Vessel MV 2201 decontamination. An ENI's refinery

Decontamination of a washing vessel with hydrocarbon sludge at the bottom and in presence of H₂S₂, mercaptans, sulfurs, ammonium.

Introduction

A vessel for storage of residuals from gas washing at an ENI refinery was seriously contaminated by pollutants that generated an irritating strong smell. That smell was so disturbing that the technical staff of the refinery was prevented from accomplishing the periodical maintenance of the machinery, therefore causing loss in the production.

Preliminary inspection

At a preliminary inspection, persistent deposits of hydrocarbon sludge formed at bottom of the vessel MV 2201 and in presence of H₂S₂, mercaptans, sulfurs, ammonium adsorbed to its walls. These deposits still remained although the container had been already reclamated by flushing with N2 and hydrodynmic cleaning in streaming and downstream modes.

Treatment goals

The aim of the treatment was to remove all the residuals responsible for the smell, like mercaptans, and that were still adsorbed on the vessel walls. The action was articulated in four stages: filling and heating, feeding WET-Treat GE Clean 2000 at the head and bottom of the system, conditioning, and finishing.

In elaborating the procedure, it was necessary to adapt the process to the internal geometry of the vessel. In fact, it didn't allow an optimal flux distribution during the liquid recirculation and as a consequence, the parts that could be reached were limited to the higher side of the vessel. Also, operating in medium pressure steam would have allowed to arrive at higher temperatures and have a more efficient transport of the chemical, increasing much the performances, but it wasn't possible.

The overall scheme for the process is represented in visual form in the process diagram below.

Process

The four phases of the treatment will be in the operating procedure articulated in the fourteen points below:

1. The temporary lines were connected to the recirculation pump with the 2” bottom drain of the vessel.
2. The outlet line of the recirculation pump was connected to a rotary head directed upwards.
3. The rotary head was installed in the vessel with a central PDU.
4. The hoses for process fluids and medium-pressure steam were set in the vessel.
5. The central PDU was then temporarily sealed.
6. The vessel was filled at 25% of its volume with process water.
7. The vessel was then heated to 80-90°C.
8. The WET-Treat GE Clean 2000 was fed at 5-10% volume percent calculated on the water.
9. The liquid recirculation was then started.
10. The amounts of H2S, mercaptan, sulfur was measured until they were totally removed.
11. The solution was then discharged.
12. The vessel was finally washed until the chemical residuals were totally removed and the turbidity of the solution was the same as the process fluid.
13. GE DEO V was vaporised.
14. The machinery was eventually aired in environmental atmosphere.

All the passages are grouped into four phases explained further as follows.

Phase 1 – filling and heating

The bottom of the vessel was filled with process water until 25% of the whole volume by a 1” hose. In order to heat, low-pressure steam was bubbled at its bottom at the temperature of 60°C.

Phase 2 - WET-Treat GE Clean 2000 addition and head/bottom recirculation of liquids

The WET-Treat GE Clean 2000 chemical treatment was added to the vessel with a centrifugal pump set on the 7% of the volume of the water within (2.600 kg). Then, the water was recirculated between the drainage lines and the head of the vessel with a volumetric pump processing 150 m3/h. This phase was directed to remove from inside all possible solid deposits or sludge thanks to the surfactant action of the chemical.

Phase 3 – environmental conditioning

After 4 hours, the recirculation of the solution was interrupted and the central opening was sealed, then the solution temperature was raised at 70°C by the hose that was flushing bubbling steam.

It was possible to condition the whole volume by employing the mechanical and thermal effect of the steam. That operation created the best circumstances to maximize the oxydising action of the chemical. that's a saturated fog at a temperature comprised between 60° and 80° degrees, on the sulfur compounds adsorbed on the vessel walls.

The goal was to benefit the features of WET-Treat GE Clean 2000, that is very active in the gas and phase and in aerosol.

Phase 4 – finishing

After about 12 hours of streaming and having ensured mercaptan absence in the machinery, the washing solution was drained to the system for refinery water treatment. It was then all washed and aired at environmental atmosphere through drainage lines, vessel head and central PDU.

At least, a solution of water and GE DEO V at 10% was vaporised. That product combined the technical features of WET-Treat GE Clean 2000 with an effective covering power.

Conclusion

The treatment described resulted in a very effective removal from the top to the bottom of the vessel of all the residual sulfurous matter responsible for the smell.

