Document g1jjnbg9aMLLn47dNap4RwK3

1 Date To From Interoffice 0 PITTSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION P. O. BOX 1000 LAKE CHARLES, LOUISIANA Correspondence November 11, 1966 Ben Walker Fred Hallemann Subject Silica Pigments Plant Prc cess Reprc sentative Status Report as of Ncvember 4, 1966 Reference The following report outlines the status of the process and equipment design for the new Silica Pigments plant at Lake Charles, Loui; iana as of November 4, 1966. Any changes in design from the Silica Pigments plant in Barberton, Ohio are specifically rated. Areas that mist be followed closely in construction and start-up are discussed as well a,s recommended spare parts that should be obtained. FH:bs Attachment cc: R. Baker C. Dye (Barberton, Ohio) R. Kaspar J. Mitchell BB 0011397 I / Process Design 1) Sand Unloading System Dry sand will be purchased and facilities have been provided so that sand can be received in either trucks or hopper cars. A sand unloading rubber belt conveyor and elevator capable of handling 150 tons per hour has been inquiried. Note: Careful consideration should be given in the design of the pit that houses the unloading conveyor and the bottom of the elevator to insure that there :.s enough room to work on the equipment in this area. Also provisions should be made to keep water out of the pit or removing any wate : from the pit. Since the sand handling equipment and storage bin has jeen set up for handling dry sand, some provisions should bi made to keep the sand dry while it is being unloaded. 2) Sand Storage Bin The sand storage bin has been designed for 1000 tons of dry sind. This bin has been sized so as to eliminate, the need to receive sand on holidays or weekends. 3) Frit Reactor The frit reactor design has been carefully coordinated with Mr. Frank Yarsa of Barberton, Ohio and all the design and operating criteria determined in the pilot plant unit have been incorporated. Note: It is recommended that this unit be expedited and installed as early as possible to allow as much time as possible for starting up and de-bugging this piece of equipment prior to startup of the rest of the plant. 4) Frit Conveyor from Frit Reactor to Frit Sirge Tin Present thoughts are to pneumatically conrey tie hot frit from the frit reactor to the frit storage bin. Incuiries are out on the design of this pneumatic conveying system. Note: There is some concern among the verdors on designing a rotary valve for handling the hot frit. It is very po? sible that a blow-tank pneumatic conveyor design is best suiled for this application. Since this is a very important ]art of the operation, serious consideration should be givei to also installing a spare unit for ccnveying this frit. j BB 00 11 898__l -1 / . 5) Silicate Furnace The design of the No. 2 silicate furnace at Barberton has been closely followed in designing the furnac; for Lake Charles. Some of the changes are as follows: a) The suspended end wall has been repliced by a sprung arch design which is like the one on the lo. 1 furnace at Baroerton, b) A 24" x 8" x 60" skimmer block will >e installed in the discharge end of the furnace. This will help _o retain the undissolved material in the furnace. A deep skimmer block was choser rather than a throat because the skimmer bl>ck can be replaced ohile the furnace is in operation whereas a considerable outag; is required to replace a throat. Note: Careful consideration must be given to the approv il prints of the furnace and regenerators to insure that proper support has been provided for the regenerator bricks and also that there is no chan;e that if the area under the furnace and regenerators settles, the flues could be cracked and damaged. Mr. Cloyde Dye should inspect all the furnace prints for his final approval. 