestion Roasting Filtration Clarification Sulfuric Acid Concentration Crystallization Evaporation Filtration Crystallization Calcination Aftertreatment Drying Grinding Shipping Packing Flowserve RED 08/99 1-2 . and water treatment chemicals. The TiCl4 is oxidized to produce TiO 2. The sulfate process utilizes ilmenite ore. the most abundant titanium bearing ore. It is believed that over the long-term most TiO 2 production will be through the chloride process. The iron sulfates are processed for use in color pigments. Flowserve RED 08/99 1-3 . TiCl4) and the production of only the rutile form of TiO 2. and produces both crystalline forms of TiO 2: anatase and rutile. The disadvantages of the chloride process include the handling of toxic materials (chlorine. The sulfuric acid that is not recycled is treated to form gypsum. Exhibit 2 is a simplified schematic of the chloride process. which is used in building materials. the rutile bearing ore is reacted with chlorine and coke at a very high temperature to form an intermediate compound. This is essentially a two step process. the anatase form is preferred for paper treatment because it has better optical properties. The ore used is black and before the separation stage of the operation is considered the “black end” of the process. Reference is made in the chloride process to the “black end” of the plant. dried. titanium tetrachloride (TiCl4). ground. uses less energy. The rutile form is generally preferred for paints because it has less chalking and yellowing tendencies and greater hiding power. produces much less waste materials. and packaged.Titanium Dioxide (TiO 2) Applications waste materials into useable products and to recycle most of the sulfuric acid. In the first step. However. which is used by soft-drink manufacturers. The chlorine is recovered and recycled. and carbon dioxide. this process is much more environmentally friendly. However. fertilizers. is filtered. and produces a superior flame-formed rutile crystal. The TiO 2 receives various aftertreatments to impart the desired properties. 1 Market Drivers and Growth There are three principal uses for TiO 2 with a fourth “Other” category of general uses.Titanium Dioxide (TiO 2) Applications 2. Exhibit 3 Uses of TiO2 Other 8% Paper 13% Plastics 20% Coatings 59% Specific applications for TiO 2 include: • Paints (white and colors) • Plastics • Rubber • Paper • Cosmetics • Floor coverings • Glassware and ceramics • Frits for enameling and glazing • Synthetic fibers • Inks • Welding rod • High temperature transducers The demand for TiO 2 is largely driven by consumer spending. However. Market Profile 2. Global GDP growth will be a principal factor in determining demand for TiO 2. capacity exceeded demand by about 20%. In fact. The distribution of use is shown in Exhibit 3. the market began showing Flowserve RED 08/99 2-1 . No significant TiO 2 capacity has been added since about 1995. at the end of 1998. and residential and commercial construction. due to strong objections from the U. In the recent past. Rhone-Poulenc sold its European plants to Millenium Inorganic Chemicals. Flowserve RED 08/99 2-2 . It does seem certain that. with time. Federal Trade Commission (FTC). Bayer sold 80% interest in its German and Belgium operations to Kerr-McGee and its Tibras operation in Brazil to Millenium. Flowserve chemical process pumps have a long history of dependable operation at most plant sites of the major TiO 2 producers. Just recently.2 Competition The usual global competitors will be factors in TiO 2 projects. it has been stated that efficiency now drives this market. and KSB. worldwide capacity will shift toward the Asia/Pacific region.3. However. IDP. These include ITT-Goulds. but nothing major seems to be planned. For the short term.8%). 2. the tentative deal has been terminated. however. Flowserve’s global presence will allow the company to serve this market as it shifts and grows. In late 1997 ICI announced the sale of its Tioxide business unit to Dupont and Kronos. It is estimated that global demand will grow about 3. The ability to assist TiO 2 producers in improving pump reliability will be key because these operations are under tremendous pressure to improve efficiency. Kemira has expressed interest in Tioxide. In fact. TiO 2 operations present some unique pumping challenges and Flowserve chemical process pumps can offer some unique features that will benefit the end-users.S.1% per year through 2003 with the major growth being in the Asia/Pacific region (4. Paintmakers account for such a large part of the demand for TiO 2 that consolidation and globalization in the paint industry has forced consolidation in TiO 2 markets. A growing number of the paintmakers are multinationals and they want to be supplied by the same TiO 2 manufacturer worldwide. no firm deal has been announced.Titanium Dioxide (TiO 2) Applications some life in late 1997 and prices began to rise then. there may be some smaller acquisitions. The features that provide Flowserve chemical process pumps with competitive advantages will be highlighted in Section 3. Three of these companies (Dupont. Asia-Pacific 20% Latin America 5% Asia-Pacific 21% USA & Canada 36% Latin America 4% Europe.Titanium Dioxide (TiO 2) Applications 3. future success will depend.6 metric tons (t). Table 1 below lists these companies and their share of global capacity. there are tables for the four regions shown in Exhibit 4 listing the global producers of TiO 2. Six companies account for 70% of the global production capacity and these companies are all recognized customers for Flowserve chemical process pumps. Middle East. Kemira. on local efforts. 3.4 million metric tons (t)1 and annual demand of 3. as the capacity and demand shifts towards the Asia/Pacific region. Africa 40% USA & Canada 35% In Appendix A. Middle East. Flowserve Experience 3.6 million t.000 kg) Flowserve RED 08/99 3-1 . enduser personnel are part of the project team and final authority for equipment purchases may fall with the senior end-user person. Capacity: 4. Many times.1 Flowserve Sales TiO 2 production is a global business with estimated annual capacity of 4.4 million t.205 lb (1. Exhibit 4 below shows the global distribution of capacity and demand: Exhibit 4 Global Capacity and Demand for TiO2 Demand: 3. Africa 39% Europe. However.2 Decision Makers New plants and major expansions are often handled by an engineering firm and the project manager and rotating equipment expert are key individuals. offer special opportunities. 1 metric ton (t) = 2. in large part. Kerr-McGee) are alliance customers and. as such. With the Mark III reverse vane impeller.346 Share of Global Capacity 23% 14% 10% 9% 7% 6% 30% 100% For MRO1 purchases. plant materials personnel can be influential.3 Competitive Advantage of Flowserve Chemical Process Pumps Flowserve RED has been a principal supplier of chemical process pumps to the major producers of TiO 2 and has gained a wealth of experience in solving the pumping problems confronted in the two processes used in producing this key chemical. however. since the Mark III reverse vane design makes the rear cover/seal chamber the primary wear surface. 3. Also. 1 MRO = maintenance. operations Flowserve RED 08/99 3-2 . many pumps show some erosive wear with time. Again. one can never overlook the purchasing function at the plant level. thousands of t 987 590 473 410 301 241 1. plant maintenance is a key area and for the TiO 2 processes aftermarket parts sales are significant. The environment in many TiO 2 plants can subject pumps to fairly harsh surroundings. The ANSI 3A power end and ISO equivalent positively seals the bearings and bearing lubricant from these surroundings and prolongs bearing life.344 4. Flowserve chemical process pumps have some unique features that will lead to extended pump life. repair. and some plants receive guidance from a corporate materials group relating to materials reliability issues and contact with these individuals can be beneficial. These include: • • • • • • Mark III and Chemstar reverse vane impeller ANSI 3A power end and Chemstar equivalent SealSentry mechanical seal chambers Baseline™ Pre-Engineered Baseplates Materials for erosive services Sealless pump technology The Mark III and Chemstar reverse vane impeller offers many operational benefits in TiO 2 plants.Titanium Dioxide (TiO 2) Applications Table 1 Principal Producers and Share of Capacity Company Dupont Tioxide Millenium Kronos Kemira Kerr-McGee Other Total Capacity. In addition to being able to offer recommendations for improving pump performance based on this experience. Because of the many slurry services found in these processes. any erosion that occurs is on this less costly component. a simple impeller clearance adjustment can compensate for this wear and restore pump performance to like-new levels. Finally. and erosion/corrosion are critical factors in the production of TiO 2. Many of the older pumps were initially supplied with packing and this arrangement is still in use with some units. Because of the harsh surroundings encountered in many applications. 3. There are other chemicals handled in typical TiO 2 operations that may require the use of sealless pumps. but for the more difficult services. CD4MCu offers excellent performance in mild to moderate erosive services. For many of the more severe slurry services. Flowserve chemical process pumps are available in a broad range of materials. The slurry applications offer the greatest challenge in extending pump life. Kemira has standardized on the Polybase design. Baseline™ Pre™ Engineered Baseplates offer a range of options to meet the many requirements found in TiO 2 operations. Standard dual seals with an external flush are used for many slurries. dual seals are utilized and the CBL design is ideal for these services. however. In addition to slurry handling. Later this year. The chloride process produces an intermediate compound. there are significant sealing challenges. TiCl4. Baseplate selection is critical in reducing internal pump stress and vibration thus prolonging Mean Time Between Planned Maintenance (MTBPM). there are many other applications involving chemicals used during processing. slurry seal designs are used. 3. These slurries vary in percent solids and present some real pumping challenges. erosion. The Sealmatic design has found some used since this approach avoids introducing flush liquid into the process.Titanium Dioxide (TiO 2) Applications There are many sealing challenges in TiO 2 operations and the family of SealSentry seal chambers provides choices to create a sealing environment that will maximize seal life and minimize operating costs. that is a very hazardous and toxic material. There are many slurry services and many corrosive chemicals are used in the processes. both standard and special. Corrosion. the recommendations of a Flowserve FSD sealing specialist should be sought. This is a natural application for the Flowserve family of sealless pumps and these pumps have been successfully applied on this critical service. Because of the severity of many of the services found in the TiO 2 process. In fact. the Polybase baseplate finds widespread use. The FM (Flow Modifier) seal chambers provide protection for the seal in many of the slurry services and they permit the use of single seals without an external flush. Selection of the materials of construction will significantly influence pump performance and life. Special materials like DC8 have proven successful in highly erosive services and hard coatings have also extended component life. by-products and waste Flowserve RED 08/99 3-3 .5 Plant and Pump Details The principal pump application in TiO 2 operations is handling the slurries found at various stages in the processes. No other manufacturer routinely offers process pumps in this very hard material and this will provide TiO 2 producers with the proven Flowserve chemic al process pump designs in this very erosion resistant alloy. Other services utilized reinforced designs. an extremely erosion resistant material. a number of Mark III and Chemstar pumps will be available in high chrome iron.4 Guidelines for Mechanical Seals Because of the many slurry applications in TiO 2 production. most applications are being converted to mechanical seals. In Section 4. sealing methods. various pump configurations (materials.) that have proven successful in TiO 2 plants will be presented. etc. Applications for other types of Flowserve pumps will be presented in Appendix B. flush plans. and aftertreatment reagents added to impart specific properties to the TiO 2. Flowserve RED 08/99 3-4 . Pump Applications.Titanium Dioxide (TiO 2) Applications generated. Other specifications not addressed in this manual may be equally or more acceptable. Flowserve RED 08/99 4-1 . A qualified pump engineer must still be involved in the specification of any pump.Titanium Dioxide (TiO 2) Applications 4. These guidelines should not take the place of any manufacturer’s recommended specification for a given application. and manufacturers of components/accessories are to be consulted for detailed specifications as well. and are intended to raise awareness of issues associated with particular applications. Pump and Material Recommendations The recommendations that follow are general guidelines. depending on variables associated with the application. They are based on specifications which have performed well in the field. Below are some specific guidelines for handling TiO 2 slurry pumps: Materials – For standard materials. and high silicon iron (D51M) have found use. Finally. The most serious contamination problem is encountered in the chloride process where some free chlorine can be present. For some highly contaminated slurries. There are widely varying conditions in these slurry handling applications. palladium-stabilized titanium (TiPd). its major shortcoming is that machining is very difficult so production of pump parts has been limited primarily to impellers. Standard horizontal Flowserve chemical process pumps are routinely used to move these slurries. There are also many reagents used at various stages of the processes to improve processing characteristics.50. however. Operating speeds should be minimized and the operating point should be as near the best efficiency point (BEP) as possible. Flowserve’s proprietary cobalt-based alloy. CD-4MCu (CD4M) is widely used in handling TiO 2 slurries. This alloy has very good erosion resistance and has corrosion resistance at least equal to CN-7M (D20). At the end of the processes. This results in grave erosion/corrosion problems. but the problems of handling these slurries are compounded by the presence of contaminants. Some limited use has been made of DC8. Temperatures are usually within the range of ambient to about 200°F (93°C).1 Introduction to Pump Recommendations By far. but performance with these has been mixed. This material possesses good hardness for erosion resistance and has the corrosion resistance to handle many contaminants.Titanium Dioxide (TiO 2) Applications 4. In addition to the TiO 2 slurries. various chemicals are added to the TiO 2 to impart specific properties. Pump selection is a critical factor. These services include chemicals required in the main processes such as the sulfuric acid used to digest the ore in the sulfate process. TiO 2 slurries must be moved through many processing steps in a typical production cycle. Erosive wear is a constant concern. However CN-7M (D20) finds significant use in contaminated slurries where CD-4MCu has inadequate corrosion resistance. high chrome iron wet-end parts will be available. Specific gravity can range from about 1. In the future. there are by-products and waste that must be handled. some components have been supplied with tungsten carbide coatings. titanium (Ti). 