Treatment of drilling muds

Report and cost analysis for the treatment of CER 01.05.07 waste-drilling mus by Eni's well M.Enoc 10

Introduction

The drilling mus was extracted from a M.Enoc 10 well at Viggiano (PZ). The mud contained baryte and metals coming from the cleaning operations of the concrete tanks. It was necessary to find the best process capable of removing those pollutants from the water whilst satisfying those requirements:

• ensuring the best waste tractability
• effectivity
• cheapness

Treatment strategy

The treatment was chosed through laboratory tests with the goal of selecting the appropriate chemicals feed - in terms of typology and amount - that was able to perform satisfying coagulation and flocculation. Then, the treated mud was further processed with centrifugation and filter-pressing to separate the water from the sludge. At least, the predictive overall costs of the chosen solution were calculated to compare the cheapness in the proposed solution against the starting costs.

Laboratory tests

The tests were accomplished in four stages: pre-screening, choice of the doses, comparative assessment, final considerations. Each stage is explained as follows:

Pre-screening

During this stage, some possible treatments for the muds were tested to choose the proper chemical to feed. Four samples of mud (200 mL each) were taken anche the following chemicals were added to each:

• cationic polyelectrolyte
• a polyamine – cationic polyelectrolyte mixture
• anionic polyelectrolyte
• a polyamine – anionic polyelectrolyte mixture

The addiction of the anionic polyelectrolyte together with the polyamine mixture help the water-solid matter separation than the two separated solution. Besides, that resolution gives a better flake structure. The anionic polyelectrolyte is not effective enough by itself, so it is excluded by the following analyses.

Below are the pictures of the three samples:

Dose choice

During this stage, the sludge was treated with increasing doses of chemicals in order to assess the optimum. The limit dosages are the following:

• cationic polyelectrolyte: 100 ppm
• anionic polyelectrolyte: 100 ppm
• polyamine: 100 ppm

Comparative assessment

Considered the SST concentration of the sample (1-2%), the sludge already trated with the chemicals was then sujected to centrifugation and filter-pressing. Four samples were prepared for the purpose:

• Sample a: original mud
• Sample b: sludge with polyamine and anionic polyelectrolyte
• Sample c: sludge with polyamine and cationic polyelectrolyte
• Sample d: sludge with cationic polyelectrolyte

Centrifugation

Process duration: 15 mins
Rpm centrifugation: 2400
The sample prepared for the centrifugation had an original mass of 100g. After the process, the following data are given:

The centrifuged sludge and the clarified water from the process are represented in figures 2 and 3, respectively.

Filter-pressing

The simulated filtering process was carried out in two stages:

1. vacuum filtering
2. compression at 1 bar for 10 mins on blotting paper

The samples have original weigh of 100 g. After the process, the following data were registered:

The vacuum filtering and the filtered product from the process are represented in figures 4 and 5, respectively.

Discussion of the results

According to the analyses, the effects of filter-pressing and centrifugation are almost equal since they separated the same amount of water from the mud. Among the tested chemicals, the sample treated with anionic polyelectrolyte + polyamide solution gave the best clarified water in terms of SST. Also, the floc produced was the most stable and homogeneous. In term of the combination of costs and performances, the cationic polyelectrolyte solution at 100 ppm appeared to work best.

Final considerations

In order to assess the overall expense, the costs for:

• filter-pressing/centrifugation
• treatment of the clarified water

were calculated and they are displayed in table 3 below.

Optimization of issuance.

Assessment of the effectiveness for the chemical treatment of the so-called COVA, STOGIT and IREOS waste with dosage in line while boiler-containers are unloading.

Introduction

Before describing the treatment applied to the industrial plant, it is important to give a brief overview about odour emissions from industrial plants. Industrial odour emissions come from biological system for water treatment and they are represented by reduced catabolites, or sulfur, nitrogen, and carbon compounds that are not completely oxidized. This distasteful smell is often due to very small quantities of matter and the harassment is not always proportional to the toxicological effects they might cause. Althought distasteful smell might induce spontaneous nuisance, like nausea, emesis, headaches or other pains, it is not harmful to human health. Indeed, these effects could be more likely to be related to individual sensory or psicological perception at receptor- or brain level than a disease

Preliminary inspection

A system for industrial odor control was already installed in the area. The original system consisted in an acid/base scrubber treating the gaseous emissions from the biological aeration tanks, and an active-carbon system in dust adsorbing the organic matter responsible for the smell from the process liquid.

The present study was aimed to modify the process by adding appropriate chemicals to the process liquids, hence the treatment goal was to select the best chemicals to feed the wastewater while discharging the tanks.

Treatment proposed

The product WET-Treat BioTrol 117 was tested as it is highly reactive to H2S, mercaptans, amines and it is capabile to extend its action to muds which follows drying process as well. Also, the product doesn't contain any harmful substance to machineries, processes or people, which fitted perfectly with the purpose.

Analysis

The methods developed for odor control are classified into two general cathegories:

• anlytical methods
• olfactometry methods

The anlytical methods like GC-MS (Gas Chromatography-Mass Spectrometry) allows a primary screening and to give clues about the several responsible for the smell. Unfortunately, those main coumpounds range among some dozens and some of them, like mercaptans and hydrogen sulfide, are troublesome to detect since their concentrations are at or below the limit of detection of the instrument. In this case, the nose turns out to be more sensitive than a mass spectrometer device.