6) Furnace Venturi Fan The furnace venturi fan design is identical tc the ones at the Barberton plant except the one for Lake Charles is larger, '.'he fan stack has been designed so that it will produce enough draft to carry the furnace at standby conditions if the fan should fail. Note: Close inspection must be made of the - a) Venturi installation to make sure that there is a cut off damper or a slide between the fan and the stable so that it will be possible to wcrlc or the fan and si ill maintain a draft on the stack. b) Careful inspection must be mace to the inside of i he venturi to insure that the throat base is centerec around the flue cone before belts are drawn tight or gussets are welded to the ejector box. It is alst critical that the veins be installed properly insde the venturi. c) Since this is a very critical piece of equipment }or furnace operation and is not spared, it is recommtnded that this fan be run for a couple c-f weeks prior to starting up the furnace so that any mechanical delects might be detected and the fan capabilities can be checked to insure that they meet design conditions. j I BB 0011899*7 2 I 0 .0 7) Furnace Area Dust Collector Scrubber A scrubber has been provided to collect :he dust from around the feed end of the furnace and off the top )f the frit bin. Thi method of collecting the dust from around the feed end has not been finalized, however, care should be exerc ..sed so as not :o make it impossible to see into the feed end o: the furnace or interfere with the operation of the cooler plates and the furnace feeder. 8) Furnace Burners The burners are to be identical to those used on No. 2 furnace at Barberton, Ohio and will be provided by ?PG. As of yet these have not been fabricated. 9) Furnace Instruments The Lake Charles furnace will be instrumented considerably more than the furnaces at the Barberton plant. It is recommended that a manual control be provided on all these instruments so that the furnace can be operated on manual if any troubles develop ir. the instruments. 10) Silicate Dissolver The silicate dissolver is identical in design to the unit at the Barberton plant except that the tires have bean changed from eight foot in diameter to ten foot in diameter so that they will te interchangeable in size with the dryer tires. 11) Silicate Seed Settling and Clarification System The silicate seed clarification and settling system is identical to the system at Barberton except that the secondary settler it a coned bottom tank to facilitate easy removal of the sludge. 12) Silicate Storage Tanks Lake Charles has selected to go to sligbtly larger tanks in diameter than at Barberton due to soil loading conditions, however, <quivalent capacity has been provided. 13) Hi-Sil 233 Precipitation Equipment The Hi-Sil 233 turbo tank design is ider tical to those at B. rberton except that overflow collection troughs have been attached t o the top of the tanks to collect any slurry that right foam over and also a tank wash pump and spray system has be en incorporated for ease of washing the tank. 14) Hi-Sil 404 Precipitation Equipment Plans are to install two (50 TPD) Hi-Si] 404 precipitation units and controls which are identical to the units at the Barberton plant. 3 | BB 0011900 | ./ 15) Dorr Tanks Two sets of 90 foot Dorr tanks identical to tie larger units at the Barberton plant with a few modifications will be installed. a) The launders have been moved outside the lank to facilitate cleaning of the launders and reduce the height required ?or gravity flow from one tank to the otler. b) The Hi-Sil 233 tanks will be set up io flew the slurry by gravity on two of the tanks. Slurry will be pumped to t ;e acidification tank. Note: PPG should install vent pipes on the top of these tanks near the center well to protect the bearings in t le drive mechanism from steam. 16) Acidification Tanks and Systems The acidification tanks are identical to those at the Barber :on plant. A ground level acid storage tank will be provrded in the are i in addition to the head tank acid surge tank. 17) Slurry Filter Wheels Eimco filter wheels identical to those recently installed on the Barberton Pigment plant expansion will be installed. Note: Filter wheel blankets have not ye; been ordered and s.iould be put on order approximately fou: to nix months prior to startup. 18) Filter Cake Conveyors The design of the filter _cake conveyor has bean changed frorr a slider belt type to a troughing roller type. It is felt that the troughing roller type will provide a cleaner and better operation and also require less horsepower. 