INDUSTRIAL PLANTS v2 - Analisis-DSC · -Damages evaluation. - Operating analysis of any equipment...
Transcript of INDUSTRIAL PLANTS v2 - Analisis-DSC · -Damages evaluation. - Operating analysis of any equipment...
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INDUSTRIAL OPTIMIZATION
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CONTENTS
• Who are we: ANALISIS-DSC?
• Design, optimization and analysis of elements orgeneric situations applications in a factory:
• Valves.
• Heat exchangers/Condensers/Evaporators.
• Pumps/Fans/Turbomachinery.
• Scrubbers.
• Pollutants dispersion.
• Incidents/accidents analysis .
• Contact.
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Misión - VisiónANALISIS-DSC
Our Mission is:To be reference in the sectors: Fluid-dynamics and its interaction with structures.To be specialist in the modeling of Solid Particles.
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Results reflected on:• Costs reduction• Quality improvement• Increasing production• Increasing profits
Design optimizationIndustrial processes optimizationEnergetic Eficiency AnalysisContingency Analysis
(incidents/accidents)Equipment Damages Analysis
WHAT CAN WE PROVIDE TO
OUR CLIENTS?
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Aeronautical Mining
Naval Agriculture
Wind and thermal energy Pharmaceutical
Civil Engineering Others
Chemical
HVAC
Automotive
Enviromental
Turbomachinery
Steel
Defense
Fire Safety
TARGET SECTORS
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VALVES: BALOON VALVE
2904184.4773.3126997117071.4407490
[pa][m/s][m/s][kg*m^-3][Pa][Pa]
Pressureloss
Velocityoutlet
Velocityinlet
Density(cte.)
P(total)(outlet)
P(total)(inlet) Fluid: Water
Temperature: 25ºC
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VALVES: Declining valves, Gases
0.57847
kg*m^-3]
INLET DENSITY
958.526118.16070.575591101349101444
[pa][m/s][m/s][kg*m^-3][Pa][Pa]
PRESSURE LOSS
OUTLET VELOCITY
INLET VELOCITY
OUTLET DENSITY
P(total)(OUTLET)
P(total)(INLET)
Fluid: water vapour
Temperature: 380 k (106.85 ºC)
Inlet surface: 0.000379 m 2
STATIONARY VALUES
Streamlines for the gas used
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VALVES : Declining valves, Gases
- Transversal cut showing thefluid velocities.
- Locating backwater points.
- Fluid dynamic forces ⇒⇒⇒⇒
structural dimensioning ofthe components.
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VALVES : Declining valves, Gases
Turbulence kinetic energy:
• Pressure loss points.
• Points with bigger erosion.
• Compressive fluids analysis.
• State changes location.
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2415754.7374.694997102555344130
[pa][m/s][m/s][kg*m -3][Pa][Pa]
Pressureloss
Outlet velocityInlet velocityDensity(constant)
P(total)(outlet)
P(total)(inlet) Fluid: Water
Temperature: 25ºC
STATIONARY VALUES (WITHOUT WATER HAMMER)
At any operating or working equipment there is the possibili ty of exceptionalsituations.
Pressure considering:
• Normal operating conditions.
• Incident or accident situations.
Butterfly valve with water hammerdownstream
VALVES : Butterfly valve with waterhammer
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VALVES : Butterfly valve with waterhammer
We evaluate the resulting forceson the valve over time.
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VALVES: Ponential projects andcapacities
• Operating curves development.• Cavitation and condensation prediction.• Accurate heat transfer.• Behaviour in adverse conditions (water hammer, fluids wi th particles,
etc.):– Design conditions.– Out of design conditions.
• Erosion and product life studies.• Noise studies.• Biphase flows dimensioning.
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• Several tubes exchanger (water/ glycerol) withdeflectores.
• Fluid and solid heat transfer.• Heat loads and overpressure analysis.
HEAT EXCHANGERS
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� Temperature in cooler. � Temperature on the methal.
HEAT EXCHANGERS
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• Three plates interchanger (water/ air). • Heat transfer in fluids and solids.• Heat loads and overpressure analysis.
PLATE EXCHANGER
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PLATE EXCHANGER
Changes in cooler temperatureas times goes by.
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CONDENSERS &EVAPORATORS
�Microscopic analysis (Fins)�Including aerodynamics and thermal
�Macroscopic analysis(Complete Equipment)
�Including aerodynamics, thermal andphase change
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Heat transfer atcondensator´s fins.
Loss of pressure on the finsof the evaporator.
CONDENSERS & EVAPORATORS (Fins)
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Temperature distribution
Change of state
Velocitydistribution
CONDENSERS/ EVAPORATORS
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HEAT EXCHANGERS
Hidraulic
Design
Mechanical
Design
Thermal
Design
Materials
Choosing
Efficiency optimizationCost savingsDecrease in number of prototypes required
� THERMAL DESIGN:�Energy balance�Transmission rate
�HIDRAULIC DESIGN:�Caudales�Load drops / pumping
�MECHANICAL DESIGN:�Overpressures�Thermal stress
�MATERIALS CHOOSING:�Chemical compatibility�Corrosion
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ADVANTAGES
We consider the main advantages:
- Design support (NTU and MLTD methods):�Accurate estimation of transmission coefficients (fluid andstructure)�Efficiency curve.
- Dimensioning:�Heat exchange surfaces analysis�Tubes and housing particle deposition�Pressure upon tubes and housing
- Functioning analysis out of the design conditions:� In steady-state functioning� Transitories out of the design point.
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ADVANTAGES
- Efficiency studies:� Enthropic Analysis of heat exchange� Pressure drop due to turbulent zones
- At local level:� Detection of low velocity zones� Local loads / fracture
- Parametric studies development.