The olfactometry methods have the purpose of identifying, quantifying and giving numbers – also by statistical means – about the smell intensity. A test team, who is called panel, is subjected to the original air and to treated air.

For the test, the panel was composed of five workers in the plants who tested three different kinds of waste that are IREOS, and COVA or respectively ethanolamine, mercaptans. STOGIT was the smell of rotten egg, and it was used as marker gas. The method was tested in the laboratory, then it was applied to the plant.

Laboratory tests

Two samples of 100 mL each were collected from the two kinds of waste and the chemical 50/100 ppm were injected. After reacting for few seconds, the panel tested the samples and they soon recognized the treated one. Besides, the panel also appointed residual smell as hardly perceptible or absent.
The results are displayed in the table below.

Plant test

Successively, a a test to check the product effectiveness on treating wastewater or plant was accomplished. A dosing pump was set on 20 L/h injecting until 200 ppm of product, and it was installed in the outlet Water Line. The product was feeded to the flexible exhaust line, at the closest point to the attachment between the tanks by a proper fitting. The pump aspirated the material straight from the 250 Kg-packaging and it was added at 50 ppm to the carrier. In terms of odor perception, the result even clearer than the laboratory stage. The panel verified the odor as "non perceptible" also in this case.

Conclusion

The WET-treat Biotrol 117 was applied to the biological plant and it removed effectively the strong smell.

Potabilization of water in Office Buildings

Solution to the issues related to potabilization of the water directed to an Office building of a Plant for special waste collection and treatment

Introduction

A Plant for special waste collection and treatment placed in an industrial area in the Central Italy holds an Office building where employers and managers of the company operate. The premises with bathsrooms, showers, and several water facilities had available as service water only well water sanitized with sodium hypochlorite, filtrated and deferrizated. Despite this, the water still didn't meet the requirements to be employed for its purpose. There is below the table reporting the registered values for the water after chlorination and iron removal:

The Treatment

Green Europe Italiana set their activity in installing a complete system for potabilization at the Client's site. Tbe system comprised a Reverse Osmosis unit, a dedicated tank (image 1), an automatic pH control system coupled to an alcaline agent dosing facility (image 2).

Besides, a global service contract was stipulated for the installation of all the necessary materials as well as two technical inspections a month, the ordinary and extraordinary maintenance for all the components set by Green Europe Italiana.

The values of the water treated with this procedure are reported in the table below.

It is clear from the data reported above that the values quite satisfy the limits as for the D.Lgs. 31/01 of Italian regulations with respect to the quality fo water destined to human use.

Conclusions

Since the first day of the treatment, the quality of the water has turned out to be compliant with the legal limits imposed for drinkable water. The further monthly check that the technical staff of Green Europe Italiana accomplishes confirm the inspections by the local healthcare company.

Revamping and running of a plant for wastewater treatment

Revamping and management of a wastewater treatment system in a pharmaceutical plant due to a fall in its depurative performance

Introduction

A pharmaceutical plant located in Central Italy had a plant for wastewater treatment that didn't fit its purpose longer since it didn't guarantee the necessary depurative performance over long periods.

The situation came to happen with the analytical and operative check by Green Europe Italiana conducted for a period of six months. Therefore, it turned out that the actual volume of hte oxidation tank was not compatible with the actual hydraulic load nor with the average COD of the inlet (look at Table 1).

Another issue encountered was related to the lack of a system for solid-liquid separation for the muds at the final decanter. Indeed, since large quantities of muds that were very low in SS were produced, a scarce sludge removal was performed on the system.

Treatment

Treatment tests

Since it wasn't possible to implement the overall capacipty of the sysyem with civil works, an appointed solution was to increase this capacity by installing MBR membranes. Before doing, Green Europe Italiana tested their suitability installing a MBR pilot plant running in parallel with the exising system. The MBR system was equipped with a membrane 100 square meters wide and it was placed in a 20 foot container. The results of the experiments turned out to be positive, as displayed in Table 2.

Application

Following the positive result of the MBR pilot system installation, the plant modifications that Green Europe Italiana designed and attended in full were applied the together with the Direction of the site. These adjustments involved the installation of:

1. Rotary Drum processing 30 cmeters/hour with 1sq-mm perforations
2. Two plane MBR membranes of 4000 sq-meters each
3. Backwashing system for theMBR membranes controlled by a PLC
4. Reverse Osmosis system of 16 sq-meters/hour following the outlet from MBR system comprehensive of prefiltration at 20 and 5 microns and backwash whenever necessary
5. Horizonal centrifugating pump of 7 cube meters/hour of hydraulic load for sludge centrifugation with an attached collection istem for centrifuged sludge

The images of the installations of the revamping follow below.

