FGC Services
SO3 System Audits | Injection Probe BiasingSO3 System Audits
The purposes of an engineering audit of an SO3 system is to provide a detailed report of the condition of the existing equipment, make recommendations for upgrades and long term operational requirements, and review the operating needs of the plant.
The specific work scope for an evaluation of an SO3 System includes:
Visual inspection of the following equipment: sulfur storage & pumping equipment, steam generating equipment, control cabinets, process air blower, heaters, control valving, instrumentation, and dilution piping. If the system is in operating mode, we will record all possible data to calculate the performance and output. If the system is off-line and access to the ductwork is possible, we will also inspect the condition of the injection probes.
To assist the FGC, Inc. inspector with the audit, we request certain basic information be available at the site. This information would include P&I Diagrams, Skid Layout Drawings, and Equipment Capacities. This information is usually available within the original operation manuals, but we understand that only a limited amount of system data may be available for this specific equipment. In addition, we would request that all available process data (flue gas flows, temperatures, etc.) be pre-recorded during a period of operation for subsequent evaluation by FGC, Inc.
A formal report will follow within two to three weeks of the site evaluation. This report will include findings from the audit as well as captioned photographs. Also included in the report will be predictions and operational recommendations based on process information gathered from the system controls such as SO3 feedrates & injection rates, and plant data such as boiler load, flue gas flow and temperature. The report will include long and short term recommendations as well as suggested repairs with budget numbers to evaluate which portions are most important to address.
Typically full system audits require 2-3 days including travel time, plus additional office time to complete the written report.
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Injection Probe Biasing
To improve the effectiveness of SO3 conditioning, FGC has utilized CFD modeling to predict the flow of the SO3 from the probes to the face of the precipitator. The modeling allows the engineers to modify injection locations and sizing to customize the injection grid to fit the plant conditions. The optimized grid effectively distributes the SO3 gas across the entire face of the precipitator, therefore maximizing precipitator performance. Flue gas temperature is considered in the SO3 gas distribution to compensate for the temperature stratification from the air preheater rotation.
The final injection probe design uses varying orifice sizing to match the biasing as shown in the CFD model. The CFD modeling with injection probe biasing is crucial when dealing with complicated flue gas paths, short retention time between the injection point and the face of the precipitator, or temperature stratification > 40°F.
Typical Slides from SO3 Injection Probe Modeling project
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DSI Silo and Container
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American Lewa Pumps
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