4. there are a number of other services requiring Flowserve chemical process pumps. Finally. and the company possesses a wealth of knowledge and expertise regarding materials of construction and pump configurations that have provided reliable service in this difficult environment.00 up to as high as 2. slurry handling is the predominant application for Flowserve chemical process pumps in TiO 2 plants.2 Slurry Applications Erosion is the most serious materials problem confronted in TiO 2 production. This information should be helpful in understanding Flowserve’s successful involvement in the manufacture of this important chemical. Below is a discussion of various Flowserve chemical process pump configurations that have proven successful in many TiO 2 operations. This material has outstanding erosion resistance but fairly poor corrosion resistance so it will not handle Flowserve RED 08/99 4-2 . the standard black Polybase should be replaced with the special GT45 (red) material. The FML seal chamber should be used. this is a common application for Guardian. Sealing – Many older TiO 2 slurry pumps were supplied. if released. Single mechanical seals with FML seal chambers are suitable.3 Other Applications There are many other liquids. If dual seals are specified. another material that has found widespread use with TiO 2 slurry pumps is polymer concrete used to produce the Polybase. that must be pumped during the production of TiO 2. Slurry-type dual seals are used in the tougher slurry services. In the more concentrated slurries. CF-8M and CD-4MCu are commonly used as materials of construction. called “tickle”. Some Sealmatic pumps are being used in TiO 2 slurries particularly where is important not to introduce flush liquid into the process fluid. The Polybase offers the advantage of excellent rigidity plus outstanding corrosion resistance. some of them very corrosive. Titanium tetrachoride (TiCl4) . and are still operating. Because of the difficulties encountered in sealing NaOH. Sodium hydroxide (NaOH) – This chemical is used for pH control. Because this can be a difficult liquid to seal. 4. Above 70% acid concentration. this is an application where magnetic drive pumps are widely used. Both standard and abrasive service designs are used. however.This material. Because of the concentrations and temperatures of the acid handled in typical TiO 2 operations. In the absence of water. is an intermediate chemical in the chloride process. Alloy 20 seal parts may not be suitable and Hastelloy C is the normal material selected. CN-7M (D20) is usually suitable. With time the packing is being changed out to mechanical seals. with packing. however. it is toxic and hazardous.Titanium Dioxide (TiO 2) Applications contaminated slurries. but due to the highly oxidizing nature of acid above 70% concentration. and PolyChem M magnetic drive pumps. The Sealmatic design is normally supplied with a repeller chamber bypass to avoid packing of the solids in the repeller chamber. a steam or water quench must be provided to avoid solids build-up on the seal faces. Although not used for pumping the slurries. For some lower concentration slurries. The Polybase is frequently used with sulfuric acid pumps.3. Chemstar MD.1 Process Chemicals and Intermediates These chemicals are used in the actual process stream: Sulfuric acid (H2SO4) – This chemical is used to digest the ore in the sulfate process. These are divided into five categories below and guidelines for handling these chemicals with Flowserve chemical process pumps are presented: 4. this is not a particularly corrosive liquid. The primary concern in mechanical seal selection is corrosion. dual seals are normally specified. Dual seals are flushed from an external source or a recirculating flush plan may be used. It is handled with standard pumps and Flowserve RED 08/99 4-3 . plus all new pumps are generally supplied this way. However. care must be used in selecting the flush liquid as neither water nor alcohol is suitable. it should be very suitable for the slurries found in the finishing areas. single seals with FML seal chambers are used. The Guardian and ChemStar MD models with CN-7M/Alloy 20 construction are suitable plus the Polychem M series will also be an acceptable alternative. silicon carbide faces are generally used. These properties include drying time. Phosphoric acid can be handled with CF-8M or CD-4MCu. 4. 4. 5. Amines (polyamines) – aminoethane.3. compatibility with vehicle solvents. sodium aluminate 3. 4.3. Single seals with FML seal chambers are suitable. Single seals with 316 SS metal parts are suitable and FML seal chambers are recommended. 5. gloss. photochemical sensitivity. 2. 3. Zinc sulfate Titanium sulfate Sodium silicate Sodium aluminate Phosphoric acid Sulfuric acid Sodium hydroxide The first four chemicals are normally handled with CF-8M or CD-4MCu. TSPP (tetrasodium pyrophosphate). morpholine 5. Below are some common flocculents: 1. chalk resistance. Below are some common end treatment chemicals: 1. diethylene triamine 4. 6. Alkali salts – sodium silicate.2 Dispersants These chemicals are added to the TiO 2 slurries during processing to improve slurry stability. 3. 4. CF-8M/316 SS units are suitable. Polyorganic acid salts – sodium citrate These chemicals are not very corrosive and are generally handled with CF-8M or CD-4MCu. 7.3. Flowserve RED 08/99 4-4 . TKPP (tetrapotassium pyrophosphate). but this is a prime candidate for Guardian and Chemstar M magnetic drive pumps. Below are the general categories of dispersants with a few examples of each: 1. STPP (sodium tripolyphosphate) 2. color stability. Amino alcohols – amino methyl propanol. and tinting strength. sodium borate. along with CF-8M to handle these chemicals. Single seals with FML seal chambers are suitable.3 Flocculents These chemicals are added to the TiO 2 slurries to increase the efficiency of filtration. 2.4 End Treatment Chemicals These chemicals are used to impart specific properties to the end product. Single seals with FML seal chambers are suitable. Phosphates – TSP (trisodium phosphate). Sulfuric acid and sodium hydroxide are covered above. Sodium chloride Sodium sulfate Magnesium sulfate Aluminum sulfate Aluminum chloride CD-4MCu is commonly used. particularly for the chlorides.Titanium Dioxide (TiO 2) Applications elaborate seal systems. 4. sodium hypochlorite (NaOCl). the FRP self-priming pump has found use. The common metallic material used is titanium. If metallic materials are required. The chlorine is stripped from the TCE and returned to the process. Hydrochloric acid is commonly handled with non-metallics like Durcon 730 FRP (fiber reinforced plastic) and the fluoropolymers (PTFE/PFA). Trichloroethylene (TCE) is used to absorb chlorine that is not reacted with the ore. Pollution Abatement Some of the most corrosive services in a TiO 2 plant are found in this area. Because of the difficulties encountered in sealing HCl. Again sealing is difficult and the PolyChem M series will find use here. although high silicon iron (D51M) is also suitable. It reacts with chlorine (Cl2) and forms sodium hypochlorite (NaOCl).Titanium Dioxide (TiO 2) Applications 4. TCE is not a corrosive chemical and is normally handled with ductile iron (DCI). Specific knowledge of the wastewater composition is required to select the proper materials. then the Hastelloys are normally used. For non-metallics. Flowserve RED 08/99 4-5 . hydrochloric acid (HCl). the fluoropolymers are used. Sodium hypochlorite is very corrosive chemical. Either costly single seals are required or dual seals with the attendant flushing requirements are used. Where applicable. Other chemicals found in this category include sodium hydroxide (NaOH). and contaminated wastewaters. The contaminated wastewaters are handled with non-metallics and higher alloy metallics. By-Products. Sodium hydroxide (NaOH) is used in scrubbing gaseous effluents from the chloride process.3.5 Recycling. the PolyChem M series pumps will be ideally suited for this service. The handling of sodium hydroxide is covered above. A single mechanical seal with the FML seal chamber is also used. There is one organic chemical used in the recycling part of a chloride plant that is not corrosive. Sealing of HCl is difficult and costly. Wastes. GA Hamilton. PQ (Canada) Lake Charles. DE Antioch. OH Baltimore. MS Varennes. LA Ashtabula.Titanium Dioxide (TiO2) Applications Appendix A TiO2 Producers USA and Canada COMPANY Dupont Kemira Kerr-McGee Kronos Louisiana Pigment Millenium Inorganics PLANT LOCATION De Lisle. MS Edgemoor. MD OUTPUT (thousands t) Chloride Sulfate 280 128 38 320 91 54 145 55 20 110 104 86 51 44 Flowserve RED 08/99 A-1 . TN Savannah. CA New Johnsonville. Titanium Dioxide (TiO2) Applications Appendix A TiO2 Producers Latin America COMPANY Dupont Tibras Titanio PLANT LOCATION Altamira. Mexico Salvador. Brazil OUTPUT (thousands t) Chloride Sulfate 100 55 Flowserve RED 08/99 A-2 . Belgium Uerdingen. Ger. France Calais. South Africa OUTPUT (thousands t) Chloride Sulfate 24 105 90 56 55 105 35 60 31 109 80 65 110 35 110 81 80 80 80 45 Flowserve RED 08/99 A-3 . UK Greatham. Spain Grimsby. Finland Rotterdam.Titanium Dioxide (TiO2) Applications Appendix A TiO2 Producers Europe. UK Duisburg-Hamborn. Le Havre. Germany Pori. France Scarlino. Germany Nordenham. Italy Huelva. Belgium Leverkusen. Norway Stallingborough. Middle East. Germany Fredrikstad. Netherlands Gent. UK Johannesburg. and Africa COMPANY Bayer Kemira Kronos Millenium Inorganics Sachtleben Saudi Arabia-Other Thann et Mulhouse Tioxide PLANT LOCATION Antwerp. France Thann. Malaysia Kwinana.Titanium Dioxide (TiO2) Applications Appendix A TiO2 Producers Asia-Pacific COMPANY China . Australia OUTPUT (thousands t) Chloride Sulfate 113 88 36 22 55 100 42 166 79 50 80 Flowserve RED 08/99 A-4 .Other Dupont Hankook India . Japan Jurong.Other Ishihara Sangyo Japan . Australia Telok Kalung. Tioxide Tiwest PLANT LOCATION Kuan Yin. Singapore Bunbury. Taiwan Inchon. Korea Yokkaichi.Other Millenium Inorg. In addition. There may also be requirements for very large pumps to handle various water applications. it is not uncommon for the sulfate operations to have a captive sulfuric acid plant. Flowserve RED 08/99 B-1 . These sorts of applications must be sought out at any TiO 2 facility. However.Titanium Dioxide (TiO 2) Applications Appendix B Other Pump Applications The focus of this manual is on the application of Flowserve chemical process pumps in TiO 2 operations. Many plants have their own power plants so there are boiler feed water applications. there are potential applications for other types of Flowserve pumps. . 5 Operating Unit and Pump Details 4. Pump Recommendations 4.2 Competition 3.3 Competitive Advantages of Flowserve Petroleum Process Pumps 3.1 Flowserve Sales 3. Flowserve Experience 3.2 Charge Pump and Hydraulic Turbine 4.1 Market Drivers 2.2 Hydrocracking Process 2.Hydrocracking Applications Table of Contents Page Number 1. Introduction 1.4 Guidelines for Mechanical Seals 3.1 Introduction to Pump Recommendations 4.1 Rationale and Methodology 1.2 Decision Makers 3.3 Other Hydrocracking Unit Pumps Appendix A Appendix B Appendix C Hydrocracker Units API Material Designations for Pumps and Mechanical Seals Other Pump Applications 4-2 4-2 4-2 A-1 B-1 C-1 3-1 3-1 3-2 3-3 3-3 2-1 2-1 1-1 1-1 Flowserve RED 12/99 i . Market Profiles 2. Typical Hydrocracker Unit 2. Global Distribution of Hydrocracking Capacity 4. Typical Power Recovery Turbine Arrangements 1-3 2-1 3-1 4-4 Flowserve RED 12/99 ii . World Oil Consumption 3.Hydrocracking Applications Exhibits Page Number 1. Heavy (large) hydrocarbon molecules are decomposed. Flowserve possesses a wealth of applications and problem solving expertise. converts the fractions into intermediate streams that eventually become finished products. solvent extraction. jet fuel. Refiners have spent much time and effort on the conversion step because this is where the money is made in a refinery through the conversion of low value fractions to high value products. Some useable products are realized here. these are complex systems with multiple operations and the specific operations found at any given refinery will depend on the properties of the crude oil being refined and the desired product output. dependable service. but the use of a catalyst has largely replaced pure thermal cracking because this results Flowserve RED 12/99 1-1 . Cracking means decomposition by heat. customer specifications and government standards. purifying. or “cracked”. dewaxing. The conversion step.2 Hydrocracking Process There are three basic steps in refining: separation.Hydrocracking Applications 1. according to weight and boiling point. catalytic reforming. polymerization. coking. hydrotreating. the manual will present proven pump configurations that have provided reliable. The separation step is essentially fractional distillation where liquids and vapors are separated into components. The exact composition of crude oils varies significantly depending on their source. kerosene. Cracking can be performed by heat alone. Crude oil is a mixture of many different hydrocarbons and small amounts of impurities.1 Rationale and Methodology The petroleum refining industry consists of approximately 700 facilities located around the world. Finally. This manual will look at one downstream process—hydrocracking—in some detail with the goal of increasing familiarity with this key operation. conversion. catalytic cracking. also called downstream processing. and naphtha. isomerization. there is the treatment step where streams are carefully combined through blending. Common conversion processes include thermal cracking (visbreaking). Even though the basics of all refineries are the same. A petroleum refinery is a factory that takes a raw material—crude oil—and turns it into finished products. The most commonly used conversion method is cracking. Because no two refineries are the same. but more commonly. Through long and close collaboration with the major refiners in the world. and fine-tuning to produce finished products that meet market demand. In addition to discussing hydrocracking technology. or fractions. primarily gasoline. into lighter (smaller) molecules. Introduction 1. and treatment. propane deasphalting. Flowserve petroleum process pumps enjoy widespread use in all phases of refining. the fractions are sent on to the conversion step. features unique to Flowserve petroleum process pumps will be highlighted along with the benefits these features provide to end-users. the application requirements present a broad range of pumping challenges. most notably gasoline but also hundreds of other useful products including diesel fuel. alkylation. Finally. catalytic hydrocracking. 