Conclusions

The parameters registered returned to normal and the system is running regularly since Aug 2016.

Consulting

Water can be devoted to several purposes. It can indeed be used as a thermal fluid in cooling systems or in steam production, as a process fluid in several kinds of industries - pulp and paper industries, sugar industries, food industries, etc. -, as a waste or as a municipal water for public and private use. Some situations may require optimization to improve the yield and reduce consequently both operating costs and environmental impact. In addition, should water not be within the limits due to purposes or regulations, it might need threating to satisfy the requirements.

The solution to these problems often needs in-depth knowledge in the field and Green Europe Italiana can help you find the best solution to your problems with its competence and thirty-year expertise of its technicians.

The treatment strategy accomplished is the following:

• acknowlegment
• study of the optizations to apply
• final report

During the first stage, our technicians will visit your plant/site under request to start a complete study of the status, collect data, make a deep analysis of the technical data. With such work we will be able to provide the flow sheets of the site systems and whenever possible, the evolution scheme of the issues encountered.

Basing on the collected data and our knowledge, we will be able to suggest possible solutions to optimize or modify of the plant. We will draw an operational plan comprising all the neceassary modifications that will be taken into account by our company or be consigned to third parties.

Following the "audit" a detailed report will be given cointaining this information:

• description of the contest, of the ongoing process and its limits
• inventory of the existing systems and the treatment programs already in use
• material and/or thermal balances
• analytical reports of the circulating water
• problems detected
• suggestions to improve the overall process and its control
• impact assessment for the proposed suggestions, the time required and the economical and environmental outcome (ROI)
• whenever available, a related literature about the existing technical regulations as well as a guide to industrial practices in th e field

Analyses

Our analyses are realized by our technicians or in specialialized laboratories holding the following certifications:

Certifications

The products we use hold the following certifications:

Domestic Water Treatment

Water is widespread. It it used in household activities, the first of which is personal and environmental care, food or health. It is therefore important for water to be compositionally adequate to satisfy the requirements for such purposes. Among these, there are hardness, microbiological composition and presence of heavy metals.

Hardness is an important parameter for water quality assessment since calcium and magnesium ions at high contents can generate incrustations in the pipes or in other parts of the hydraulic system like faucets or boilers (calcareous deposits). They can also bind the constituents of the liquid detergents to produce low-soluble compounds with a double consequence. By one side, limestone accumulation causes a rise in the energetic bill. On the other side, the detergent power of soap, additives, hair conditioners, fabric softeners or rinse aid for dishwashers goes greatly reduced bringing to serious waste of the economical and environmental sources. The total of this loss is esteemed around 1500 euros a year per family.

All waters are populated by microbacteria, some of which are really dangerous towards animals, like Legionella or Salmonella that are just some of the organisms growing in water bodies. The consequences of this colonization are really hazardous against human health as demonstrated by the incresing number of cases of legionellosis and salmonellosis worldwide so that it should be controlled. An ideal support for bacterial proliferation are the same crusts forming on watersaver attachment, to give a case in point.

Some inorganic compounds that are known as "heavy metals" are also present in waters and are really toxic to healt. They are metallic ions like cadmium, chrome, lead, arsenic, nikel, mercury, aluminium, manganese from natural or anthropic activities. In the first case, they occur as oxides, on the second case as ions coming from a number of industrial processes (metallurgical industry, paints industry, and so forth) generating muds or acting directly on human metabolism.

The issues of above can be avoided installing household systems for water purification. These facilities are small, easy to install and to maintaing, economically and technically speaking.

Green Europe Italiana can make analytical studies on your domestic water to check the main parameters for quality assessment of drinkable water and to find a solution to your needs.

Water Reuse

Industrial waters are a good source of water for industries for two main reasons:

1. reusing water allows to reduce retrieval from natural sources and the consequent costs for picking and primary treatment in the industrial plant. This is very important especially in those cases when the water quality is not compatible with industrial purposes
2. reusing water generated less damaging pollution, and particulary for groundwaters from which the water can emerge.

Reusing industrial waters is a good approach for the nature and company's economy but, increasing the limits and restrictions to the final disposal, this practice has become harder. A solution to the issue can be found in accomplishing rationally by three ways:

1. reusing the outlet from one process to feed a second process without passing through any chemical-physical treatment
2. combining usage and regeneration - the outlet from one process will be treated successively before filling a second process
3. focusing on the tretment of a critical effluent: before mixing with other waters, the outlet is treated with chemical or physical-chemical methods

The last one of these approaches develops further considerations about the position of the treatment:

1. end of pipe, or at the end of all processes - wastewater treatment
2. inside the pipe, or at one or more critical outlet on the line that have to be treated specifically to return good water for reusing.