19) Dryers Three dryers identical to the new dryer recently installed in the Barberton expansion with a few modifications will be installed. These modifications are as follows: a) A mixer section has been added to each dr/er at the feec end. b) The first 50 feet of the dryer tubes at tie feed end will be teflon coated. c) The pigtail design will be patterned after the design tl at the German firm (Degussa) has employed on their rotary dryer. -4- 0011 901 J Note: a) Extreme caution must be taken in he:ating these dr/ers for the first time. Care must be taken to insure that the tubes do not bind as they pass through the flie head. b) Caution must be taken to insure th;.t the pigtail ring is free to move over the dryer shell. c) Care must be taken to insure that no tubes are biiding in the tube supports. d) Careful check must be made that thnre is no binding in the steam neck. e) The dryers must be aligned satisfactorily. f) Carrying rolls must be proper.y adjusted. g) Close attention to the condensate system is required to insure that the condensate is being removed properly. Check for junk being washed oi t of the tubes and milding up inside the condensate pot or unc er the valve seat of the automatic condensate valve. 20) Dryer Scrubbers The dryer scrubbers are identical to the dryer scrubbers installed at Barberton during the recent Silica Pigments expansion. Note: The plastic (polyethylene) packing rings for the scrubbers have not been purchased yet. 21) Dryer Dust Clean-up Scrubbers (Ducon) Scrubbers have been installed to collect any cust that comes from the dryers during an upset condition. These have been installed to improve health and housekeeping conditions. 22) Dryer Discharge Conveyors Plans are to use a closed pneumatic conveying system for conveying the pellets from the dryer to the pellet bins. These units have not been purchased yet but from observation of terts run on this material, it is recommended that Sprout Waldron Pneumatic Conveying Systems be purchased for all the silica pigments. 23) Milling Equipment The Hi-Sil 233 roller mills and Hi-Sil 4C 4 veitical mills ar-. identical to the units in operation at the Barbertcn plent except that larger motors have been installed on the verticil mills to increase their output. Throw out devices will be included on the Lake Charles mills if they prove successful on the Barberton mills. | DB 0011902 | 5 . / 24) Mill Dust Scrubbers Ducon scrubbers have been provided to ta ee the dust from the mills and from the top of the bins and the dus : in .he bleed air f rom the pneumatic conveyors. After the pneumatic conveyor systems have been sized, a close check will be required to insure that the scrubbers purchased will be large enough to handle all the dust laden air. The amount of air to be cleaned up was estimated at the time the scrubbers weri purchased. It is felt that they were adequately sized, but :o insure against air pollution it would be wise t> recheck these requirements and purchase an additional scrubber unit if m cessary. 25) Vacuum Engines Nash vacuum engines identical to the new unit installed at Barberton will be installed in the Lake Charles Si .ica Pigments plant. 26) Low Pressure Air Compressors Two Fuller rotary air compressors identical to the unit in tie Barberton plant have been purchased for supplying low pressure air for the filter wheels. 27) Two high pressure air compressors will be installed for supplying instrument air. One of the air compressors w:ll be used as a spare for the instrument air and it can also be usee as a spare fo: the low pressure air compressor after passing the air through a pressure reducing station. 28) Dryer Scrubber Fans The dryer scrubber fans are equivalent to the units installed at Barberton. Note: Care must be exercised in designing the damper and th : damper operator on this fan in on.er to take care of :he torque that will be required to move t! e damper while the fan is in operation. Fan blades must be teflon coated. 29) Dryer Discharge Recirculation Elevators Rubber belt bucket elevators will be provided to recirculate the dryers in the event that the pneumatic conveyers plug in ord-r to , take care of the wet pellets and eliminate the necessity of shutting down the dryer. 30) Packaging Bins Bins have been provided to handle Hi-Sil 210, Roll Deaerated Hi-Sil 233, Roll Deaerated Hi-Sil 404 anc Hi-il 220 when it is | j 6 I BB 0011903 | produced. Facilities for bulk loading and bagging of this material is provided. A track scale will be installed for weighing bulk cars. After viewing the recent packaging tests at St. Regis, the writer feels that the forced-flow packer should be used on the Hi-Sil 210, the Hi-Sil 220, and the Hi-Sil 404 (deaerated). The jet-flow packer should be used on the deaerated Hi-Sil 233 if the inplant tests at Barberton prove successful. It may be recessary to install the 131 FS screw type packer if no other packer can be found to pack Hi-Sil 233 successfully. Export shipmerts must be taken into consideration when deciding on the packer installed for Hi-1 il 233. 