1. and many others. It offers the capability for upgrading existing facilities to produce lighter products. hydrocracking is the best source of low-sulfur. Two-stage configurations can handle a wider range of feedstocks and feed rates with nearly complete conversion. is used to process the most difficult to crack fractions. Catalytic cracking in the presence of hydrogen. while optimizing catalyst performance and prolonging catalyst life. hydrocracking has gained worldwide recognition for the high-quality distillates it produces. In addition to producing gasoline. in this environmentally conscious period. replacing hydrotreating. And. Flowserve RED 12/99 1-2 . With twostage systems. The feedstock is often hydrotreated first to remove impurities (hydrogen sulfide and ammonia) that will poison the catalyst. The unit utilizes a fixed-bed catalytic cracking reactor operating at pressures up to 3000 psig (210 kg/cm2) and temperatures up to 700oF (370oC). It is the most versatile of the conversion operations and can process a wide range of feedstocks. Two factors drove the development of this process: heavy demand for gasoline and the availability of large amounts of byproduct hydrogen from catalytic reformer units. impurities can be removed in the first stage. Hydrocracking was developed in 1962 by Chevron.Hydrocracking Applications in higher yields of gasoline. Hydrocracking technology is being continually improved. Exhibit 1 is a simplified schematic of a single-stage hydrocracker unit. low-aromatics diesel fuel as well as high-smoke-point jet fuel. or hydrocracking. Two-stage systems are also very common. it is a common process selection because it offers so much operating flexibility. The hydrocracking catalysts are typically regenerated off-site after two to four years of use. For grassroots facilities. EXHIBIT 1 TYPICAL HYDROCRACKER UNIT MAKEUP HYDROGEN PROCESS GAS HYDROGEN RECYCLE LIGHT NAPTHA F R A C T I O N A T O R HEAVY NAPTHA R E A C T O R FURNACE HP S E P A R A T O R LP S E P A R A T O R KEROSENE JET FUEL DIESEL FEED PUMP MOTOR HYD. TURBINE SOUR WATER RECYCLE Flowserve RED 12/99 1-3 . Today. However. Exhibit 1 shows crude oil consumption now and the projected consumption in 2005 for four regions of the world. One forecast predicts that gasoline supplies are adequate and demand will grow about 2% per year through 2005. For many refiners. demand for other transportation fuels—most notably jet and diesel fuels—will grow much more rapidly through this period at a rate of 5-6% per year. Middle East. Regional competitors are Ebara and Shin-Nippon in the Asia-Pacific region and David Brown in Europe. expanding hydrocracking capacity is one way to meet this growing demand. Africa Asia-Pacific Latin America 1999 2005 Projected growth rates in consumption in these regions between now and 2005 are: USA & Canada Europe.1 Market Drivers Refiners today are finding that increased demand for high-quality transportation fuels is forcing them to convert a higher percentage of crude oil to lighter products. Flowserve’s global presence will allow the Flowserve RED 12/99 2-1 .Hydrocracking Applications 2. Exhibit 2 World Oil Consumption Million barrels per day 35 30 25 20 15 10 5 0 USA & Canada Europe. Middle East. refiners can maintain profitability without sacrificing yield or product quality. Africa region. However. future growth will be elsewhere. petroleum refining is a global endeavor. Obviously. Middle East. Market Profile 2.2 Competition The primary global competitors in hydrocracker projects are IDP and Sulzer. much of the hydrocracking capacity is located in the USA. Flowserve petroleum process pumps have a long history of dependable service in petroleum refineries all over the world. With hydrocracking. Africa Asia-Pacific Latin America 9% 12% 19% 23% 2. Hydrocracking Applications company to participate in the refining market as hydrocracker units are de-bottlenecked and added to refineries worldwide. Petroleum refining is a very competitive and costconscience business and the company’s ability to assist refiners in improving pump reliability will be key as this can lead to improved profitability. The features that provide Flowserve petroleum process pumps with competitive advantages will be highlighted in Section 3.3. Flowserve RED 12/99 2-2 . Hydrocracking Applications 3. The global distribution of this capacity is shown in Exhibit 3. Also. These two regions of the world will likely see growth in hydrocracking capacity over the next five years. Africa 33% As was shown in Exhibit 2. Even though an engineering firm may handle the design and construction of the unit. Flowserve RED 12/99 3-1 . In Appendix A.1 Flowserve Sales Hydrocracking capacity worldwide is about 3. Past experience with hydrocracker applications will weigh favorably for potential charge pump and hydraulic turbine suppliers. if a hydraulic turbine is part of the system. Flowserve Experience 3. 3. the growth in oil consumption is projected to be greatest in Latin America and the Asia-Pacific regions. Middle East. Exhibit 3 Global Distribution of Hydrocracking Capacity Asia-Pacific 20% Latin America 4% USA & Canada 43% Europe. this component will most likely come from the same supplier as the charge pump since they will be operated together. The buying decision involving the process pumps is much more subject to competitive pressures. although here again.75 MMbpd (million barrels per day). locations with the lowest hydrocracking capacity.2 Decision Makers The charge pump is a key component in any hydrocracker unit. there are tables for the four regions shown in Exhibit 3 listing the locations and capacities of the existing hydrocracking units. experience and installed base are important considerations. the end-user will generally be heavily involved in the selection of the charge pump supplier. lubricated babbitt-lined radial bearings. + there is uniform heat distribution throughout the pump inner case. double-suction impeller design The axially split inner casing design offers many operational benefits in hydrocracker units: + the design is inherently safe at any pressure. High temperature is the major cause of seal problems. The SCE family of pumps. pivot-shoe thrust bearings and self-aligning. double-suction impeller design gives the user the benefits of: + low NPSH requirements. Finally. offers some unique features that will increase pump performance and reliability. + the axial hydraulic loads are inherently balanced. which are fully compliant with API 610 (8th Edition). In fact. but new seal developments. Flowserve RED 12/99 3-2 . overhung and between bearings API process pumps. and multistage. the very large installed base of these pumps provides a history of successful performance in all types of petroleum services. + the fully assembled rotating element is balanced as a unit. which is fully compliant with API 610 (8th Edition). + elimination of need for a separate booster pump. The most critical pump service in a hydrocracker unit is the charge feed pump. The Flowserve HDO pump is the ideal selection for this critical service. The special bearing construction consists of double-acting. double-case pumps are normally used. Also. These features include: • • • Axially split inner casing design Special bearing construction First-stage. + all running clearances remain concentric due to special inner casing machining. the advice of a Flowserve FSD sealing specialist should be sought. can handle a very broad range of single stage applications. dependable pumping equipment to the petroleum industry and has gained a wealth of experience through handling the critical services found in refinery applications.Hydrocracking Applications 3. This pump must be able to handle very high pressures and temperatures. The construction offers the benefits of: + maximum reliability. The HDO design. seal failures were a significant problem with early hydrocracker units. The other pump applications in hydrocracker units can normally be handled by singlestage. The Flowserve overhung designs combine a long history of expertise and experience. the optional first-stage.3 Competitive Advantages of Flowserve Petroleum Process Pumps Flowserve has achieved a reputation for supplying high quality. Proper seal selection is critical to trouble-free operation and because of the severity of many of the applications. 3. have lead to acceptable seal life. particularly the introduction of metal bellows designs.4 Guidelines for Mechanical Seals There are many challenging mechanical seal applications in a hydrocracker unit. + reduced maintenance costs. + low noise levels. and any auxiliary pumps must provide reliable service for the unit to operate dependably and profitably.5 Operating Unit and Pump Details The critical application in a hydrocracker unit is the charge pump. flush plans.Hydrocracking Applications 3. Flowserve RED 12/99 3-3 . proven pump configurations (materials. However.) will be presented. the process pumps. seals. etc. Pump Applications. If a hydraulic turbine is used. it will be coupled to the charge pump and it also represents a critical component in the system. In section 4. water handling pumps. Pump and Material Recommendations The recommendations that follow are general guidelines. They are based on specifications which have performed well in the field. A qualified pump engineer must still be involved in the specification of any pump. and manufacturers of components/accessories are to be consulted for detailed specifications as well. These guidelines should not take the place of any manufacturer’s recommended specification for a given application.Hydrocracking Applications 4. Flowserve RED 12/99 4-1 . depending on variables associated with the application. Other specifications not addressed in this manual may be equally or more acceptable. and are intended to raise awareness of issues associated with particular applications. 2 Splitter Charge Pump Operating conditions: 450 oF (232oC). Exhibit 4 shows schematics for two typical PRT arrangements.1 Introduction to Pump Recommendations The key pump in a hydrocracking unit is the charge pump. 120 psig discharge pressure.3. 4. It is not uncommon practice to utilize a hydraulic turbine (also called a power recovery turbine or PRT) in conjunction with the reactor charge pump. Mechanical seal: Metal bellows. API code – BSTRX. Recommended pump: Byron Jackson® Type SCE. An auxiliary sealing device comprised of a close clearance floating carbon throttle bushing is also used. An API Plan 32 seal flushing system and an API Plan 62 auxiliary system with an anti-coking device are included. 4. Auxiliary seal systems: API Plan 32. API Plan 62 with anti-coking device. The API 610 material designation normally specified for this service is either C-6 or A-8 (see Appendix B). API material code – C-6 or A-8. Recommended pump: Byron Jackson® Type SCE.1 Recycle Pump Operating conditions: 670 oF (354oC). Auxiliary seal systems: API Plan 32. From onethird to one-half the power required by the reactor charge pump can come from the turbine. Metal bellows seals are normally used with an API 610 seal code of BSTRN (see Appendix B). close clearance floating carbon throttle bushing. a double case. API material code – S-5 or S-6. Because of the high temperature and pressure encountered in this application.3. The same pump configuration detailed above for the reactor charge feed application would be used for the hydraulic turbine. API code – BSTRX. Below is a discussion of typical Flowserve petroleum process pump applications and representative pump configurations that have proven successful in hydrocracking units. This information should be helpful in understanding Flowserve’s involvement in this critical refinery process.2 Charge Pump and Hydraulic Turbine Typical operating conditions for the reactor charge pump in a hydrocracking unit are 450oF (232oC) liquid temperature and 3.3 Other Hydrocracking Unit Pumps There are a number of other applications with the hydrocracking unit and these are listed below with comments relative to typical configurations: 4. 200 psig discharge pressure. API Plan 62 with anti-coking device. Flowserve RED 12/99 4-2 . Mechanical seal: Metal bellows. The Flowserve petroleum process pump best suited for this service is the Byron Jackson® Type HDO.000 psig (207 bar) discharge pressure. there are a number of other services requiring Flowserve petroleum process pumps. The turbine is essentially the same as the reactor charge feed pump except the liquid enters the discharge and exits the suction. close clearance floating carbon throttle bushing.Hydrocracking Applications 4. Mechanical seal selection is key to trouble-free operation of this critical pump. however. The turbine develops power from the pressure reduction of the liquid leaving the high-pressure separator. multistage pump is normally used. The power developed by the turbine is used to operate the reactor charge pump. 4. Mechanical seal: Pusher seal.6 Kerosene Pump Operating conditions: 390 oF (199oC). 250 psig discharge pressure. Recommended pump: Byron Jackson® Type SCE.Hydrocracking Applications 4.3. 200 psig discharge pressure. Auxiliary seal systems: API Plan 11. API Plan 62 with anti-coking device.3. close clearance floating carbon throttle bushing. 4. Auxiliary seal systems: API Plan 11.5 Heavy Naphtha Pump Operating conditions: 235 oF (113oC). 