To do that, Green Europe Italiana applies several technologies ranging from filtrating systems at several degrees (micro-, nano or ultrafiltration) to more complex solutions like RO (reverse osmosis), EDI (electrodeionization), vacuum vaporization or other means. The water returned can be effectively used as reintegrating water for several industrial systems:

• closed cooling circuits
• cooling tower circuits
• steam generators
• process waters

Green Europe Italiana can help you finding the best solution to your problems related to water usage and pollutant discharge.

Water Utilities Treatment

In an industrial area water is used as a raw material added to productive activities (process water) or as a fluid for cooling high-temperature systems or production of the steam feeding the production. In addition, water are present in plants as first rain water that get full of ground pollutants by dissolution in the liquid.

Throughout the plant activity, several problems with regard to the life of single components or important variations in the yield can happen to arise.

Considering what stated before, water utilities can be classified into:

raw water pretreatment

depending on the kind of source water is taken from, - acquatic groundwater, well, river, lake, sea, waterwater to reuse - it can have particular compositional features so its preparation/softening/demineralization/purification is tailored for it.

treating systems for meteoric water

the activities related to first rain water (and sometimes second rain water also) include design, carrying out, implementation of the specific treating systems. In case of systems for first rain water, oiling and coalescence filtration are particularly important, while the overall scheme for second rain water needs studying and organized according to its final destination (look at ZLD plants).

process water treatment

1. cooling water treatment

Since industrial waters may be corrosive or act as corrosive agents against some components of the systems in relation to some chemical-physical features (Langelier index), it is common to condition these waters with chemical treatments dedicated to avoid either corrosion or fouling. It is also important to check microbiological growth (biofouling) since it prevents proper thermal exchange and causes corrosion under cover due to deposition on exchange surfaces. Those phenomena appear in both open and closed circuits with evaporative tower. Green Europe Italiana offers chemical treatments specifically studied for each situation.

2. boiler water

Depending on the kind of boiler (low, middle, high pressure boiler), increasing purity is required for the inlet. Indeed, should a certain degree of salinity be considered acceptable for low pressure boilers but it is not the same as high pressure boilers, which needs very pure water. A similar criterion is considered for dissolves gases (oxigen and carbonium dioxide).

Our company advances complete and specific programs treatment programs that take in account the features of steam production.

Green Europe Italiana can solve your problems related to water utilities treatment with a variety of solutions including:

• filtration (normal, micro, and ultrafiltration)
• reverse osmosis (RO)
• exchange resins
• disinfection systems
• water softening
• pump installation
• materials supply (mechanical components, chemicals)

Wastewater Treatment

An Overview

Waste water treament is intended as a series of chemical, physical an biological processes aimed to remove the pollutants from urban and industrial wastewater. Chemical processes are intended for the dissolved fraction in wastewater to treat chemically, physical methods are aimed to remove the suspended solids, and biological treatment has the purpose of separating the solids from the water.

This complex series of operations consists in pretreatment, oxidative-biological, and further treatment. Pretreatment is accomplished to "relieve" water from coarser component as well as SSS (Settleable Suspended Solids) before passing through biological treatment. It consists mostly of grating, sieving, primary sedimentation, flottation (with DAF plants) ans sometimes also oiling (whenever the waters are rich in fatty compounds), and sand separation. The choice for one system rather than another depends heavily upon chemical-physical features of the water to treat.

Then, oxidative-biological treatment is made through microbiological aerobic populations (or anaerobic at limited extents) that attack the SSS escaped from the primary sedimentation together with biodegradable and not biodegradable NSS (non settleable solids). Although microbacteria don't digest non-biodegradable NSS, it is segregated within the biomass and just increase the overall dimension. At the same time biodegradable NSS is processed as metabolites via enzymes. In all cases, biomass generates dense sludge from which water is separated through sedimentation or filtration (MBR membranes). From this point, sludge and water can be treated separately in two lines different lines (water line and sludge line) and each can be treated further.

According to the composition and function they accomplish, water can be further treated with chemical, physical-chemical, biological, natural-biological systems to produce water of better purity. This step includes further removal of remaining SSS, nitrogen, phosphorus compounds, disinfection, an so forth. Finally, sludge can be processed to extract water (centrifugation, for instance) or be recirculated at the head of the oxidative-biological line.

Green Europe Italiana's Activity Related to Wastewater Treatment

Wastewater treatment is one of the fields where Green Europe Italiana developed particular specialisms and one of the most critical areas as well. In most cases, issues related to treating systems management appear whenever the output changes greatly in positive or in negative since it changes the inlet flow consequently. Also, environmental fluctuations and temperature especially, can affect negatively the performances of those systems in the physical and biological balance of some or many of the dynamic cited before.

