Project Synopsis
Perform process alternative evaluations including hydraulic modeling for the addition of new dynamic ovens and ductwork at a catalyst manufacturer’s production facility.
Project Summary
The client, a catalyst manufacturer, is proposing the addition of new dynamic ovens at one of their existing production facilities. The new equipment is intended to include ovens, an forced-draft (FD) booster fan, and exhaust ductwork. Due to this addition, there is a need to evaluate the best way to route the exhaust from the new oven ductwork into the existing building Pollution Control System (PCS).
Process Engineering Associates, LLC (PROCESS) was contracted by the client to evaluate the three (3) options. The primary purpose of PROCESS’ work was to evaluate the system hydraulics and assist the client in their decision-making process. This included evaluating proposed duct sizes, oven FD fan size, and the flow path to the PCS.
An evaluation basis was developed to guide the evaluation process. A detailed list of information is included in the text below. The evaluation basis includes information on the configuration, ductwork, and equipment that comprise the current and proposed PCS. Equipment performance and geometry as well as the ductwork geometry was used in the modeling effort.
Process Flow Diagrams (PFDs) were developed for the configurations under evaluation.
- Option 1 – the new oven exhaust entering the main exhaust manifold for the existing dryers.
- Option 2 – routes the oven exhaust into the IPS oven ductwork prior to the FD fan.
- Option 3 – was configured with the fan vent gas ducted across the roof to join in with the main flow prior to entering the heat exchanger.
Steady state mass and energy balances were developed for each of the options. The results of the steady state models indicated that Option 2 generated a large pressure drop. The pressure drop would require a large amount of work for the FD scrubber fan. Option 2 was dropped from consideration.
The steady state model results were then used to develop the hydraulic models. Evaluation of modeling results indicated that Option 1 was preferred over Option 3. The reason for this is that the dryer ductwork is under-utilized so there is ample volume available to accommodate the flow from the new ovens. Also, it negates the expense of running new ductwork across the roof (Option 3).
The hydraulic model was used to verify the duct diameter for the new oven exhaust header and ducting to the dryer exhaust header. The hydraulic model was also used to identify appropriate fan size and speeds for the new oven FD fan.
Industry Type
Metal Catalyst Manufacturing
Utilized Skills
- Process technical alternatives
- Process simulation modeling
- Process hydraulic modeling
- Process gas ventilation design and sizing.