140 psig discharge pressure. 4. close clearance floating carbon throttle bushing. Mechanical seal: Pusher seal. close clearance floating carbon throttle bushing. Recommended pump: Byron Jackson® Type TSHO. Flowserve RED 12/99 4-3 .4 Stabilizer Reflux Pump Operating conditions: 100 oF (38oC). API material code – S-5. API code – BSTRN. 430 psig discharge pressure.3. API material code – S-5. API Plan 62 with anti-coking device. API code – BSTFM. Recommended pump: Byron Jackson® Type SCE. API material code – S-5. 4. Mechanical seal: Metal bellows. 4. Auxiliary seal systems: API Plan 11. Recommended pump: Byron Jackson® Type SCE. API code – BSTFX. close clearance floating carbon throttle bushing. Auxiliary seal systems: API Plan 11. API code – BSTRN. Mechanical seal: Metal bellows. Recommended pump: Byron Jackson® Type SCE.3. API Plan 62 with anti-coking device.3. API material code – S-5. Mechanical seal: Pusher seal. API code – BSTFM. close clearance floating carbon throttle bushing. 130 psig discharge pressure.3 Stabilizer Feed Pump Operating conditions: 450 oF (232oC).7 Diesel Pump Operating conditions: 500 oF (260oC). Auxiliary seal systems: API Plan 11. API material code – S-5. API Plan 62 with anti-coking device. Hydrocracking Applications EXHIBIT 4 TYPICAL POWER RECOVERY TURBINE ARRANGEMENTS FEED PUMP ELECTRIC MOTOR CLUTCH POWER RECOVERY TURBINE Arrangement 1 ELECTRIC MOTOR GEAR FEED PUMP CLUTCH POWER RECOVERY TURBINE Arrangement 2 Flowserve RED 12/99 4-4 . 0 53.5 26. CITY Mbpd1 18.9 33.0 29.6 12.0 23.1 18.0 32.0 113.0 109.) Alberta New Brunswick Newfoundland Ontario Ontario Ontario Ontario Saskatchewan Edmonton St.0 23.0 17.4 50.0 10.0 4.0 17.0 15.0 28.0 10.6 45.3 6.0 114.1 46.2 4.000 barrels per day Flowserve RED 12/99 A-1 .5 19. Imperial Oil Petro-Canada Shell Canada Sunoco Consumer Co-op Puerto Rico United States Sun Tesoro Alaska Petro.7 29. Mississippi Montana Ohio Ohio Ohio Oklahoma Pennsylvania Texas Texas Texas Texas Texas Texas Texas Texas Valero Energy Atlantic Richfield Ergon-West Virginia 1 CAPACITY.2 24.0 36.7 31.Hydrocracking Applications Appendix A Hydrocracker Units .0 36.0 22.0 4.6 18.8 24. Sham.0 142.0 10. Tosco BP Amoco Costal Exxon Mobil Motiva Shell Deerpark Ultramar Dia.USA and Canada LOCATION COUNTRY Canada COMPANY Petro-Canada Irving Oil North Atlantic Ref.8 34.5 43.5 20. John Comeby Chance Sarnia Mississauga Sarnia Sarnia Regina Yabucoa Kenai Carson El Segundo Richmond Wilmington Bakersfield Martinez Benicia Torrance Los Angeles San Francisco Delaware City Kapolei Blue Island Lake Charles Westlake Baton Rouge Chalmette Convent Norco Pascagoula Billings Toledo Lima Toledo Wynnwood Trainer Texas City Corpus Christi Baytown Beaumont Port Arthur Deerpark Three Rivers Sunray Corpus Christi Ferndale Newell Texas Washington West Virginia Mbpd = 1.0 28.0 26.8 64.5 25.8 64. Atlantic Richfield Chevron Alaska California California California Equilon California California California Exxon Mobil Tosco California California California California Motiva Tesoro Clark Citgo Conoco Exxon Mobil Motiva Delaware Hawaii Illinois Louisiana Louisiana Louisiana Louisiana Louisiana Louisiana Chevron Exxon BP Amoco Clark Sun Gary-Williams Eng.5 13.9 24.8 STATE (PROV. Concon Pemex Petro. Mbpd1 26.1 COUNTRY Argentina Chile Mexico Trinidad Venezuela 1 COMPANY YPF.5 47. De Petro.A.Hydrocracking Applications Appendix A Hydrocracker Units Latin America CAPACITY.000 barrels per day Flowserve RED 12/99 A-2 . S. Co.0 10.0 18.0 9. of Trinidad Corpoven LOCATION Lujan de Cuyo Talcahuano Concon Salamanca Pointe-a-Pierre Judibana Falcon Mbpd = 1.0 52. Petrox Ref. 5 26. Shell U.5 9.0 50.4 38. Di Milazzo Saras Ivory Coast Jordan Kuwait Soc.0 10.1 4.0 12.3 22. Oil Co.6 6.0 39.6 2.Hydrocracking Applications Appendix A Hydrocracker Units Europe. Ref. Russia Omsk. Middle East.0 15.2 15.3 31.0 45. Coraf Ina Ref. Bratislava Sasolburg Tarragona Brofjorden-Lysekil Collombey Banias Izmir Izmit Kirikkale United Arab Emirates United Kingdom Abu Dhabi Nat'l. COUNTRY Bahrain Congo Croatia Czech Republic Finland FSU Bahrain Petro.0 36. Kuwait Nat'l.7 24. Jordan Petro.5 Ruwais Shell Haven Grangemouth Mbpd = 1.K. Raff. Ivoirienne de Raff.8 17. Priolo Gargello Milazzo Sarroch Abidjan Zerka Mina Abdulia Mina Al-Ahmadi Shuaiba Netherlands Esso Nederland Shell Nederland Total Poland Portugal Romania Saudi Arabia Petrochemia Petrogal Arpechim Petromin Shell Saudi Aramco Rotterdam Pemis Vissingen Plock Sines Petesti Ras Al Khafji Ras Tanura Jeddah Riyadh Slovakia South Africa Spain Sweden Switzerland Syria Turkey Slovnaft Nat'l.0 33. Refiners Repsol Petro.0 14. Chemopertrol Neste Oy P. Turkish Petro. Russia Lavera Wesseling Godorf Gelsenkirchen Lingen Aspropyrgos Sannazzaro Tarento Isab SpA.0 44.O. Agip Raffinazione COMPANY Sitra Pointe-Noire Rijeka Litvinov Porvoo Slavneft-Mozyr.0 16.0 28.2 19.5 15. Bashneftekhimzavody Sibneft France Germany Ste.0 11.0 48. Petro. Des Petroles DEA Mineraloel Deutsche Shell Veba Oel/Ruhr Oel Wintershall Greece Italy Hellenic Petro.2 9.4 25. Skandinaviska Raff.0 36.0 30.0 30. Petro.4 23. Fran.000 barrels per day Flowserve RED 12/99 A-3 .0 16. Tamoil Banias Ref.0 23.7 49.9 25.5 65.2 44.0 31. and Africa CAPACITY.0 14.0 19. Naftan Ref.0 11. BP 1 LOCATION Mbpd1 48.0 30.0 87. Ref. Belarus Ufaneftekhim. Table H-1 – Materials for Pump Parts Material Class and Material Abbreviationsa I-1 Fullb Compliance Material? Yes No CI CI I-2 STL S-1 STL S-3 STL S-4 STL S-5 STL S-6 STL S-8 STL S-9 C-6 12% CHR A-7 AUS A-8 316 AUS D-1 DUPLEX Hydrocracking Applications Flowserve RED 12/99 B-1 a b Part Pressure Casing Inner case parts (bowls, diffusers, diaphragms) Impeller Case wear rings Impeller wear rings Shaft (2) Shaft sleeves, packed pumps Shaft sleeves, mechanical seals Throat bushings Interstage sleeves Interstage bushings Seal gland Case and gland studs Case gasket CI Cast Iron Cast Iron BRZ Cast Iron Bronze CI Carbon Steel Cast Iron NI-RESIST Carbon Steel Ni-resist STL Carbon Steel Cast Iron STL 12% CHR Carbon Steel Carbon Steel 12% CHR Carbon Steel 12% CHR 316 AUS Carbon Steel 316 AUS MONEL Carbon Steel Monel 12% CHR 12% CHR 12% CHR AUS (1&2) AUS AUS 316 AUS (1 & 2) 316 AUS 316 AUS DUPLEX Duplex Duplex Yes No No Yes No Cast Iron Cast Iron Cast Iron Carbon Steel 12% CHR hardened AUS or 12% CHR Cast Iron Cast Iron Cast Iron 316 AUS (5) Carbon Steel AUS, spiral wound (6) Carbon Steel Nitrile (7) Carbon Steel Bronze Bronze Bronze Carbon Steel Hard bronze AUS or 12% CHR Bronze Bronze Bronze 316 AUS (5) Carbon Steel AUS, spiral wound (6) Carbon Steel Bronze Carbon Steel Cast Iron Cast Iron Cast Iron Carbon Steel 12% CHR hardened AUS or 12% CHR Cast Iron Cast Iron Cast Iron 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) Carbon Steel Filled carbon Carbon Steel Ni-resist Ni-resist Ni-resist Carbon Steel 12% CHR hardened or hard faced AUS or 12% CHR Ni-resist Ni-resist Ni-resist 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) Carbon Steel Nitrile (7) Carbon Steel Carbon Steel Cast Iron Cast Iron Carbon Steel 12% CHR hardened or hard faced AUS or 12% CHR Cast Iron Cast Iron Cast Iron 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) Carbon Steel Filled carbon Carbon Steel Carbon Steel 12% CHR 12% CHR Hardened AISI 4140 12% CHR hardened or hard faced AUS or 12% CHR 12% CHR 12% CHR hardened 12% CHR hardened 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) Carbon Steel Filled carbon 316 AUS 12% CHR 12% CHR 12% CHR Hardened AISI 4140 (4) 12% CHR hardened or hard faced AUS or 12% CHR 12% CHR 12% CHR hardened 12% CHR hardened 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) Carbon Steel Filled carbon 316 AUS 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS Hard Faced 316 AUS (3) AUS or 12% CHR 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS (5) AISI 4140 Steel 316 AUS, spiral wound (6) Carbon Steel Filled carbon 316 AUS Monel Monel Monel K-Monel K-Monel, hardened K-Monel, hardened Monel K-Monel, hardened K-Monel, hardened Monel K-Monel, hardened (8) Monel, spiral wound, PTFE filled (6) Carbon Steel Filled carbon K-Monel 12% CHR 12% CHR hardened 12% CHR hardened 12% CHR 12% CHR hardened or hard faced AUS or 12% CHR 12% CHR hardened 12% CHR hardened 12% CHR hardened 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) AUS Filled carbon 316 AUS AUS Hard Faced AUS (3) Hard Faced AUS (3) AUS Hard Faced AUS (3) AUS AUS Hard Faced AUS (3) Hard Faced AUS (3) 316 AUS (5) AISI 4140 Steel AUS, spiral wound (6) AUS Filled carbon 316 AUS 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS Hard Faced 316 AUS (3) 316 AUS 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS (5) AISI 4140 Steel 316 AUS spiral wound (6) 316 AUS Filled carbon 316 AUS Duplex Duplex (3) Duplex (3) Duplex Duplex (3) Appendix B No No No No Yes Yes No Duplex Duplex Duplex (3) Duplex (3) Duplex (5) Duplex (8) Duplex SS spiral wound (6) Duplex Filled carbon Duplex Discharge head/ suction can Column/bowl shaft bushings Wetted fasteners (bolts) Yes No Yes The abbreviation above the diagonal line indicates the case material; the abbreviation below the diagonal line indicates trim material. Abbreviations are as follows: BRZ = bronze, STL = steel, 12% CHR = 12% chrome, AUS = austenitic stainless steel, CI = cast iron, 316 AUS = Type 316 austenitic stainless steel See 2.11.1.1 Hydrocracking Applications Appendix B Reference and General Notes for Table H-I: 1. Austenitic stainless steels include ISO Types 683-13-10/19 (AISI Standard Types 302, 303, 304, 316, 321, and 347). If a particular type is desired, the purchaser will so state. 2. For vertically suspended pumps with shafts exposed to liquid and running in bushings, the shaft shall be 12 percent chrome, except for Classes S-9, A7, A-8, and D-1. Cantilever (Type VS5) pumps may utilize AISI 4140 where the service liquid will allow. 3. Unless otherwise specified, the need for hard-facing and the specific hard-facing material for each application shall be determined by the vendor and described in the proposal. Alternatives to hard-facing may include opening running clearances (2.6.4) or the use of non-galling materials, such as Nitronic 60 and Waukesha 88, depending on the corrosiveness of the pumped liquid. 4. For Class S-6, the shaft shall be 12 percent chrome if the temperature exceeds 175°C (350°F) or if used for boiler feed service (see Appendix G. Table G-1). 5. The gland shall be furnished with a non-sparking floating throttle bushing of a material such as carbon graphite or glass-filled PTFE, in accordance with 2.7.3.20. Unless otherwise specified, the throttle bushing shall be premium carbon graphite. 6. If pumps with axially split casings are furnished, a sheet gasket suitable for the service is acceptable. Spiral wound gaskets should contain a filler material suitable for the service. 7. Alternate materials may be substituted for liquid temperatures greater than 45°C (110°F) or for other special services. 8. Unless otherwise specified, AISI 4140 steel may be used for non-wetted case and gland studs. Flowserve RED 12/99 B-2 Hydrocracking Applications API Standard 610 Mechanical Seal Materials and Classification Codes Appendix B Table H-4 – Fourth Letter of Mechanical Seal Classification Code Fourth Letter E F G H I R X Z Stationary Seal Ring Gasket FKM FKM PTFE Nitrile FFKM Graphite foil As specified Spiral wound Seal Ring to Sleeve Gasket PTFE FKM PTFE Nitrile FFKM elastomer Graphite foil As specified Graphite foil Mechanical seal materials and construction features shall be coded according to the following classification system: First letter: Second letter: Balanced (B) or unbalanced (U) Single (S), unpressurized dual (T), or pressurized dual (D) Seal gland type (P = plain, no throttle bushing; T = throttle bushing with quench, leakage and/or drain connections; A = auxiliary sealing device, type to be specified) Note: See 2.7.3.21. Gasket materials (see Table H-4) Face materials (see Table H-5) Third letter: Table H-5 – Fifth Letter of Mechanical Seal Classification Code Sealing Ring Face Materials Fifth Letter L M N O P X Ring 1 Carbon Carbon Carbon Tungsten carbide 2 Silicon carbide As specified Ring 2 Tungsten carbide 1 Tungsten carbide 2 Silicon carbide Silicon carbide Silicon carbide As specified Fourth letter: Fifth letter: For example, a seal coded BSTFM would be a balanced single seal with throttle bushing seal gland and would have a fluoroelastomer (FKM) stationary gasket, an FKM seal-ring-tosleeve gasket, and carbon against tungsten carbide 2 faces. Seal materials other than those listed above should be coded X and defined on the data sheets (see Appendix B). Mechanical Seal Notes 1. Unless otherwise specified, the spring materials for multiple spring seals shall be Hastelloy C. The spring material for single spring seals shall be austenitic stainless steel (AISI Standard Type 316 or equal). Other metal parts shall be austenitic stainless steel (AISI Standard Type 316 or equal) or another corrosion resistant material suitable for the service, except that metal bellows, where used, shall be of the material recommended by the seal manufacturer for the service. Metal bellows shall have a corrosion rate of less than 50 ìm (2 mils) per year. 2. Unless otherwise specified, the gland plate to seal chamber seal shall be a fluoroelastomer O-ring for services below 150°C (300°F). For temperatures 150°C (300°F) and above or when specified, graphite-filled austenitic stainless steel spiral wound gaskets shall be used. The gasket shall be capable of withstanding the full (uncooled) temperature of the pumped fluid. 3. A metal seal ring shall not have sprayed overlay in place of a solid face. 4. When the pumping temperature exceeds 175°C (350°F), the vendor and seal manufacturer should be jointly consulted about using a cooled flush to the seal faces or running the seal chamber dead-ended with jacket cooling. 5. The temperature limits on mechanical seal gaskets shall be as specified in Table H-6. Table H-6 – Temperature Limits on Mechanical Seal Gaskets and Bellows Gasket Material PTFE Nitrile Neoprene FKM a Metal bellows FFKM Graphite foil Glass filled TFE Mica/graphite Ethylene propylene a Ambient or Pumping Temperature Minimum Maximum (°C) (°F) (°C) (°F) -75 -100 200 400 -40 -40 120 250 -20 0 90 200 -20 0 200 400 -12 -240 -212 -240 -57 10 -400 -350 -400 -70 260 400b 230 700 180 500 750b 450 1300 350 Consult manufacturer for minimum and maximum ambient pumping temperature. b Maximum temperature is 870°C (1600°F) for nonoxidizing atmospheres; consult manufacturer. Flowserve RED 12/99 B-3 Hydrocracking Applications Appendix C Other Pump Applications The focus of this manual is on the application of Flowserve petroleum process pumps in the actual hydrocracking unit. However, there are potential applications for other types of Flowserve pumps in auxiliary services. Some of the potential applications and applicable pumps would be: • Water services (drain water, sour water, cooling water) – potential for Durco Mark III ANSI and Chemstar ISO pumps. Also potential for Flowserve Vertical Circulator type pumps. Boiler feedwater pumps – potential for type MX pumps. Fire water pumps – potential for type DVS and Vertical Circulator type pumps. • • Flowserve RED 12/99 C-1 . 