The solution to those problems requires wide competence ranging from plant building, engineering, chemistry, and so forth, hence the number of people who hold this expertise is really low. Green Europe Italiana is among this limited number and can:

• make in situ surveys
• make chemical analyses for water quality assessment
• interpret data and highlight critical issues
• draw strategic plans and a variety of operational plans to accomplish it
• manage the accomplishment of the chosen solution until they are completed
• check the status while works are ongoing and create a collaborative interaction with clients
• handle of the following maintenance of the upgrated plants in modalities and times previously arranged

Analyses

Green Europe Italiana accomplishes analyses of:

• Odour
• Colour
• Coarse matter
• pH
• Conducibility
• SST
• COD
• BOD
• Animal and vegetable fats/oils
• N ammonium
• N nitrates
• N nitrites
• P total
• Phosphates
• Sulphates
• Sulphides
• Fluorides
• Surfactants (anionic, cationic, non ionic)
• Chlorides
• Free Cl
• Heavy metals (Al, Cr, Mn, Fe, Co, Ni, Cu, Zn, As, Cd, Pb, Hg)
• Silica
• Hardness test
• Alcalinity test

Gas turbine Power plant – cod. PP 07-15

The power plant is in excellent conditions and well-maintained. Currently used as a stand-by power station, it regularly proofs its capability to smoothly run according to its needs. Equipped with an emergency diesel it is capable of black start operation.

The station provides a total installed capacity of 147 MWe, consists of three (3) Gas turbines type GE LM 6000 PC Sprint, 49 MWe each, and by design is offering a significant advantage to the interconnected system, i.e. a very quick start-up reaching its maximum capacity performance in only 20 minutes. The offered scope of supply is all the equipment for a complete plant (turnkey) i.e. from gas supply including gas compressor and reducing station up to the 150 kV SF6 substation and requires no additional equipment to be installed at the new site.

The plant is being sold „as it is and where it is“. In agreement with the seller plant surveys are possible as well as attending trial runs or boroscopic inspections.

Images

Gas turbine generator 1,2 MWe – cod. GT 01-15

Saturn® gas turbines have proven themselves in over 4800 installations. Introduced in 1960, they have logged more than 620-million operating hours and are available in a single-shaft, constant-speed configuration for driving generators.

The machine that we have is a Saturn 20 a gas turbine coupled with an alternator AWK 400 V.

The system has had a complete overhaul and actually has about 8300 hours of running.

GRP Pipe Plant – cod. VTR 01-14

Plant was built in the south of Sicily (Italy) in 2003, but due to bureaucratic reasons it started very recently.
Technology used: a filament winding reciprocal process (discontinuous)

Plant is composed by

Two complete lines for production of GRP pipes
Length 12.500 mm
Diameter 200 ÷ 3.000 millimeters

Each line is composed by:

• N° 1 Filament Winding machine with 8 multiple loader
• N° 1 Filament Winding machine with 2 head overlapped
• N° 1 Rode Puller for conical mandrels
• N° 1 Multiple Tool facing machine (grinding)
• N° 2 Mandrels rotation machine for liner
• N° 1 Fixed distribution for roving
• N° 2 stainless steel Tanks to mix resin
• N° 2 Pumps to mix and deliver resin
• N° 1 Dust aspirating device for facing machines
• N° 3 (three) Filament winding dedicated to special production.
• Mandrels ND 200÷3000 mm length 13200 mm
• Moulds for Elbows 25÷1200 mm
• Mandrels ND 25÷500 mm length 7200 mm
• Equipment for laboratory testing

The plant is able to produce GRP pipes using polyester and epoxy resins.

Raw materials used

• Polyester resins (ortoftalic,isoftalic,bisphenolic,vinylesther)
• Epoxy resins
• Fiberglass (Roving 2400/4800 Tex; Matt 300/450 g/sm; Vel “C”)
• Catalyst
• Accelerator (Inhibitors)

Pipes produced through this equipment can reach following value classes:

• Pressure up to 32 bar
• Diameter from 25 mm up to 3000 mm
• Stiffness up to 10.000 N/mq and more

Ulteriori informazioni:

• Yearly quantity of raw material needs : over 8000 tons/year
• Personnel necessary for the production: n°. 25 people
• Power needs : max 150 KWh

Diesel generator – cod. OCG 01-14

Main components:

• Generator:
  • Engine GMT B230.20
  • 20-cylinder 4-stroke diesel V
  • Supercharger with turbocompressor
  • 1000 turns / min
• Alternator Ansaldo GSN 800 W6:
  • Power 3125 kVA
  • Rated voltage 6600V
  • cos? 0,8

Frequency 50 Hz
Circulation pumps oil circuit

• Circulation pumps fuel circuit
• Air compressor for lighting and accessories
• Oil Filters
• Water Coolers
• Water tanks
• Tanks intermediate for fuel
• Storage tanks for oil
• Filtering of air combustion with accessories
• Control cabinets-power control
• Refrigeration air of local diesel
• Fire-fighting system
• Set of major spare parts and equipment for working on engine and alternator

Power Plant – capacity 50MWe

This combined cycle power plant is able to produce electrical power and steam.

