((@] Research Centre MAT. TECH. REPORT Loe Porsgrunn Classification: Internal Tite: HAE Gaskets / Packings in Nitric Aci Rathore Mette Roland Plants r 1999-11-12 [Doene: 99D_BW2.iwp 9: See distribution list 1613 Pagesiape: 6 Projno: —-F70493.400 | rot: MM:(VN) Copy: Archper: Permanent G. Hognestad, HRE Kenarie K. Helland, Porsgrunn SALPETERSYRE P, Klavenes /HAP-SS, B.15 PAKNING A, Olsen, HRE Regucirk ‘Checked by: ‘Approved project responsibilty Guidelines for approval ae described inthe Research Cantve Quality Handbook (RE ‘Summary/Conclusion: ‘The report decribes the gaskets and packings used in a nitre acid plant in general. The information mostly stems from Porsgrunn, but experiences from other plants are also included, Distribution list: To: ‘Tom Hallan Neeringsparken, Porsgrunn Sigbjom Vestmoen, 8.17, Porsgrunn Wenche Olsen, Glomfjord Bo Andersson, Képing Kari Olsson, Landskrona ‘Tom Grundy, Immingham Wolfgang Wolff, Rostock Henri Lambotte, Sluiskil Dominique Briquet, Ambes Philippe Chaboche, Montolr Frank Ortiz, Pardies Martino Bassett, Ravenna Luciano Diomei, Terni Ricardo Rodriquez, Maitland Bystein Nirison, HRE, Porsgrunn Bert Swensen, HRE, Porsgrunn Copy: Matte Roland, HRE, Porsgrunn Halvor dien, HRE, Porsgrunn (L.p.) Ame O. Egner, HRE, Porsgrunn (t-p.) ‘Ame Anundskas, HRE, Porsgrunn (tp.)34 3.2 Internal Research Centre Page 2 of 6 Introduction Gaskets are crucial components in nitric acid plants. In some areas, white asbestos is used, as that has so far been the only gasket material functioning in these areas. The asbestos is mainly used in the ammonia burner. Other gaskets/packings are also in use in the burner, and recommendations regarding the burner have been given elsewhere (ef.1 to 5). In the following, experiences from all of a nitric acid plant, mainly from the Porsgrunn plant, have been gathered For some areas of the process, recommendations regarding alternative solutions are given, Where the experience is good, there are no further comments. General ‘The following streams have been followed: water, steam, ammonia, air, process gas and nitric acid. All flanges have gaskets, It is only the ammonia burner (with some exceptions) which has packings on the flanges, and some of these are made of asbestos. Earlier, asbestos was used in other areas too, but these are now replaced by other gaskets. Process stream / gasket material Water Cooling water, T < 100°C, p < 10 bars : synthetic rubber (chloropren, e.g. neopren). Earlier rubber bound aramide gaskets were also used, but the visual similarity between these and solid PTFE led to removal of rubber bound aramide gaskets in stock due to possibilities of taking this gasket instead of solid PTFE (in stock for other purposes), which in some instances could be critical. Steam In steam piping with pressure above 40 bars, spiralwound gaskets with graphite filler are used, see figure 1. At lower pressures (7 bars) with raised face flanges, graphite gaskets are used. Stale Figure 1. Schematic drawing of a spiral wound gasket ‘The graphite gaskets can be either one-layer or two-layers, see figure 2. Mue(viNy99D_BW2.lp3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 Internal Research Centre Page 3 of 6 ceaphte Figure 2. Graphite gasket, schematic Both gaskets gives the same degree of tightness, but the “one layer" is difficult to handle at larger dimensions. Ammonia On the ammonia side, only graphite gaskets are used. Air All connections down to the mixed gas filter are welded. Process gas Mixed gas filter At larger mixed gas filters (diameter > 1000mm), expanded PTFE is used. This is a string shaped gasket, and by using this, there is no loss of gasket material. Making a graphite gasket for such large dimension causes relatively large losses of gasket material, and spiral wound gaskets are expensive (and limited in sizes). For smaller mixed gas filters, graphite gaskets are used. Ammonia burner inlet. In the beginning, the gasket in the SS3 ammonia burner inlet was a graphite gasket This did not work, and asbestos was installed on dispensation. Later, this has been replaced by a home made cam profile gasket with graphite sealing attached. The gasket is re-used, after each take-out, and the graphite ribbon is replaced by a new ribbon (self adhesive). The gasket is made by applying self adhesive strips of expanded graphite to cover either a plain stainless steel gasket or a cam profile gasket. The graphite is mounted on both sides of the steel gasket. In $S2, where the inlet is smaller, a standard graphite gasket is successfully used. The reason for using a home made gaskets in some cases is that the flange is too large for commercially available graphite gaskets (and itis inexpensive). Ammonia burner, top flange Several of the plants with grooved flange, sizes above ~ 2 m, in this area are now operating with a glassfibre (Flexitallic) packing and a "sealing" compound (Loctite Permatex), which is a relatively inexpensive gasket solution, This should also be applicable in the upper flange of double flanged burner tops. Other solutions, such as PTFE/graphite or graphite fibre with Inconel reinforcement also work well, but at higher costs. For smaller flanges (1 m), spiral wound or metal jacketed gasket could be used, but at higher costs. Mqviy860_8we.twp3.5.4 3.5.5 3.6 37 Internal Research Centre Page 4 of 6 In the lower flange of the double flange system by the gauzes, asbestos is used at the moment. With a requirement of resistance to 900°C in case of leakage, ceramic fibre packings is the only alternative. Adding a "sealant" compound similar to Permatex but with higher heat resistance, will improve tightness. Another