4 Introduction to Pump Recommendations Coker and Heater Charge Pumps Coke Cutter Water Pump Other Delayed Coker Unit Pumps Delayed Coker Units API Material Designations for Pumps and Mechanical Seals Other Pump Applications 4-2 4-2 4-2 4-2 A-1 B-1 C-1 Appendix A Appendix B Appendix C FLOWSERVE RED 01/00 i . Flowserve Experience 3.2 Market Drivers Competition 2-1 2-2 3.4 3.5 Flowserve Sales Decision Makers Competitive Advantages of Flowserve Petroleum Process Pumps Guidelines for Mechanical Seals Operating Unit and Pump Details 3-1 3-1 3-1 3-2 3-3 4.1 3.1 1.1 2. Rationale and Methodology Delayed Coking Process 1-1 1-1 Market Profiles 2.3 3.2 3. Pump Recommendations 4.1 4. Introduction 1.2 2.2 4.Delayed Coker Applications Table of Contents Page Number 1.3 4. Global Distribution of Delayed Coker Capacity 1-3 2-2 3-1 FLOWSERVE RED 01/00 ii .Delayed Coker Applications Exhibits Page Number 1. World Oil Consumption 3. Typical Delayed Coker Unit 2. Through long and close collaboration with the major refiners in the world. Finally. but more commonly. isomerization. In addition to discussing delayed coking technology.2 Delayed Coking Process There are three basic steps in refining: separation. catalytic reforming. purifying. and many others. Introduction 1. Coking is a conversion process that uses residues to produce distillates and petroleum coke. Refiners have spent much time and effort on the conversion step because this is where the money is made in a refinery through the conversion of low value fractions to high value products. high-sulfur crudes. also called downstream processing. or fractions. solvent extraction. the application requirements present a broad range of pumping challenges. most notably gasoline but also hundreds of other useful products. Finally. there is the treatment step where streams are carefully combined through blending.1 Rationale and Methodology The petroleum refining industry consists of approximately 700 facilities located around the world. the fractions are sent on to the conversion step. converts the fractions into intermediate streams that eventually become finished products. refiners are required to convert as much of the feedstock as possible to useable products. Crude oil is a mixture of many different hydrocarbons and small amounts of impurities. conversion. Even though the basics of all refineries are the same. coking. The separation step is essentially fractional distillation where liquids and vapors are separated into components. catalytic cracking. The exact composition of crude oils varies significantly depending on their source. dewaxing. This manual will look at one downstream process—delayed coking— in some detail with the goal of increasing familiarity with this key operation. Flowserve petroleum process pumps enjoy widespread use in all phases of refining. To meet the formidable processing and economic challenges of producing clean transportation fuels from heavy. Because no two refineries are the same. and treatment. alkylation. according to weight and boiling point. primarily gasoline. the manual will present proven pump configurations that have provided reliable. polymerization. FLOWSERVE RED 01/00 1-1 . and fine-tuning to produce finished products that meet customer specifications and government standards. The conversion step. the company possesses a wealth of applications and problem solving expertise. catalytic hydrocracking.Delayed Coker Applications 1. A petroleum refinery takes a raw material—crude oil—and turns it into finished products. This operation is sometimes referred to as “bottom-of-the-barrel” processing because its feedstock is the heavy residues from the distillation towers. Common conversion processes include thermal cracking (visbreaking). dependable service. hydrotreating. these are complex systems with multiple operations and the specific operations found at any given refinery will depend on the properties of the crude oil being refined and the desired product output. features unique to Flowserve petroleum process pumps will be highlighted along with the benefits these features provide to end-users. propane deasphalting. Some useable products are realized here. 1. for the manufacture of electrodes for the aluminum industry. Delayed coking will play an increasingly important role in the modern refinery because of its ability to convert heavy residues to useful. the other drum is being decoked. Naphtha – can be hydrotreated and used as catalytic reformer feedstock or can go directly to the gasoline pool. developed at Standard Oil of Indiana in 1929. Coke – depending on the composition of residue feedstock. The output of the delayed coking unit includes: • • • • • • Gas – C4 and lighter gases are fed to a vapor recovery unit where LPG (liquid petroleum gas) and fuel gas are produced. In other words. HGO – heavy gas oil is used as catalytic cracker or hydrocracker feedstock. is the most widely used residue-conversion process. To make this a continuous process. FLOWSERVE RED 01/00 1-2 . While one drum is receiving the coke heater effluent and converting it to gas and coke. There are insulated surge tanks (coke drums) downstream of the furnace and coke deposits in these tanks after passing through the heater tubes. but delayed coking. into lighter. This process involves heating the residue feedstock in a furnace to above the coking point so rapidly that coke does not deposit in the furnace heater tubes. thus the process name. LGO – light gas oil is usually hydrotreated and sent to the distillate pool. Exhibit 1 is a simplified schematic of the delayed coking process.Delayed Coker Applications Coking is a non-catalytic thermal cracking process. at least two coking drums are required. the coking reaction is delayed. or “cracked”. but before subsequent processing. profitable products. There are a number of different coking operations. the coke can be used for fuel. Cracking simply means decomposition by heat whereby heavy (large) hydrocarbon molecules are decomposed. as a gasification feed. Gasoline – goes to the gasoline pool. for metallurgical applications in ferrous foundry operations and steelmaking. for a new application. smaller molecules. or. Delayed Coker Applications FLOWSERVE RED 01/00 1-3 . Mexico Minatitlan. Texas Jose. PEMEX PEMEX PEMEX BP Amoco Clark Oil Petrolera Ameriven Petrozuata Sincor Location Jamnagar. units will be built where crude oil consumption growth will be the greatest. Venezuela Capacity. Exhibit 2 below shows crude oil consumption now and the projected consumption in 2005 for four regions of the world.000 barrels per day delayed coking capacity will be added in the U. India Cuidad Madero. These residues result from processing crude oils that. over the next 10 years.S. The primary use for petroleum coke is as a fuel although it also finds use in metallurgical applications and as a gasification feed stock. the refiners can increase profitability. By being able to economically convert these residues into light distillates. Below is a list of some planned. in the future.S. are frequently purchased at a discount.S.000 barrels per day Flowserve RED 1/00 2-1 . leads the world in installed and operating delayed coker capacity. Venezuela Jose. Venezuela Jose.Delayed Coker Applications 2. Mexico Toledo. near term. high sulfur residues. delayed coker units: Company Reliance Ind. The use of petroleum coke in solid fuel power stations has been growing recently because it provides an inexpensive way to displace coal. because of their high sulfur content.1 Market Drivers Petroleum refining is a very competitive endeavor and refiners work very hard to obtain as much saleable product as possible from each barrel of crude oil. it seems logical that. Mexico Salina Cruz. in the U. This represents an increase of about 18%. petroleum coke is about 30% lower than that of bituminous coal. and up to about 300. Mbpd1 122 ------28 --90 120 140 Planned Completion 1999 2001 2001 2001 1999 2000 2003 2000 2001 Even though the U. 48 out of 54 existing coking units are of the delayed coking type. 1 1. Of all the coking processes. In fact. The marketability of petroleum coke is a plus in favor of the delayed coking process. Market Profile 2. Ohio Port Arthur. The petroleum coke produced by the delayed coking process is not an insignificant byproduct. delayed coking is preferred. Delayed coking permits refiners to process very heavy. On a cost-per-heat unit basis.. Africa Asia-Pacific Latin America 1999 2005 Projected growth rates in consumption in these regions between now and 2005 are: USA & Canada Europe. Africa Asia-Pacific Latin America 9% 12% 19% 23% 2. Flowserve petroleum process pumps have a long history of dependable service in petroleum refineries all over the world. Middle East. Regional competitors are Ebara and Shin-Nippon in the Asia-Pacific region and David Brown in Europe. The features that provide Flowserve petroleum process pumps with competitive advantages will be highlighted in Section 3.3. Middle East.2 Competition The primary global competitors in delayed coker projects are IDP and Sulzer. Middle East. Flowserve RED 1/00 2-2 . Flowserve’s global presence will allow the company to participate in the refining market as delayed coker units are added to refineries worldwide. Petroleum refining is a very competitive and cost-conscience business and Flowserve’s ability to assist refiners in improving pump reliability will be key as this can lead to improved profitability. Africa region.Delayed Coker Applications Exhibit 2 World Oil Consumption Million barrels per day 35 30 25 20 15 10 5 0 USA & Canada Europe. The critical pumps in a Flowserve RED 1/00 3-1 . Exhibit 3 Global Distribution of Delayed Coker Capacity Asia-Pacific 11% Latin America 9% Europe. the end-user will generally be heavily involved in the selection of the supplier of the charge pumps. 3.95 MMbpd (million barrels per day). Middle East.Delayed Coker Applications 3. although here again. These two regions of the world will likely see growth in delayed coker capacity over the next five to ten years. Past experience with delayed coker applications will weigh favorably for potential charge pump suppliers. Flowserve Experience 3. Even though an engineering firm may handle the design and construction of the unit. locations with the lowest delayed coker capacity. the growth in oil consumption is projected to be greatest in the Asia-Pacific and Latin American regions. 3. In Appendix A. Africa 22% USA & Canada 58% As was shown in Exhibit 2. The buying decision involving the process pumps is much more subject to competitive pressures. there are tables for the four regions shown in Exhibit 3 listing the locations and capacities of the existing delayed coker units.2 Decision Makers The delayed coker charge and the heater charge pumps are key components in a delayed coker unit.3 Competitive Advantages of Flowserve Petroleum Process Pumps Flowserve has achieved a reputation for supplying high quality. The global distribution of this capacity is shown in Exhibit 3.1 Flowserve Sales Delayed coker capacity worldwide is about 2. experience and installed base are important considerations. dependable pumping equipment to the petroleum industry and has gained a wealth of experience through handling the critical services found in refining applications. the advice of a Flowserve FSD sealing specialist should be sought. Rotating element balanced as a unit. between bearings pump with a double suction first stage is ideally suited for these services. DSTHO. a very large installed base of these pumps provides a history of successful performance in all types of petroleum services. and. Reduced maintenance costs. Axial hydraulic loads are balanced. The Flowserve SCE family of process pumps are fully compliant with API 610 (8th Edition) and can handle a very broad range of single stage applications. Gives maximum bearing support. For the coke cutter water application. to a somewhat lesser degree. Low noise levels. Double suction impellers minimize NPSHR over a wide range of flows. The introduction of high temperature.4 Guidelines for Mechanical Seals There are many challenging mechanical seal applications in a delayed coker unit. metal bellows designs have helped reduce the problems in these critical pumps. The DSTHF and DSTHO designs offer maximum reliability for the two charge services because of the following features and benefits: Feature Between bearing design Impellers Circular bearing housing and adapter Benefit Minimizes deflection at mechanical seal thus increasing seal life. Flowserve RED 1/00 3-2 . Maximum reliability. The DSTHF. The HDO design offers the following features and benefits to enhance overall performance and reliability: Feature Radially split outer casing Axially split inner casing Special bearing construction First stage double suction impeller design Benefit Inherently safe at all pressures. The very high temperatures endured by seals in the charge pumps can cause severe problems. The Flowserve models DSTHF and DSTHO horizontal. double-case design is used.Delayed Coker Applications delayed coker unit are the delayed coker charge pump and the heater charge pump. Also. The other pump applications in delayed coker units can normally be handled by singlestage. the pump must achieve a very high discharge pressure. Provides better stiffness and lower vibration. overhung API process pumps. The Flowserve model HDO multistage. 