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FANS: Axial fan
Operating conditions:
• Speed: 1740 r. p. m.
• Mass flow rate: 1 kg/s
Pressure distribution at 0.5 span:
•Performance
•Noise level
•Others
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• Axial fan:
• 9 blades
• Internal radius = 5.0 cm.
• External radius = 13.2 cm.
SPL or sound pressurelevels at differentpoints on the suctionarea.
Frequencies andharmónicos analysis.
FANS: Acoustics
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Operating conditions:
• 890 r. p. m.
• Pressure drop = 300 Pa
Pressure levels Velocity distribution
FANS: Radial fan
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1. Help on the design:
- Operating curves. Savings in prototypes and scales.
- Performance and power optimization.
- Achievement of specifications and with the authorities on n oiselevels.
- Competiveness as acoustic pollution is diminished.
2. At local level:- Vibrations.- Effect of the spaces between blades and the on the housing.
3. Behaviour out of the desing conditions:- Knowledge of operations in installations.- Operating on dirty atmospheres. Element erosion.
FANS: Case studies and capacities
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Operating conditions:
• Speed: 3450 r. p. m.
• Pressure drop: 1 bar
Pressure distribution
PUMPS: Radial pump
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Pressure curves and velocity inlet to oulet.
PUMPS: Radial pump
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Cavitation areas
Pressure distribution, vectors and cavitation area
PUMPS: Cavitation
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Operating conditions:
• Speed: 1000 r. p. m.
• Pressure drop: 5000 Pa
PUMPS: Axial pump
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Span = 0.2 Span = 0.5 Span = 0.8
Inlet to outlet chart
PUMPS: Axial pump
Blade loading chart
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1. Help on the design:– Real H-Q curves determination: savings in prototypes and
scaling problems.– NPSH curve.– Hydraulic and power performance.
2. At local level:– Recirculating and waterback locations: looking up
undesirable local effects.– Cavitation: cavitation area locations during operating
conditions.
3. Behaviour out of design conditions:– Optimal installation case by case for auto-hooving: pu mp
adapted to installation.– Starting up operating.
PUMPS Case studies and capacities
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4. Coupled effects to the operating:– Non-Newtonian fluids: local determination of the pump/f luids
interaction.– Pressure loads on materials evaluation: local pressure f ields.– Heat loads.– Erosion.– Dirtyness and deposits.– Vibrations and noise.– Cooling and heating effects: optimization.– Lubrication.
PUMPS Case studies and capacities
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SCRUBBER
• Objective: simulation to observe and study the relevant phenomena when the liquid injection volume of flow is changed.
• Scrubbers:
• Big importance for the chemical and process industry. Enviroment.
• Gas treatment: eliminate noxious fumes for the enviroment (SOx from combustion gases and others).
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Typical design:• Height = 6.5 m
• Diametre = 2 m
• Injector phases = 2
Gases outlet
Filter (demister)
Liquid injector
Gases inlet
Liquid outlet (slurry)
SCRUBBER
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• Results (Q1= 0,015 kg/s)
SCRUBBER
Drops path
Volumetric fraction
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• Results (Q1= 0,015 kg/s)
SCRUBBER
Drops residence time
Gas residence time
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773800Temperature [ºC]
0,0560,050H2O.mf
0,000630,001SO2.mf
OutletInlet
SCRUBBER
• Improving design/starting up (Q1= 0,015 kg/s):
• Flow homogeneization baffles:
• Avoid backwater areas.
• Avoid preffered ways.
• More number / better distribution of injectors:
• Bigger contact area gas/liquid.
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• Land: 3,6 X 5,2 km.
Town
Chemical industry (leak of 50 kg/s ofethane and chloro)
Wind with velocity profile. 2 m/s at 10 m height
• Ideal gas air
• Cl2 (chlorine)
• C2H6 (ethane)
Ethane explosion riskChlorine toxic cloud
POLLUTANTS DISPERSION
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Exposure time = 15 min.
POLLUTANTS DISPERSION• Results: Vulnerability: death probability (PROBIT method)
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1. Security projects. Emergency and evacuation plans desi gn:- Vulnerability for toxics or radiations PROBIT analysis.
2. Risk analysis. Leak risks evaluation.- Immediately Dangerous to Life or Health risk.
3. Emergency plans.
4. Toxic clouds dispersion coupled to complex orographies analysis.
5. Explosion risk analysis (explosive mixtures coming up ).
6. Study of spills in rivers and ports.
POLLUTANTS DISPERSION Case studies and capacities
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Industrial plantsWhat can we provide?
- Development of projects of different equipments at an indus trial plant:
- Design / optimization.
- Behaviour detailled evaluation:
- Normal operating conditions.
- Transitories out of the operating conditions.
- Damages on equipments analysis.
- The same kind of projects can be applied to other equipment s like:
- Boilers.
- Refrigerating towers.
- Others.
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Industrial plantsWhat can we provide?
- It can also be applied to elements like:
- Reactors (including kinetics of the reaction)/scrubbers/ etc...
- Incidents or accidents evaluations:
-Pollutants dispersion.
- Damages evaluation.- Operating analysis of any equipment in which a fluid int ervenes. - Locating and solving bottle necks in plants.- Diminishing and 0 pollutants systems.- Leak or scape risk analysis.
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Contact
���� www.analisis-dsc.com, click on the top right part for the English version.
���� [email protected]
� +34 914614071 or +34 914284802
���� ANALISIS-DSCC/ Nuestra Señora de la Luz, 21 local Izq. 28025 Madrid (SPAIN)
If You are interested in a technical meeting or in getti ng more informationabout our products and services, do not hesitate to contac t us.