sealant, "Molycoat G-n plus” have been tested at the Research Centre. This worket well up to 400°C, but was difficult to remove after use. Spiral wound gaskets or metal jacketed gaskets are not feasible due to the large dimensions. Some plants, mainly 1 bar, but also 3 bar plants, have gaskets in this flange. The 1 bar ones have ceramic gaskets, while in a 3 bar burner graphite with asbestos has been used. Ammonia burner, lower flanges Some of the ammonia burners have one or two flanges in the lower half of the burner shell. The gaskets here are made of asbestos today. A graphite gasket with Inconel sheet was tried as a substitute on a Jarge diameter flange (~ 4.5 m). This caused a gasket blowout, leading to shut down of the plant. After this, asbestos was put back as gasket material. Graphite fibre gaskets have also been tried, this on smaller diameters (~ 1 m). This caused leakage, It was replaced by Inconel 600 gaskets which have worked well. ‘The Research Centre has carried out tests in order to find an asbestos substitute, ref.(1), (2) and (3) Downstream ammonia burners Metal jacketed gaskets with graphite filler are used at all temperatures above 230°C, at lower temperatures solid PTFE is used. In the burner outlet in SS2, Porsgrunn, a graphite gasket is used (outlet temperature. ~ 300°C). This is because the flanges are not in a condition to work well with a metal jacketed gasket. The graphite gasket has worked well for three years, but recently failed and caused shut down of the plant. However, the prime reason for failure is thought to be lack of retightening. A cam profile gasket with graphite sealing could also be used and may work better, Some plants have a welded flange connection at the outlet of the burner. Nitric acid In this system both expanded PTFE and solid PTFE are used. It should be noted that, there are different types of the solid PTFE. gasket, with different properties. Trade names SigmaS11 and Gylon work well. A problem is during start/stop conditions, due to relaxation during service. In the piping system for nitric acid (up to 65 %) at ambient temperatures, spiralwound stainless steel gaskets with PTFE filler in combination with tension bolts are used at two storage tanks, with very good result. Tail gas In the tailgas system upstream the tail gas turbine, graphite was used in the first instance. This did not work, and asbestos was used as replacement. This has later been replaced by metal jacketed gaskets. In other areas, solid PTFE is used. In other plants, spiralwound gaskets with mica filling are used. This spiralwound gasket has replaced Milam PSS, which is a mica gasket with a tanged stainless steel insert. MM(VNYe90 BW2.hwp4d 4.2 43 Internal Research Centre Page 5 of 6 Alternatives New packings As has been mentioned in earlier reports (ref. I - 3), the glass fibre packing Delvotherm 750 is considered a good gasket and is recommended as a substitue for the asbestos gaskets used in the lower flanges of the burners. Maximum operating temperature is ~ 700°C. New gaskets For the top flange of burners with raised face flanges, Novatec Premium could be used at temperatures up to 250-300°C. This should not be used in areas where NO, or HNOs might be present. For smaller diameters, also in NO, environment, the Thermiculite gasket is a preferred gasket compared to metal jacketed gaskets at most temperatures. Also, it does not require the same amount of tightening torque, thus preventing the flanges to be deformed. The flanges ‘When no gasket that works well can be found, something may at times be done by the flange connection itself. + Machine it so it becomes straigth + Use disc spring to keep the connection tight even at shut downs + Use a “hinge” system so that the load of the bolts comes on top of the gasket + Welded connection + Welded lips + Keep flanges without insulation Conclusion - In water systems, synthetic rubber (e.g. neopren, EPDM) is used. In steam and on the ammonia side, different types of graphite gaskets are in service, included spiralwound gaskets for high pressure steam. In some cases expanded PTFE string can be used. - Downstream the burner, metal jacketed gaskets, spiral wound with mica filler, or solid PTFE are used. Use of graphite is not recommended downstream the catalyst gauze. - Application of expanded PTFE, solid PTFE and spiralwound gaskets with graphite filler have worked well in HNOs system, However, use of graphite is not recommended, - For the burner shell top flanges different types of packings are used, but lately the glass fibre Flexitallic with Permatex (Loctite) has been applied in up to four plants. In the lower flange asbestos is widely used. It is recommended to substitute this asbestos with Delvotherm 750 when it eventually is opened. Mne(vIy/860_BW2IWpInternal Research Centre Page 6 of 6 ~ As for gaskets, Thermiculite is recommended as substitue for metal jacketed gaskets, and Novatec Premium for larger flange diameters (not in NOx/ HNO environments). Porsgrunn, 12.11.1999 Mette Roloct Mette Roland (1) "Gaskets/Packings for Nitric Acid Burners, Summary report", HRE doc. 99C_CY7, A. Olsen, M. Roland, G. Hognestad, 1999-09-23 (2) "Gasket for Nitric Acid Burners", HRE doc. 99C_BOS, . Olsen, M. Roland, Hognestad, 1999-08-24 (3) "Nitric Acid Burners, Gasket for the shell flanges", HRE-doc, 99B_BI2, M. Roland, 1999-05-05 (4) "HAB. Nitric Acid Plant, Montoir. Recommendations regarding gasket/packing for the top flange, ammonia reactor", HRE doc, 99D_xxx, M. Roland, A. Olsen, 1999-11-02. (5) "HAE. Nitric Acid Plants. Gaskets/packings in the top flange in the burners”. HRE doc. 97R_BH1, M. Roland, 1997-09-29 MNe(UNyo90._BWe.Mp