It was first synchronized in 1994, entered commercial operation in February 2005 and was finally put in conservation mode in 2010, after the end of the steam purchase agreement with the steam customer.

It is mainly composed by:

• N°1 General Electric MS 6541B gas turbine (Frame 6B) with its own generator
• N°1 Ansaldo Steam generator producing steam at two different pressure levels (70 and 6 bar).
• N° 1 Ansaldo steam turbine, connected to its own generator, with three steam extractions (24,13,6 bar) designed for final user steam necessities.

Power Plant for Sale

The Central, in commercial operation since 1994, consists of a group of generation, fueled with natural gas, as follows:

Gas turbine EGT RLM 1600 (G1), electric generator and recovery boiler with production of 19 tons/h of steam at rated load, at a pressure of 40 bar and temperature of 400 ° C.
The group is completed by a condensing steam turbine, fed with steam coming from the boiler of the gas turbine group, and by an air cooled condenser.

Are also present in the Plant following facilities:

• System of natural gas supply, measuring and pressure reduction.
• System of condensation at Air Cooled.
• Water make-up System (Including the section of Treatment for feedwater).
• Auxiliary cooling system with cooling towers.
• gas and fire detection system.

The Plant is completed by:

• A system for collecting and conveying to wastewater treatment waters of Central.
• An electrical substation.
• Technical buildings (control room, technical office, warehouse, workshop).

Description of the Main Component of the Plant

Generation Unit gas Turbine RLM 1600

As previously mentioned, the generation group of this Power Plant is composed of a gas turbine EGT RLM 1600 and (G1), electric generator and recovery boiler.
The RLM 1600 turbine is of type dual spool consists of two shafts of which the first associated to the compressor and the high-pressure turbine (HP), while the second format from power turbine to two stages of expansion.

The turbo gas is equipped with a soundproof compartment which entirely covers the turbine, the gearbox and the generator. This compartment, made ??entirely made in carbon steel supports directly on the base of the turbine.

The turbine is powered exclusively by natural gas, with capacity at nominal load to 3,500 Sm3/h, provided at about 40 bar (33/75 bar) from SNAM network.

Inside the combustion chamber, the control of the flame temperature for the primary reduction of oxides of nitrogen products, is obtained by direct injection into combustion chamber of superheated steam (approximately 1,200 kg/year of steam), product in the recovery boiler.

The mechanical energy produced by the turbine is converted into electrical energy, in the form of alternating current, from a three-phase alternator with frequency 50 Hz.

The alternator, with rated power equal to 17500KVA, produces current at 15/20KV that, through the transformer, switch to 130KV.

The fumes produced by combustion of natural gas, after the drive of the turbine, are conveyed to the recovery boiler, able to produce, at rated load, approximately 19 tons/h of steam at a pressure of 40 bar and temperature of 400 ° C.

The boiler is a water tube type with natural circulation. The heat exchange surface is constituted by pipes made ??of carbon steel, in which water flows in countercurrent with combustion smokes.

To increase the efficiency of the boiler a bank of high pressure superheater and an economizer that warms the incoming water before it happens the state transition, are present in the opposite position.

The steam produced flows into the steam turbine for the production of additional energy.

The group is completed by a steam turbine, condensation type, coupled to a synchronous generator 4-pole three-phase type. The steam turbine is he axial type at multistage condensation action with a levy adjusted for the extraction of the feed steam of thermal loads. The extraction adjusted divides the turbine into two sections, AP and BP, whose sizing is designed to optimize the overall performance of the machine.
The flow of steam entering to the turbine, (400 ° C and 41 ATA), is equal to 32.5 tons /h.

At the exit from the turbine, the steam is condensed in an air condenser, for a description of which, reference should be made to a next paragraph.

Auxiliary Systems

Water make-up System

The make-up water system for the boiler blow down consists of a demineralisation unit and a thermal deaerator, which treats the demineralized water produced.

The water for the DEMI unit treatment is drawn from wells for industrial use; surface water is also available.

Each demineralization line can treat a maximum flow rate of 20 m3/h of water, which reaches at the output a conductivity equal to 0.5 µS/cm and an SiO2 content of 0.05 ppm.

Demineralizer

The demineralisation unit is able to produce all demineralized water that Plant needs.
To meet the specific requirements of steam injection into the gas turbine is necessary to perform with two stages of treatment:

• Demineralization mixed bed
• Demineralization countercurrent

The mixed bed unit is a total demineralisation plant consisting in a single container having strong cationic resin, regenerated with hydrochloric acid at 30%, and strong anionic resins regenerated with caustic soda at 30% in mixed bed.