31) Roll Deaerators Two roll deaerators identical to the units irstalled at Barberton will be installed at the Lake Charles Stlica Pigments plant. One will be used for deaerating Hi-Sil 233 end ore for Hi-Sil 404. 32) Packaging Stations As of this time none of the packaging statiors or conveyors from the packers to the automatic palletizer: have been laid out. 33) Pellet screening system has not been oruered as yet but the Rotex System has been decided upon for 210 ant chilsonated material screening. 34) Shipping Building and Facilities Plans are to install bag squeezers and palletizers to handle all the pigment packed. The material will be taken directly from the palletizers to be loaded or put into stock. 35) Clean-up System An adequate pneumatic clean-up system with stations throughout the mill building, packing building, and shipping building should be installed. This system has not been engineered as yet. 36) Lubrication System An automatic lubrication system installation is planned, however, design of this system has not been finalized nor the system ordered. J J3B 0011904 J 7 / .v' General 1) Piping a) Silicate Piping Silicate handling problems that have been encountered at the Barberton plant over the past years have been taken intc consideration in the design and sizing of the piping. lord, Bacon & Davis has been instructed tc make all silicate transfer lines as short as possible, all pump suction lines as siort ad possible, all lines set up so they can be drained and steamed, no dead ends or legs for the silicate to collect and so"idify, all elbows, tees and valves are to be flanged, and no ri n of pipe over forty (40) feet without being flange 1. All gravity flow lines are to be set up with a good slope and all piping runs Installed so that there is no low spot in the lines for accumulate on. All lines, valves, and pumps must be capable of withstanding 150 psig steam. Wherever the silicate lines are connected to silicate storage tanks, there must be provisions made for rodding out this tank opening. All silicate shut-off valves should be lccated as close to the tank wall as possible. b) Slurry Piping All slurry piping has been sized allowing for some scaling. Ford, Bacon & Davis has been instructed tc design the piping layout so that there is no low spots for accumulation, all valves, elbows and tees are flanged for easy removal except for some of the drain valves which are screwed, all transfer lines to be flanged at least every forty (40) feet, and consideration to be gi\en when locating these pipes on the pipe racks so as to make them easily accessible for cleaning and descaling. All slurry lines are to be piped up so that they can be washed out and steamed cut. 2) Utilities a) Superheated steam approximately 250 psig (originally 400# steam at the power house) will be the stean supply for the Silica Pigments plant. A desuperheating and pressure reducing station will be installed in the Silica Pigments plant to reduce the steam to 150# saturated. The 150# steam header feeding the dryers has been sized to supply steam for a 400 to 4i0 ton per day pigment plant. Since the dryers are designed for 201# steam pressure, it is very possible that after the dryers lave seen put into operation capacity on these dryers could be increased by operating these dryers at 175# pressure. Safety relief vlives of adequate size must be put into the lines feeding t lese iryers because there is no safety relief valves or rupture discs provided in the dryer steam neck or steam chest. ! Note: This desuperheating" system has qot been finalized yet and the instrumentation desigi mus: be checked out to 1 BB 0011905 | -8 / .0 see that smooth operation is obtained. b) Water A 2500 gpm deep well will be drillt b in the Silica Pigment plant area and tied into the general plait heed tank distribution system. This will assure a constai t supply of water ti the pigment area and especially the u:nace cooler plates. A 16 inch line header will be run through the pigr.ent plant for mater supply. c) Power Two sources of electricity will supply the pigment are.*.. One transformer will carry the normal operating load and a second transformer will supply emergency power to keep the critical motors operating in case of a power failure on the normal circuit. The equipment that will be protected in an emergency consists of all Dorr tank rakes, furnace venturi far., furnace cool .ng fans, furnace electrical controls, and dissolver drive. 