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Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance

Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance. 6 th  to 10 th  of May 2013. AGADIR MOROCO. Neville Jordison Solex Thermal Science Inc. Canada. A Brief History.

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Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance

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  1. Indirect Plate Heat Exchangers for Cooling Fertilizer offer long term operating performance 6th to 10th of May 2013. AGADIR MOROCO Neville Jordison Solex Thermal Science Inc. Canada

  2. A Brief History • Indirect Heat Exchanger introduced to the fertilizer industry approximately 25 years ago • Today more than 100 coolers installed in fertilizer plants round the world • Equipment operating successfully in every type of fertilizer- Urea (prills & granules), AN, CAN, LDAN, NPK, MAP, DAP, AS • Company History • 1990 - creation of Bulkflow Heat Exchangers – a technology division within Cominco Engineering Services Ltd • 1999- BULKFLOW TECHNOLOGIES is incorporated with headquarters in Calgary, Canada • 2008 - Rebranded as Solex Thermal Science Incto enhance profile as a world leader in the science of heating and cooling bulk solids

  3. Advantages compared to Air Cooling (Rotary or Fluid Bed) • Low energy consumption • No air usage – eliminates chillers, fans ducts and scrubber • Compact design • Lower installed capital cost

  4. Principle of Operation • Combines the science of mass flow with indirect heat transfer • Product flows slowly by gravity between water cooled plates • Product flows in uniform velocity mass flow • Water flows counter-current inside plates • Heat Exchange by conduction

  5. The Secret to Long Term Operating PerformanceWhat causes Caking ? HYGROSCOPIC PRODUCT HUMIDITY IN VOID SPACE WATER COOLED PLATES CONDENSATION × CAKING ON PLATES

  6. The Secret to Long Term Operating PerformancePreventing the Caking Mechanism ADD PURGE AIR TO LOWER DEWPOINT CORRECT WATER TEMP PROFILE PURGE AIR ELIMINATE CONDENSATION  NO CAKING

  7. The Secret to Long Term Operating PerformanceThe CRH Curve

  8. The Secret to Long Term Operating PerformanceThermal Modelling – Process Input Conditions

  9. The Secret to Long Term Operating PerformanceThermal Modelling – Output Temperature Profile

  10. The Secret to Long Term Operating PerformanceEnsuring Water Temperature is above the Dew Point Water temperature must be to right of dewpoint line to prevent condensation mechanism

  11. The Secret to Long Term Operating PerformanceComplete System • Tempered Water Module to provide controlled cooling water temperatures • Purge air system controlled flowrate and dewpoint • Instrumentation and Control System

  12. Pilot Testing at OCP Jorf Lasfar • DAP • Product Inlet Temperature 65 – 75°C • Maintain discharge temperature below 50°C • Demonstrate long term run capability without caking

  13. Pilot Testing at OCP Jorf Lasfar PRODUCT IN • Test Set-up • Double Bank Exchanger • Controlled Cooling Water Temperatures • Purge Air system • Demonstrate long term run capability without caking PURGE AIR PRODUCT OUT

  14. Pilot Testing at OCP Jorf Lasfar Results

  15. Pilot Testing at OCP Jorf Lasfar • Plate Banks checked after each run • Removable Plexiglas plate • Plate surfaces stayed clean throughout testing

  16. Typical DAP Cooler A = 10740 B = 1650 C = 1580 E = 150 F = 1800 G = 2470 J = 1390 • Product Flowrate: 100 t/h • Product Size: 1 – 4 mm • Product Temperature in: 85C • Required Product Temp. out: < 50C • Cooling Water: Cooling Tower at 28C • Purge Air: Required

  17. Typical DAP Cooler • Water Temperature Control Module • Primary water supply can be cooling tower or sea water – use 254SMO or titanium plate heat exchanger • Purge Air Supply • Unit typically installed immediately following the screens

  18. Recent Fertilizer Projects

  19. Large urea prill cooler during installation in India

  20. Long Term Operating Performance “This campaign the CAN Plant startedup on 5th of June and until now The Solex Cooler hasn’t needed cleaningyet and is operating perfectly”. Quote from Alp Bulent GULES Gemlik Gubre Sanayii A.S. Sept 26th 2010 Thank you for your attention

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