Water quality is continuously monitored with a conductivity meter with alarm threshold for high conductivity.

The unit is completely automatic by means of pneumatic valves and electronic programmer PLC. The start of the regeneration occurs through signal from counter predetermination.

The unit consists of two lines of treatment so as to ensure the full functioning even during the regeneration phases.

The storage system associated with the demineralizer is formed by two vertical cylindrical tanks both the capacity of 10 m3, one for the storage of hydrochloric acid and the other for the soda.

The demineralization unit in countercurrent is constituted by two lines of ion exchangers.

The two lines will automatically toggle between the operating phase and the regeneration or standby, so as to provide continuous delivery of demineralized water.

Each line consists of:

• 2 carbon steel columns with anticorrosive coating, designed for a working pressure of 5 bar and tested to 7.5 bar; sharing system that distributes the water flow on the mass of resin through filters of synthetic material;
• a charge of strong cationic resin in acid cycle high exchange capacity;
• an inlet regenerants system consisting of PVC ejectors for placing regenerants in columns and by flow meters for controlling the flow rate of the acid and soda during regeneration step.

Thermal deareator

The demi water produced is subsequently sent to the deaerator, constituted by a vertical tower of degassing in carbon steel, installed above the tank for collecting the degassed water and with a manhole.

The tower has a diameter of 1,600 mm and a height of about 3 m, was calculated for an hourly capacity of more than 10% to that of operation.

The collection tank of degassed water, it also in carbon steel and equipped with a manhole, has a diameter of 2,200 mm, a length of 10.100 mm and a capacity of 35 m3. The tank is supported by two saddles for supporting the load distribution, one of which acts as a fixed point and a sliding point to allow for expansion.

The deaerator can treat at most 35,000 kg/h of water at a temperature of 110 °C.

Air cooled system

The condenser, positioned downstream of the steam turbine, is a vertical beams inclined type, with forced draft, has a heat exchange surface of bare pipe equal to 860 m2, which becomes 20,250 m2 of finned tube.
The steam flow rate varies from 25,000 to 33,000 kg/h at a pressure between 0.2 and 0.36 ATA, while the air temperature used is 21 ° C.
The condenser consists of:

• 8 beams in parallel each having 245 tubes of 5 electrowelded files and calibrated and a diameter of 7350 mm. The fins of type “embedded” are made of aluminum with diameter 57 mm;
• 8 fans with aluminum blades each having a diameter of 4880 mm and a drive by means gearbox with gears in an oil bath;
• 8 three-phase 75 kW electric motors;
• 1 supporting structural steel profiles with plan dimensions 19600 x 7350 mm and height 3800 mm.

The receiving drum of the condensate, of diameter 1.200 mm and length 2,600 mm, has a capacity of 2,500 liters.

The unit includes a vacuum group in two stages for the air extraction and non-condensable, comprising 2 ejectors for each stage, one in operation and the other in reserve, and two condensation chambers, one in a first stage (intercooler) and the other in the second stage (aftercooler). The group vacuum consumes about 110 kg/h of steam.

Cooling System

The closed cooling system cools the oil of the steam turbine through a heat exchanger and feeds the circuit of condensation of air conditioners placed in control rooms. The water used circulates in a closed loop circuit and is cooled by air in 2 cooling towers.

The water of the cooling circuit is replenished in the amount evaporated, with water taken from the Chiebbia river and is conditioned with specialty chemicals to prevent the microbiological growth of algae and the formation of scale.

To maintain the salts concentration in the cooling water to acceptable levels is necessary to eliminate a certain amount of water (blow-down or bleed) that is released into the white water network.

Fire and Gas Detection System

The system of protection against gas leaks has been specially developed to be placed inside the compartment of the gas turbine. The system is fully automatic and provides detection, alarm, and phase of extinction of any fire.

The system includes:

• gas detectors and fire;
• control panel of the system;
• equipment of CO2 extinguishing.

The presence of gas is monitored inside the compartment, and in the event of a gas leak is first activated an alarm signal (corresponding to a concentration of 20% of the LEL, the lower explosive limit), and subsequently, to the achievement of a concentration of 60% of the LEL the lock pattern of the group is activated with closure of the ball valves. In this case the ventilation continues however to be activated in order to disperse the gas. In case of fire presence relief, immediately the sequence of block is activated, with closing the shutoff valves of the gas, of dampers ventilation and activation of the extinguishing fluid CO2.

Energy balance

The table below shows a summary of the energy performance of the Central under the current set.

In the Table is shown an Electrical nominal power of 20, 5 MW as was also installed in the generation unit, a second gas turbine EGT Typhoon, electric generator and recovery boiler with production of 7.5 tons/h of steam at nominal load, at a pressure of 40 bar and temperature of 400 ° C., today no longer available.

Turbines