3. Low NPSHR. Also. and HDO designs are fully compliant with API 610 (8th Edition). some users are specifying tandem seals for the hydrocarbon services to help meet permitting requirements. Proper seal selection is critical to trouble-free operation and because of the severity of many of the applications. the coke cutter water pump. The coker and heater charge pumps must handle very high temperatures at high pressures. Delayed Coker Applications 3.5 Operating Unit and Pump Details The critical applications in a delayed coker are the charge pumps, and to a somewhat lesser degree, the coke cutter water pump. However, the process pumps, water handling pumps, and any auxiliary pumps must provide reliable service for the unit to operate dependably and profitably. In Section 4, Pump Applications, proven pump configurations (materials, seals, flush plans, etc.) will be presented. Flowserve RED 1/00 3-3 Delayed Coker Applications 4. Pump and Material Recommendations The recommendations that follow are general guidelines. They are based on specifications which have performed well in the field, and are intended to raise awareness of issues associated with particular applications. Other specifications not addressed in this manual may be equally or more acceptable, depending on variables associated with the application. These guidelines should not take the place of any manufacturer’s recommended specification for a given application. A qualified pump engineer must still be involved in the specification of any pump, and manufacturers of components/accessories are to be consulted for detailed specifications as well. Flowserve RED 1/00 4-1 Delayed Coker Applications 4.1 Introduction to Pump Recommendations The key pumps in a delayed coker unit are the coker charge pump, the heater charge pump, and the coke cutter water pump; however, there are a number of other services requiring Flowserve petroleum process pumps. Below is a discussion of typical Flowserve petroleum process pump applications and representative pump configurations that have proven successful in delayed coker units. This information should be helpful in understanding Flowserve’s involvement in this critical refinery process. 4.2 Coker and Heater Charge Pumps Typical operating conditions for the coker charge pump are 700oF (371oC) liquid temperature and relatively low discharge pressures. For the heater charge pump, the conditions are 660oF (349oC) liquid temperature and 600 psig (42 bar) discharge pressure. The Flowserve petroleum process pump best suited for these services is the Byron Jackson® Type DSTHF and DSTHO between bearing radially split designs with a double suction first stage. The API 610 material designation for the coker charge pump is normally specified as S-6 (see Appendix B). For the heater charge pump, both S-5 and C-6 material designations are specified. Mechanical seal selection is key to troublefree operation of these critical pumps. Metal bellows seals are normally used with an API 610 seal code of BSTRX (see Appendix B). An auxiliary sealing device comprised of a close clearance floating carbon throttle bushing is also used. An API Plan 11 seal flushing system and an API Plan 62 auxiliary system with an anti-coking device are included. Dual seals with an API Plan 32 may be required if the service is particularly dirty or if the pump meets the definition of “critical service.” 4.3 Coke Cutter Water Pump This pump application deserves some brief discussion. As shown in Exhibit 1, a typical delayed coker unit has two coke drums. This enables the unit to operate on a continuous basis. As one drum is filling with coke, the other is emptied. High-pressure water is used to “cut” the coke out of the drum and this water is provided by the coke cutter water pump. Typical operating conditions for this pump are 900 gpm (204 m 3/hr) at a discharge pressure of 3500 psig (241 bar). The temperature is less than 150oF (66oC). Because of the high pressure, the Flowserve petroleum process pump best suited for this service is the Byron Jackson® Type HDO double case, multi-stage unit. The API 610 material code normally specified is S-6. The API 610 seal code normally used is BSTFM. An auxiliary sealing device comprised of a close clearance floating carbon throttle bushing is also used, and an API Plan 11 flushing system is normally provided. 4.4 Other Delayed Coker Unit Pumps There are a number of other applications with the delayed coker unit and these are listed below with comments relative to typical configurations: Flowserve RED 1/00 4-2 Delayed Coker Applications 4.4.1 Condensate Transfer Operating conditions: 300 oF (149oC), 100 psig (6.9 bar). Recommended pump: Byron Jackson® Type SCE, API material code – C-6. Mechanical seal: Pusher type, API code – BSTFM. Auxiliary seal system: API Plan 23. 4.4.2 Fractionator Overhead Reflux Operating conditions: 350 oF (177oC), 100 psig (6.9 bar). Recommended pump: Byron Jackson® Type SCE, API material code – S-5. Mechanical seal: Metal bellows, API code – BSTRX, close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 11, API Plan 62 with anti-coking device. 4.4.3 Fractionator Overhead Sour Water Operating conditions: 350 oF (177oC), 75 psig (5.2 bar). Recommended pump: Byron Jackson® Type SCE, API material code – A-8. Mechanical seal: Metal bellows, API code – BSTFM, close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 23. 4.4.4 Light Distillate Sidestream Operating conditions: 500 oF (260oC), 200 psig (13.8 bar). Recommended pump: Byron Jackson® Type SCE, API material code – S-5. Mechanical seal: Metal bellows, API code – BSTRN, close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 11, API Plan 62 with anti-coking device. 4.4.5 Gas Oil Sidestream Operating conditions: 650 oF (343oC), 200 psig (13.8 bar). Recommended pump: Byron Jackson® Type SCE, API material code – S-5. Mechanical seal: Metal bellows, API code – BSTRN, close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 11, API Plan 62 with anti-coking device. 4.4.6 Fractionator Overhead Product Operating conditions: 350 oF (177oC), 250 psig (17.2 bar). Recommended pump: Byron Jackson® Type SCE, API material code – S-5. Mechanical seal: Metal bellows, API code – BSTRN, close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 11, API Plan 62 with anti-coking device. 4.4.7 Dilute Tower Feed Operating conditions: 300 oF (149oC), 175 psig (12.1 bar). Recommended pump: Byron Jackson® Type SCE, API material code – S-6. Mechanical seal: Metal bellows, API code – BSTRN, close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 11, API Plan 62 with anti-coking device. Flowserve RED 1/00 4-3 3 bar). Mechanical seal: Pusher type. Recommended pump: Byron Jackson® Type SCE. 100 psig (6. 4. API Plan 62 with anti-coking device.9 bar). API code – BSTFM. API material code – S-6. close clearance floating carbon throttle bushing.2 bar). API material code – A-8. 100 psig (6. close clearance floating carbon throttle bushing.4. API material code – S-6.9 bar).4. Auxiliary seal system: API Plan 23. Recommended pump: Byron Jackson® Type SCE.4. API material code – C-6. 4.8 Preheat Condensate Steam Removal Operating conditions: 250 oF (121oC).Delayed Coker Applications 4. Recommended pump: Byron Jackson® Type SCE. close clearance floating carbon throttle bushing. Auxiliary seal system: API Plan 11.4. Auxiliary seal system: API Plan 23. Mechanical seal: Pusher type. Mechanical seal: Metal bellows.9 Diluent Pump Operating conditions: 225 oF (107oC). API material code – S-6. API material code – A-8. Flowserve RED 1/00 4-4 . API code – BSTFM. Mechanical seal: Metal bellows. Recommended pump: Byron Jackson® Type SCE.10 Diluent Surge Drum Sour Water Removal Operating conditions: 225 oF (107oC). Auxiliary seal system: API Plan 11.9 bar).8 bar).13 Coker Recovery Oil Operating conditions: 150 oF (66oC). Auxiliary seal system: API Plan 23. API code – BSTFM. 4. API Plan 62 with anti-coking device. API material code – S-5. API code – BSTFM. 75 psig (5. 150 psig (10.12 Wash Oil Operating conditions: 400 oF (204oC).4.4. Mechanical seal: Metal bellows. 100 psig (6. Auxiliary seal system: API Plan 11. Recommended pump: Byron Jackson® Type SCE. API code – BSTRX. Mechanical seal: Pusher type.14 Steamout Sour Water Operating conditions: 150 oF (66oC). 4. close clearance floating carbon throttle bushing. 4. close clearance floating carbon throttle bushing. Mechanical seal: Pusher type.8 bar). API code – BSTFM. close clearance floating carbon throttle bushing.11 Quench Water Operating conditions: 200 oF (93oC). Auxiliary seal system: API Plan 11. Recommended pump: Byron Jackson® Type SCE. API code – BSTFM. 200 psig (13. 4. 200 psig (13.4. Recommended pump: Byron Jackson® Type SCE. 8 22.2 18.0 23.0 71.3 8.0 16.2 28.6 64.8 25.4 23.5 40.) Alberta Ontario Saskatchewan Alabama California California California California California California California California California Illinois Illinois Indiana Kansas Kansas Kansas Louisiana Louisiana Louisiana Louisiana Louisiana Louisiana Louisiana Minnesota Mississippi Montana New Jersey Ohio Ohio Oklahoma Oklahoma Texas Texas CITY CAPACITY Mbpd1 7.4 36.0 64.5 84.8 19.8 10.0 34.0 37.1 102.5 21.0 33.8 57.0 25.5 75.1 15. Nat'l.5 23.0 16.2 42.Delayed Coker Applications Appendix A Delayed Coker Units USA and Canada COUNTRY Canada COMPANY LOCATION STATE (PROV.0 22. Co-op Refinery BP Amoco Citgo Conoco Exxon Mobil Motiva Transamerica Koch Refinery Chevron Conoco Valero Energy BP Amoco Clark Conoco Sun Amoco Citgo Edmonton Sarnia Regina Tuscaloosa Carson El Segundo Wilmington Bakersfield Martinez Benicia Torrance San Francisco Wilmington Lemont Hartford Whiting El Dorado Coffeyville McPherson Belle Chasse Lake Charles Westlake Baton Rouge Chalmette Norco Norco Rosemount Pascagoula Billings Paulsboro Toledo Lima Ponca City Tulsa Texas City Corpus Christi Flowserve RED 1/00 A-1 .8 8.0 Petro-Canada Imperial Oil Consumer Co-op United States Hunt Refining Atlantic Richfield Chevron Equilon Exxon Mobil Tosco Ultramar Citgo Clark Amoco El Dorado Framland Ind.2 22.2 25.5 50.5 20.0 70. 1 7.0 6.5 Mbpd = 1.0 1702.6 49.0 24.0 12.0 87.3 41.USA and CANADA 37.2 19.Delayed Coker Applications Appendix A (Continued) Delayed Coker Units USA and Canada Clark Costal Crown Central Koch Refinery LaGloria Oil & Gas Lyondell-Citgo Mobil Motiva Shell Deerpark Chevron BP Amoco Atlantic Richfield Equilon Frontier Oil & Gas 1 Texas Port Arthur Texas Corpus Christi Texas Pasadena Texas Corpus Christi Texas Tyler Texas Houston Texas Beaumont Texas Port Arthur Texas Deer Park Utah Salt Lake City Virginia Yorktown Washington Ferndale Washington Anacortes Wyoming Cheyenne TOTAL .000 barrels per day Flowserve RED 1/00 A-2 .1 9.5 59.5 17.5 51.5 15. 0 19.3 52. Mbpd1 25.000 barrels per day Flowserve RED 1/00 A-3 .0 30.A. S.0 31. Aruba Brazil Venezuela 1 LOCATION Campana La Plata Lujan de Cuyo Costal Aruba San Nicolas Petrobras Betim Cubatao Paulina Corpoven Judibana Falcon TOTAL .1 265.0 40.LATIN AMERICA Mbpd = 1.8 COUNTRY Argentina COMPANY ESSO SAPA YPF.0 39.4 29.Delayed Coker Applications Appendix A Delayed Coker Units Latin America CAPACITY. Ukraine Nadvornaja. Ukraine Fergena.5 24. Turkmenistan Kherson. La Coruna Puertollano Homs Refinery Homs Conoco South Killingholme TOTAL .4 45.0 8.3 COUNTRY Albania Croatia Egypt FSU COMPANY Albpetrol Ina Ind.7 22.7 11. Azerbaijan Atyrau. Mbpd1 12. Oberrhein Karlsruhe OMV.Delayed Coker Applications Appendix A Delayed Coker Units Europe.0 60. & AFRICA Mbpd = 1.5 38. Russia Turkmenbashi.2 25.0 17.3 7.6 12.7 26. A. LOCATION Germany Italy Kuwait Myanmar Norway Romania Spain Syria United Kingdom 1 Ballshi Sisnk El-Suez Baku. Russia Perm.5 28. Nafte Suez Petro.000 barrels per day Flowserve RED 1/00 A-4 .5 4.0 18.0 7.5 16. Russia Sidanco-Angarsk. Mina Abdlia Muanma Petro.5 13. Ragusa Kuwait Nat'l . Russia Sibneft-Omsk.5 13.2 28.0 23. Thanlyin Statoil Mongstad Mongstad Astra Ploiesti Petrobrasi Ploiesti Petromedia Midia Petrotel Ploiesti Refinaria Darmanesti Darmanesti Rafo Onesti Repsol Petro. Russia Volgogard. Kazakhstan Pavlodar. MIDDLE EAST.0 658.5 9.0 5.9 16.6 12. and Africa CAPACITY. Middle East. Kazakhstan Bashneftekhimzavody.G. Petro. Uzbekistan Min.EUROPE. Burghasen Veba Oel/Ruhr Oel Gelsenkirchen Wintershall Lingen Praoil Gela.0 5.2 68.9 11.1 13.0 11.0 27.8 13. 0 12.0 35.0 15.000 barrels per day Flowserve RED 1/00 A-5 . Central Samatra Japan Energy Mizushima.6 23.0 6. & Petro.0 10. Osaka Petronas Melaka II Hyundai Daesan Chinese Petro. Assam Indian Oil Barauni.0 8.1 21. Bihar Gawahati.0 324.0 19.0 12. Mbpd1 13.0 20. Bangaigon.ASIA-PACIFIC Mbpd = 1. Assam Pertamina Damai.0 8.0 8. LOCATION India Indonesia Japan Malaysia South Korea Taiwan 1 Daquint Fushun Dashanzi Jinzhou Urumqi Sinopec Anquig Baling Jingmen Jinling Maoming Qilu Zhenhai Bangaigon Ref.1 COUNTRY China COMPANY China Nat'l.0 16.Delayed Coker Applications Appendix A Delayed Coker Units Asia-Pacific CAPACITY.0 8.0 12. Kaohsiung TOTAL .0 8.0 32.4 17.0 20. Petro. Okayama Kao Oil Yamaguchi. PTFE filled (6) Carbon Steel Filled carbon K-Monel 12% CHR 12% CHR hardened 12% CHR hardened 12% CHR 12% CHR hardened or hard faced AUS or 12% CHR 12% CHR hardened 12% CHR hardened 12% CHR hardened 316 AUS (5) AISI 4140 Steel AUS.1 . diffusers. STL = steel. 12% CHR = 12% chrome. hardened (8) Monel. Abbreviations are as follows: BRZ = bronze.1. spiral wound (6) AUS Filled carbon 316 AUS AUS Hard Faced AUS (3) Hard Faced AUS (3) AUS Hard Faced AUS (3) AUS AUS Hard Faced AUS (3) Hard Faced AUS (3) 316 AUS (5) AISI 4140 Steel AUS. 316 AUS = Type 316 austenitic stainless steel See 2.Table H-1 – Materials for Pump Parts Material Class and Material Abbreviationsa I-1 Fullb Compliance Material? Yes No CI CI I-2 STL S-1 STL S-3 STL S-4 STL S-5 STL S-6 STL S-8 STL S-9 C-6 12% CHR A-7 AUS A-8 316 AUS D-1 DUPLEX Delayed Coker Applications Flowserve RED 12/99 B-1 a b Part Pressure Casing Inner case parts (bowls. spiral wound (6) Carbon Steel Filled carbon Carbon Steel Ni-resist Ni-resist Ni-resist Carbon Steel 12% CHR hardened or hard faced AUS or 12% CHR Ni-resist Ni-resist Ni-resist 316 AUS (5) AISI 4140 Steel AUS.11. spiral wound (6) Carbon Steel Nitrile (7) Carbon Steel Carbon Steel Cast Iron Cast Iron Carbon Steel 12% CHR hardened or hard faced AUS or 12% CHR Cast Iron Cast Iron Cast Iron 316 AUS (5) AISI 4140 Steel AUS. hardened K-Monel. AUS = austenitic stainless steel. spiral wound (6) Carbon Steel Filled carbon 316 AUS 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS Hard Faced 316 AUS (3) AUS or 12% CHR 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS (5) AISI 4140 Steel 316 AUS. diaphragms) Impeller Case wear rings Impeller wear rings Shaft (2) Shaft sleeves. spiral wound (6) Carbon Steel Filled carbon 316 AUS Monel Monel Monel K-Monel K-Monel. spiral wound (6) Carbon Steel Filled carbon Carbon Steel Carbon Steel 12% CHR 12% CHR Hardened AISI 4140 12% CHR hardened or hard faced AUS or 12% CHR 12% CHR 12% CHR hardened 12% CHR hardened 316 AUS (5) AISI 4140 Steel AUS. hardened K-Monel. spiral wound (6) Carbon Steel Filled carbon 316 AUS 12% CHR 12% CHR 12% CHR Hardened AISI 4140 (4) 12% CHR hardened or hard faced AUS or 12% CHR 12% CHR 12% CHR hardened 12% CHR hardened 316 AUS (5) AISI 4140 Steel AUS. mechanical seals Throat bushings Interstage sleeves Interstage bushings Seal gland Case and gland studs Case gasket CI Cast Iron Cast Iron BRZ Cast Iron Bronze CI Carbon Steel Cast Iron NI-RESIST Carbon Steel Ni-resist STL Carbon Steel Cast Iron STL 12% CHR Carbon Steel Carbon Steel 12% CHR Carbon Steel 12% CHR 316 AUS Carbon Steel 316 AUS MONEL Carbon Steel Monel 12% CHR 12% CHR 12% CHR AUS (1&2) AUS AUS 316 AUS (1 & 2) 316 AUS 316 AUS DUPLEX Duplex Duplex Yes No No Yes No Cast Iron Cast Iron Cast Iron Carbon Steel 12% CHR hardened AUS or 12% CHR Cast Iron Cast Iron Cast Iron 316 AUS (5) Carbon Steel AUS. hardened Monel K-Monel. spiral wound (6) Carbon Steel Bronze Carbon Steel Cast Iron Cast Iron Cast Iron Carbon Steel 12% CHR hardened AUS or 12% CHR Cast Iron Cast Iron Cast Iron 316 AUS (5) AISI 4140 Steel AUS. hardened Monel K-Monel. spiral wound. the abbreviation below the diagonal line indicates trim material. CI = cast iron. packed pumps Shaft sleeves. spiral wound (6) AUS Filled carbon 316 AUS 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS Hard Faced 316 AUS (3) 316 AUS 316 AUS Hard Faced 316 AUS (3) Hard Faced 316 AUS (3) 316 AUS (5) AISI 4140 Steel 316 AUS spiral wound (6) 316 AUS Filled carbon 316 AUS Duplex Duplex (3) Duplex (3) Duplex Duplex (3) Appendix B No No No No Yes Yes No Duplex Duplex Duplex (3) Duplex (3) Duplex (5) Duplex (8) Duplex SS spiral wound (6) Duplex Filled carbon Duplex Discharge head/ suction can Column/bowl shaft bushings Wetted fasteners (bolts) Yes No Yes The abbreviation above the diagonal line indicates the case material. spiral wound (6) Carbon Steel Nitrile (7) Carbon Steel Bronze Bronze Bronze Carbon Steel Hard bronze AUS or 12% CHR Bronze Bronze Bronze 316 AUS (5) Carbon Steel AUS. Flowserve RED 12/99 B-2 . 