3) Raw Materials a) Sand Dry sand will be purchased and usee' in the frit reactor- to reduce handling problems. b) C02 100 percent C02 will be purchased from Clin Chemicals Company. The Hi-Sil 233 carbonation system will he set up to use 100 percent CO2 rather than 40 percent as is used in Barber ton. c) Calcium Chloride 4) Sewers Sewer layouts throughout the plant pres2nt quite a problem and are of considerable concern. Due to the dninagr problems in the pigment | BB 0011906 | 0 area and the general surrounding area, ,_t is very difficult to obtain a considerable slope. The sewers are si-t up now undergroun I with clean out pits every 300 feet. Care has been exercised to insure that the H;-Sil 233 and the Hi-Sil 404 sewers do not mix or that the calcium chloride and any silicate leakage do not mix in order to prevent precipitation in the sewers. 5) Electrical Electrical sequencing and interlocking on all the equipment has not been finalized and should be checked clcsely. 6) Instruments Most of the instruments have been decided upen, however, the furnace sequencing operation has not been proviced b> the equipment supplier and must be checked closely to insure tl at it agrees with the correct operation of a sodium silicate furnace. It is suggested that Mr. C. Dye review this closely with the instrument personnel whenever they are ready. 7) Buildings All the proposed buildings appear to be adequate for the jol they; are to do, however, close attention must be paid to the erection to make sure they are leak proof. A good roof tlope is very essential. Spare Parts & Miscellaneous Items The following is a list of some of the-spare parts recommended or the Silica Pigments plant: 1) Cyclone Separator a) Spare wear plates b) Spare liners c) Spare orifices 2) Sand Unloading System a) Spare idler rolls b) Spare belting c) Spare elevator buckets d) Spare tail pulley bearings e) Spare head shift assembly f) Spare sprockets s) Spare drive chains LBB_00U967 7 10 00 3) Spare Pneumatic Conveying System for tra isfer'ring frit from frit reactor to frit storage bin. 4) Furnace Charger a) Spare linkages and bearings 5) Furnace a) Cooler plates on feed end b) Cooler plate on discharge end c) Furnace discharge chute d) Dissolver feed chutes e) Skimmer blocks f) Furnace burners g) Forebay burners h) Refractory mortars i) Fire viewing glass j) Asbestos or other heat resistant suits, g..oves, boots, face and head shield k) Belts and pulleys for combustion air and cooling; air fans X) Plug rods for stopping flow of the g_ass at the discharge end m) Kaowool 6) Dissolver a) Carrying rolls b) Pinions c) Bearings 7) Filter Wheels a) Filter blankets (Polypropylene & Freon) b) Winding wire c) Wire winding apparatus d) Knives and knife supports 8) er Scrubber a) Spray nozzles b) Scrubber packing 9) Mills a) Roller mill whizzer blades b) Vertical mill whizzer blades c) Vertical mill hammers d) Spare roller mill feeder motor e) Spare cyclone vibrator f) Spare cyclone rotary valve drive motor g) Spare vertical mill feeder drive motor 10) Turbo Tanks a) Spare stub shaft b) Spare C02 sparger pipe c) Spare thrust bearing d) Spare thrust bearing housing e) Spare gear reducer 11) Adequate Supply of Valves 12) Sprockets and Chains for Conveyors and hlevat ors 13) Dryer a) Pigtails b) Tube supports c) Key caps d) Hand hole covers e) Carrying rolls f) Drive shaft & pinion g) Ring gear h) Tire i) Steam neck packing & bolts j) Lubricator parts k) Tube support gaskets l) Tube support cadmium plated bolts and washers and nuts m) Flue head bolts and gasket 14) Air Compressor Filter Cartridge 15) Roll Deaerators a) Blankets b) Winding wire (piano wire) 16) Pneumatic Conveyors a) Spare adjustable tips b) Bearings c) Chains & sprockets 17) Filter Cake Conveyors a) Belt b) Idler rolls c) Troughing rolls d) Head pulley 18) Scrubber Fans & Mill Fans a) Belts b) Pulleys c) Bearings - 12 SB_o77 909~ 19) Whizzer Reeves Reducer a) Internal drive belts b) Drive shaft 20) Pumps The spare parts for the pumps should bt set up with the Preventative Maintenance Department. This includes packing and mechanical seals. 21) Vendor's recommended spare parts list vith each piece of e-uipment should be carefully reviewed and anticipated needs set up on commodity. 22) Spare Motors Critical motors have been spared and Mi. Bob Finke has these listed and ordered. 11910 13