5. Alternatives to hard-facing may include opening running clearances (2. Spiral would gaskets should contain a filler material suitable for the service. the shaft shall be 12 percent chrome if the temperature exceeds 175°C (350°F) or if used for boiler feed service (see Appendix G. 8. and D-1. such as Nitronic 60 and Waukesha 88.20.4) or the use of non-galling materials. the throttle bushing shall be premium carbon graphite.Hydrocracking Applications Appendix B Reference and General Notes for Table H-I: 1. 316.3. A7. If a particular type is desired. Austenitic stainless steels include ISO Types 683-13-10/19 (AISI Standard Types 302. 6. The gland shall be furnished with a non-sparking floating throttle bushing of a material such as carbon graphite or glass-filled PTFE.7. 2. For Class S-6. 321. 304. the shaft shall be 12 percent chrome. Cantilever (Type VS5) pumps may utilize AISI 4140 where the service liquid will allow. Alternate materials may be substituted for liquid temperatures greater than 45°C (110°F) or for other special services. a sheet gasket suitable for the service is acceptable. except for Classes S-9. in accordance with 2. If pumps with axially split casings are furnished. the need for hard-facing and the specific hard-facing material for each application shall be determined by the vendor and described in the proposal. 4. Unless otherwise specified. 303. AISI 4140 steel may be used for non-wetted case and gland studs. depending on the corrosiveness of the pumped liquid. the purchase will so state. and 347). A-8. 7.6. Table G-1). Unless otherwise specified. Unless otherwise specified. For vertically suspended pumps with shafts exposed to liquid and running in bushings. 3. shall be of the material recommended by the seal manufacturer for the service. A = auxiliary sealing device. Table H-6 – Temperature Limits on Mechanical Seal Gaskets and Bellows Ambient or Pumping Temperature Gasket Material Minimum Maximum PTFE Nitrile Neoprene FKM Metal bellows a FFKM Graphite foil Glass filled TFE Mica/graphite Ethylene propylene a (°C) -75 -40 -20 -20 -12 -240 -212 -240 -57 (°F) -100 -40 0 0 10 -400 -350 -400 -70 (°C) 200 120 90 200 260 400b 230 700 180 (°F) 400 250 200 400 500 750b 450 1300 350 Consult manufacturer for minimum and maximum ambient pumping temperature. Mechanical Seal Notes 1. Unless otherwise specified.Hydrocracking Applications API Standard 610 Mechanical Seal Materials and Classification Codes Appendix B Table H-4 – Fourth Letter of Mechanical Seal Classification Code Fourth Stationary Seal Seal Ring to Letter Ring Gasket Sleeve Gasket E FKM PTFE F FKM FKM G PTFE PTFE H Nitrile Nitrile I FFKM FFKM elastomer R Graphite foil Graphite foil X As specified As specified Z Spiral wound Graphite foile Mechanical seal materials and construction features shall be coded according to the following classification system: First letter: Second letter: Balanced (B) or unbalanced (U) Single (S). 2. Other metal parts shall be austenitic stainless steel (AISI Standard Type 316 or equal) or another corrosion resistant material suitable for the service. or pressurized dual (D) Seal gland type (P = plain. unpressurized dual (T). 3. When the pumping temperature exceeds 175°C (350°F). 5. a seal coded BSTFM would be a balanced single seal with throttle bushing seal gland and would have a fluoroelastomer (FKM) stationary gasket. Flowserve RED 12/99 B-3 . consult manufacturer. the vendor and seal manufacturer should be jointly consulted about using a cooled flush to the seal faces or running the seal chamber dead-ended with jacket cooling. type to be specified) Note: See 2.21. The temperature limits on mechanical seal gaskets shall be as specified in Table H-6. T = throttle bushing with quench. the spring materials for multiple spring seals shall be Hastelloy C. Unless otherwise specified. where used. the gland plate to seal chamber seal shall be a fluoroelastomer O-ring for services below 150°C (300°F) and above or when specified. Seal materials other than those listed above should be coded X and defined on the state sheets (see Appendix B). The gasket shall be capable of withstanding the full (uncooled) temperature of the pumped fluid. graphitefilled austenitic stainless steel spiral wound gaskets shall be used. b Maximum temperature is 870°C (1600°F for nonoxidizing atmospheres.3. Gasket materials (see Table H-4) Face materials (see Table H-5) Third letter: Table H-5 – Fifth Letter of Mechanical Seal Classification Code Sealing Ring Face Materials Fifth Letter L M N O P X Ring 1 Carbon Carbon Carbon Tungsten carbide 2 Silicon carbide As specified Ring 2 Tungsten carbide 1 Tungsten carbide 2 Silicon carbide Silicon carbide Silicon carbide As specified Fourth letter: Fifth letter: For example. 4. and carbon against tungsten carbide 2 faces. an FKM seal-ring-tosleeve gasket. no throttle bushing.7. Metal bellows shall have a corrosion rate of less than 50 ìm (2 mils) per year. The spring materials for single spring seals shall be austenitic stainless steel (AISI Standard Type 316 or equal). leakage and/or drain connections. except that metal bellows. A metal seal ring shall not have sprayed overlay in place of a solid face. cooling water) – potential for Durco Mark III ANSI and Chemstar ISO pumps. sour water. • • Flowserve RED 1/00 C-1 . Also potential for Flowserve Vertical Circulator type pumps. However. Boiler feedwater pumps – potential for type MX pumps. Fire water pumps – potential for type DVS and Vertical Circulator type pumps.Delayed Coker Applications Appendix C Other Pump Applications The focus of this manual is on the application of Flowserve petroleum process pumps in the actual delayed coker unit. there are potential applications for other types of Flowserve pumps in auxiliary services. Some of the potential applications and applicable pumps would be: • Water services (drain water. . 4 4. Rationale and Methodology Combined Cycle Process 1-1 1-1 Market Profiles 2.1 1.2 3.3 3.2 2.4 3.5 Flowserve Sales Decision Makers Competitive Advantages of Flowserve Pumps Guidelines for Mechanical Seals Operating Unit and Pump Details 3-1 3-1 3-1 3-2 3-2 4. Pump Recommendations 4.2 4.Combined Cycle Unit Applications Table of Contents Page Number 1. Flowserve Experience 3. Introduction 1.5 Introduction to Pump Recommendations HRSG Feedwater Pumps Auxiliary Steam Boiler Feedwater Pump Condensate Pumps Circulating Pumps 4-2 4-2 4-2 4-2 4-2 A-1 Appendix A Auxiliary Pumps for Combined Cycle Units Flowserve RED i .1 4.3 4.1 2.2 Market Drivers Competition 2-1 2-4 3.1 3. Combined Cycle Unit Applications Exhibits Page Number 1-3 1-4 2-2 2-3 4-3 1. Simple Cycle Unit Schematic 2. Two-Turbine Combined Cycle Unit Flowserve RED ii . Global Power Production by Fuel Source 4. Combined Cycle Unit Schematic 3. Global Distribution of Projected New Generating Capacity 5. Introduction 1. In today’s energy marketplace. gas (usually natural gas). There are many potential applications for Flowserve pumps in electric power generating operations. natural gas has emerged as the preferred energy source. usually steam. nuclear. Finally. This combination increases thermal efficiency and reduces fuel consumption. wind. Exhibit 2 is a schematic of a combined cycle unit. 1. features of Flowserve pumps will be highlighted along with the benefits these features provide to combined cycle operators. These gases are routed through a heat recovery steam generator (HRSG) and the steam produced is used to drive a steam turbine that in turn drives an electric generator. handling characteristics.Combined Cycle Unit Applications 1. The typical and traditional energy sources are coal. In fact. Steam is removed from the unit either before or after it passes through the steam turbine and is routed to other processes generally for heating purposes. Exhibit 1 is a schematic of a simple cycle unit. this forms a simple cycle generating unit with an efficiency of about 30%. The compressor pressurizes air that is mixed with the fuel. The hot gases formed during combustion drive the turbine and run the compressor. Combined cycle units can also operate as cogenerators. and environmental concerns. solar). Since natural gas has become the preferred energy source for new electric power projects. A cogenerator is a facility that produces electricity and another form of useful thermal energy. the manual will present pump configurations that will provide reliable.. However. A gas turbine typically consists of an axial-flow compressor and one or more combustion chambers. dependable service in these generating units. In addition to discussing combined cycle technology. there is much that Flowserve can offer to this market. The energy source is the most critical variable in these complex systems. hydro. Electricity is generated everywhere. which in turn drives a turbine that drives the electric generator. availability. and the fuel and air mixture is burned in the combustion chamber. The choice of the energy source depends on many factors including cost. The type of generating plant is usually defined by the energy source. combined cycle units are approaching 60% efficiency. Flowserve RED 02/00 1-1 . The energy is typically used to generate steam.g. petroleum. The industry takes an energy source and converts that energy into electricity. and other (e. usually natural gas. some systems by-pass the steam cycle and directly drive the generator. this manual will focus on a relatively new technology – combined cycle – that promises to offer rapid and continual growth. If the turbine is attached to an electric generator and the hot exhaust gases from the turbine are allowed to escape to the atmosphere.1 Rationale and Methodology The electric power generation industry is truly global. Because of the wealth of applications and problem solving expertise the company has accumulated over many years.2 Combined Cycle Process Gas turbines have been used for some time to generate electricity. A combined cycle generating unit makes use of the hot exhaust gases from the gas turbine. Flowserve RED 02/00 1-2 . To remain competitive and to meet the challenges of this rapidly changing market. electricity producers must strive for maximum efficiency. Combined cycle technology is proving to be one of the key tools that permits producers to meet these challenges.Combined Cycle Unit Applications The electric power generating industry is changing rapidly with the major trend being from regulation toward competition. Combined Cycle Unit Applications EXHIBIT 1 SIMPLE CYCLE UNIT SCHEMATIC Fuel Compressor Turbine Generator Electricity Air Exhaust Flowserve RED 02/00 1-3 . Combined Cycle Unit Applications EXHIBIT 2 COMBINED CYCLE UNIT SCHEMATIC Fuel Compressor Gas Turbine Generator Electricity Air Exhaust Steam Heat Recovery Steam Generator Steam Turbine Generator Electricity Condenser Flowserve RED 02/00 1-4 . In fact. Market Profile 2.Combined Cycle Unit Applications 2. There are four major providers in the electric power generation industry. One example of profound change is shown in growth forecasts for the major electric power providers. In the emerging economies. most of the growth in the electric power generation industry is in IPP’s and merchant producers and not in the traditional utility and industrial segments. The electric power generation industry is in the midst of profound change and is being buffeted by many forces. It is estimated that the current global generating capacity is about 3.1 Market Drivers There are two major segments of the electric power generation industry and the market drivers are very different in these segments. this trend has been the major contributor to growth of IPP’s and merchant producers. Another industry trend that is causing profound change is the shift from regulation to competition. the growth rate will be limited by financing constraints and political uncertainties. In the developed economies. The future growth of electric power generation in these two segments will be influenced by different factors. Table 1 below shows the percentage of new projects either completed in 1997. Exhibit 2 below shows the distribution of this global capacity by the primary energy sources. independent power producers (IPP). growth will be driven by surging demand for electricity. and merchant producers. or planned for 1999 and 2001. utilities. particularly in the emerging economies. namely. The segments are the developed world economies (primarily North America and Western Europe) and the emerging world economies. the growth will not be closely related to GDP growth because GDP growth will be in low energy usage industries and energy conservation efforts are prevalent and effective. 1 One gigawatt = one billion watts Flowserve RED 02/00 2-1 . there is the pressure to grow to meet increased demand. Rather. industrial (captive). In addition to competitive pressures. Table 1 Percentage of New Project by Type Provider 1997 38% 12% 50% 0% 1999 25% 10% 55% 10% 2001 20% 12% 50% 18% Utilities Industrial IPP Merchant As this table shows. Growth worldwide should average slightly over 3% for the foreseeable future with 30% of the growth occurring in the developed economies and 70% in the emerging economies.000 gigawatts (GW)1. growth will be driven by the aging of the existing power infrastructure and the required upgrading and replacement of this infrastructure. Even though there will be strong demand for more generating capacity. the growth rates of each of the input energy sources are quite different as is shown in Table 2 below.2%. the projected growth in generating capacity fueled by gas is twice the overall growth rate and 73% greater than coal. However. This forecast further estimates that gas will fuel at least 40% of the new capacity.Combined Cycle Unit Applications Exhibit 3 Global Power Production by Fuel Source Other 16% Petroleum 10% Coal 44% Nuclear 18% Gas 12% The growth rate in generating capacity over the next 10 years is forecast to be about 3. Even though gas fired units will not be dominate globally. As further proof that gas will be the predominant fuel.S. Flowserve RED 02/00 2-2 . the number two fuel. Natural gas is used to fuel many traditional steam turbine units. because of the advantages of combined cycle technology. One recent forecast has projected the growth of new electric generating capacity over the next 10 years.4% 3. electric power generation industry will be gas turbine based. It should be noted that natural gas will not fuel only combined cycle or even gas turbine units.5% As this table shows.7% 2. Table 2 Global Growth Rates by Input Energy Source Input Energy Source Gas Coal Petroleum Nuclear Projected Annual Growth Rate 6. much of the natural gas will go toward fueling these types of units. however.2% 0. they will be major factors particularly in regions where natural gas is readily available. it is estimated that over the next 5-7 years over 85% of the new capacity added to the U. This forecast estimates 695 GW of new capacity with a global distribution as shown in Exhibit 3. Table 3 below is presented. and with increased emphasis on competition and profitability. combined cycle units should be the preferred technology. Flowserve RED 02/00 2-3 . Below is a summary of the factors that make combined cycle technology attractive: • • • • • • • • Lower initial investment cost Smaller land parcels needed Higher efficiency Lower operating and maintenance costs Faster return on investment Environmental factors (very low pollution potential because most units fired with natural gas) Versatility Ease of obtaining permits As a more definitive comparison of combined cycle technology versus the other types of generating units.Combined Cycle Unit Applications Exhibit 4 Global Distribution of Projected New Generating Capacity USA & Canada 12% Latin America 11% Asia-Pacific 52% Europe. Middle East. Africa 25% All the above indicates that gas fired turbines will be a major factor in the growth of the electric power generation industry. There are other factors that also favor combined cycle technology. Active research projects are underway in advanced gasification systems. Europe will favor combined cycle units because of environmental concerns. and Sulzer. The global presence of the Flowserve organization will allow the company to participate in Flowserve RED 02/00 2-4 .023-0. and short construction cycles. has Flowserve pumps installed for the boiler feedwater and water circulating applications so the company is gaining valuable experience in this emerging technology.2 Competition The primary global competitors in the electric power generation industry are IDP. coal is still a very abundant fuel and will continue to be a factor particularly as coal gasification technology advances. hot gas particulate removal. and advanced turbine systems.040/kWh $0. waste disposal) Conventional coal $750/kW w/ FGD 1 Conventional coal $700/kW Combined cycle $600/kW 1 – flue gas desulfurization OPERATING EFFICIENCY 32% OPERATINGCOSTS US$/kWh $0. which has huge potential. Natural gas is currently a preferred fuel for electricity generation because it is readily available at attractive prices and it is environmentally friendly.040-0. environmental issues. However. KSB.S.. located in Tampa. Florida. the Department of Energy is assisting in the development of integrated gasification combined cycle (IGCC). 2. Combined cycle units will be favored in North America because of competitive factors.057/kWh 38 – 42% 39 – 43% 57% $0. Flowserve pumps have performed well in many power industry applications for many years. Fully developed and proven IGCC technology could lead to coal being the most economical. Three operating demonstration projects are up and running. China. One major regional competitor is Ebara in the Asia-Pacific. In fact.S. long-term fuel of choice for electricity production. In the U.000/kW Nuclear (incl. These plants will use gasified coal as fuel to operate a standard combined cycle unit. the Department of Energy estimates that successful development of IGCC technology could lead to it providing about 30% (approximately 450 GW) of the U. Combined cycle units will be built in parts of Latin America because of the availability of natural gas.030/kWh There are some regional comments worth considering.Combined Cycle Unit Applications TABLE 3 COMPARISON OF GENERATING UNITS INVESTMENT GENERATING METHOD COSTS – US$/kW Nuclear >$5. will likely stress traditional coal fired units short term. hot gas desulfurization. Weir. combined cycle will receive increased emphasis. electricity by the year 2050. One of these projects. but as natural gas becomes more available. Flowserve RED 02/00 2-5 . The electric power generation industry is becoming more competitive and cost-conscience and Flowserve can assist power companies in improving pump reliability that leads to improved profitability.3.Combined Cycle Unit Applications the power industry worldwide. The features that provide Flowserve pumps with competitive advantages will be highlighted in Section 3. but the USA-Canada and Latin America regions will see significant growth also. condensate services. Price is important along with the past experience and reputation of the pump supplier.2 Decision Makers Engineering firms are the key players in determining the equipment supplier(s) for new electric power generating facilities. Demand for new capacity will be strongest in the Asia-Pacific and Europe-Middle East-Africa regions. MSN. or “pancake”) design. For very high pressures. diffuser. The condensate services typically have very low values for NPSH available and vertically suspended double case pumps are used. and HDBI are commonly used. At least 40% of the new demand will be supplied by gas turbine facilities and most of these will use combined cycle technology. 3. These firms generally have a rotating equipment specialist assigned to each project and this individual will be the key decision maker regarding pump selection frequently with input from the end-user’s rotating equipment specialist. and water circulating services. double case pumps are sometimes required. The boiler feedwater pumps must handle high pressures and fairly high flow rates and for these services between bearing multistage pumps are commonly used. Flowserve RED 3-1 . boiler feedwater services. HDB.1 Flowserve Sales There will be global demand for new electric power generating capacity for the foreseeable future. Flowserve competes against this type of pump by promoting the lines. and the features and benefits. 3. Flowserve Experience 3. Flowserve models MX. DVMX.3 Competitive Advantages of Flowserve Pumps Flowserve has achieved a reputation for supplying high quality. listed above. The global presence of Flowserve should allow the company to be an active participant in this growth. For the boiler feedwater services. These between bearing single and double casing multistage pumps offer the following features and benefits: Feature Axially split case Double suction first stage impeller (option) Finned bearing housing Dynamic balancing of fully assembled rotating unit Benefit Ease of maintenance Minimizes NPSHR Maximum heat dissipation Minimize vibration Another type of pump used for boiler feedwater services in combined cycle units is the ringsection (also called segmental ring. namely. The water circulating services characteristically have very high flow rates at low pressures and vertically suspended mixed flow and axial flow pumps are used. dependable pumping equipment to the electric power generation industry and has gained a wealth of experience through handling many of the critical services found in central power generating units.Combined Cycle Unit Applications 3. Most of the critical applications in combined cycle units involve water handling. Typical models include the HQ. As the temperature increases. Flowserve vertically suspended axial and mixed flow pumps are commonly used. proven pump configurations (models. etc. safe operation Depending on the combined cycle unit design. reduced maintenance Maximize efficiency Reliable.4 Guidelines for Mechanical Seals Water. reduced vibration Superior alignment. Flowserve model VLT pumps are commonly used. Appendix A lists some of the possible auxiliary applications. eases seal replacement For the circulating water services. In Section 4. HXH. Features and benefits of these pumps include: Feature Open. 3. semi-open. of water drops dramatically. materials. seals. and closed impellers available Integral bearing retainer Engineered to customer specifications Split-ring. Flowserve RED 3-2 . and RXL. the advice of a Flowserve FSD sealing specialist should be sought. For this reason. keyed impeller Benefit Optimum hydraulic coverage Positive alignment.5 Operating Unit and Pump Details The critical pump applications in a combined cycle unit are the water handling pumps. particularly hot water. 3.) will be presented.Combined Cycle Unit Applications For the condensate water services. Pump Applications. proper seal design and materials of construction are critical to providing long and dependable life. there can be applications for other types of Flowserve pumps. the viscosity. and therefore the lubricity. is difficult to seal. To insure proper seal selection for the critical water handling pumps in a combined cycle unit. These vertically suspended double case pumps offer the following features and benefits for these difficult services: Feature Standard large eye first stage impeller Integral wear rings Registered motor fit Four piece rigid adjustable coupling Benefit Very low NPSH required Lower initial cost Better alignment. They are based on specifications which have performed well in the field. These guidelines should not take the place of any manufacturer’s recommended specification for a given application. and manufacturers of components/accessories are to be consulted for detailed specifications as well. Flowserve RED 02/00 4-1 . Pump and Material Recommendations The recommendations that follow are general guidelines. A qualified pump engineer must still be involved in the specification of any pump.Combined Cycle Unit Applications 4. Other specifications not addressed in this manual may be equally or more acceptable. and are intended to raise awareness of issues associated with particular applications. depending on variables associated with the application. These are used as start-up pumps or as fill pumps for the system and their location will depend on the individual system design. 4. This is a two-turbine unit and Exhibit 4 is a schematic of this unit showing the placement of the pumps. 12 stage) Material of construction – Case and impeller (ASTM A743. below is presented the water handling pumps (HRSG feedwater.) Total dynamic head (TDH) @ rated capacity – 760 ft (232 m) Capacity @ rated TDH – 550 gpm (125 m 3/hr) Temperature – 220oF (104 oC) Pump Model – SCE (3X6X15M) Material of construction – Case (Carbon steel).560 m 3/hr) Temperature – 80oF (27oC) Pump Model – 48 HXH (1 stage VCT) Material of construction – Case (Cast iron). condensate. the water handling pumps are critical elements in the performance of the unit. Grade CA-6NM) Mechanical seal – Flowserve Type QB (Material Code – 5N4A.1 Introduction to Pump Recommendations Regardless of the size of a combined cycle unit. auxiliary steam boiler feedwater.5 Circulating Water Pumps Total dynamic head (TDH) @ rated capacity – 80 ft (24 m) Capacity @ rated TDH – 55. To give a sense of the types of pumps typically used and the configuration of these pumps. impeller (316L SS) 2 MW = megawatt = one million watts Flowserve RED 02/00 4-2 . API Code – BSTFM) 4. Grade CA-6NM) Mechanical seal – Flowserve Type QB (Material Code – 5N4A.3 Auxiliary Steam Boiler Feedwater Pumps (These pumps are not shown in Exhibit 4. API Code – BSTFM) 4. and circulating water) for a 500 MW 2 combined cycle unit. API Code – BSTFM) 4.Combined Cycle Unit Applications 4.2 HRSG Feedwater Pumps Total dynamic head (TDH) @ rated capacity – 5800 ft (1768 m) Capacity @ rated TDH – 950 gpm (216 m 3/hr) Temperature – 300oF (149 oC) Pump Model – MSN (6X6X11MM.300 gpm (12. impeller (ASTM A743.4 Condensate Pumps Total dynamic head (TDH) @ rated capacity – 575 ft (175 m) Capacity @ rated TDH – 1475 gpm (335 m 3/hr) Temperature – 100oF (38oC) Pump Model – VLT (1300) Material of construction – Case and impeller (Cast iron) Mechanical seal – Flowserve Type QB (Material Code – 5N4A. Combined Cycle Unit Applications Compressor Gas Turbine Generator Electricity Air Compressor Fuel Gas Turbine Generator Electricity Exhaust Steam Heat Recovery Steam Generator Steam Turbine Generator Electricity Condenser Condensate Pump Cooling Water Circulating Pump HRSG Feedwater Pump Condenser Hot Well Flowserve RED 02/00 4-3 . These may not be part of the specification for the actual unit but rather these may be found in specifications for auxiliary services. Some common descriptions for auxiliary pumps include: • • • • • • • • • • • • Service water Chlorine booster Evaporator coil feed Filter backwash Gland water circulation Auxiliary cooling water Glycol solution recirculation Evaporator feed Service water jockey Glycol heater drain Turbine oil transfer Chemical feed An integrated gasification combined cycle unit (IGCC) will include a coal handling system and there will probably be need for the following pumps: • • • • • Dust suppression spray Dump building sump Coal pile runoff pond Treatment pond discharge Floor drain sump Flowserve RED 02/00 A-1 .Combined Cycle Unit Applications Appendix A Auxiliary Pumps for Combined Cycle Units There are a number of potential applications for other types of Flowserve pumps in combined cycle units.