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...this seminar is designed to give participants a better understanding of the properties, characteristics, hazards, and installation procedures associated with carbon dioxide.
Our mission is for you to leave this session with not only an increased skill level but, with an added confidence in your ability to work safely.
QUESTION:
WHAT DO WE INTEND TO ACCOMPLISH IN THIS SEMINAR?
ANSWER:
ELIMINATE PREVENTABLE ACCIDENTS THROUGH EDUCATION!!!
WHY?
BECAUSE INFORMED EMPLOYEES CREATE A SAFER WORKPLACE!!!
LEARNING OBJECTIVES
Explore what you know See where you need to expand your knowledge Obtain a general knowledge about the CO2 industry Have some fun while you learn
CARBON DIOXIDE
Chemical symbol: CO2 Molecular weight: 44.01 Color: vapor-none, solid-translucent white Odor: slightly pungent odor taste: biting Specific gravity: 1.5289 @ 1 atm @ 70 F
CARBON DIOXIDE
Density, lbs/ft3: solid: -109.25 F = 97.6 lb/cu. ft. liquid: +1.7 F, 300 psig = 63.36 lb/cu. ft. liquid: 70 F, 830 psig = 47.35 lb/cu. ft. liquid: -69.8 F = 73.5 lb/cu. ft. Specific volume, lbs/ft3 : 8.57 @ 1 atm @ 60 F 8.74 @ 1 atm @ 70 F Normal boiling point: -109.35 F
CHEMICAL PROPERTIES
Carbon dioxide is stable and relatively inert Specific heat-gas-varies (at constant pressure of 1 atmosphere): 70 F.........................................0.20 BTU/lb (at constant volume)...............0.15 BTU/lb
CHEMICAL PROPERTIES
Viscosity-gas at atmospheric pressure & 70 F temperature.............0.015 centipoise liquid at 0 F..........................0.14 centipoise Dissolved in water, carbon dioxide forms carbonic acid (H2CO3) Becomes chemically active in moisture or high heat
HEAT OF VAPORIZATION
Solid: -109.25 F = 246.6 BTU/lb Liquid: +1.7 F, 300 psig = 119.2 BTU/lb Liquid: +70 F, 839 psig = 63.9 BTU/lb
TRIPLE POINT
Temperature/pressure combination at which carbon dioxide can exist simultaneously as a solid, liquid, or gas: -69.83 F 60.4 psig
CRITICAL POINT
Highest temperature & pressure at which carbon dioxide can remain a liquid CRITICAL TEMPERATURE 87.82 F CRITICAL PRESSURE In lbs per sq. in. abs.: 1071.6
PRODUCTION
Carbon Dioxide is obtained as a by-product from one of several sources: Ammonia Plants Fermentation ethanol plants Hydrogen Plants within refineries Ethylene oxide Natural gas process plants Extractions from flue gases from the burning of natural gas or fuels In some parts of the South and Southwest, CO2 is obtained from CO2 wells at extremely high concentrations and pressures
PRODUCTION PROCESS
Feed gas collection CO2 compression Purification and liquefaction Refrigeration for the liquefier unit Storage of product liquid carbon dioxide Recompression of flash carbon dioxide Reactivation of dryers and adsorber dryers Carbon filter Shipment of product liquid carbon dioxide
I. REFINERY AND AMMONIA PLANTS - (REFORMERS) CH4 + 2H20 METHANE + STEAM STEAM REFORMER METHANE (CH4) STEAM CO2 + 4H2 CO2 + HYDROGEN H2 ADSORBER STRIPPER CO2 TO BOC SOLVENT
STEAM
NATURAL GAS
TYPICAL SOLVENTS -
II. ETHANOL PLANTS - FERMENTATION C6H12O6 + DEXTROSE YEAST 2C2H5OH + 2CO2 ETHANOL
CO2 TO BOC
FERMENTERS
CO2 TO BOC
GYPSUM
IV. COMBUSTION/COGENERATION CH4 + 2 (O2 + N2) FUEL + AIR ADSORBER FLUE GAS CO2 +H20+N2 CO2 + 2 H20 + 2N2 CO2 + WATER + N2 N2 STRIPPER SOLVENT CO2 TO BOC
H20 AIR (02 + N2) FUEL (NATURAL GAS OIL OR COAL) CO2 AND SOLVENT
TYPICAL SOLVENTS -
THE PROCESS
Each CO2 plant is built specifically to handle the type of impurities found in the particular feed gas
The standard grade purity for bulk liquid is defined as: Maximum Impurities Parts per Million by Volume Minimum % Purity Inerts Hydrocarbons (Volatile) Water Oxygen Ammonia 99.9 1000 50 32 30 25 Carbon Monoxide Hydrocarbons (non-volatile) NOx Sulfur Dioxide Carbonyl Sulfide Hydrogen Sulfide 10 10 5 5 0.5 0.5
PURIFICATION METHODS
Zinc Oxide Beds Dryers Adsorbers Noble Catalyst Beds Carbon Beds Molecular Sieve Beds Water Wash Columns Potassium Permanganate Beds
CO2
Feedgas
KMnO4 Column
Catalytic Combuster
Compressor
Driers Ammonia
Carbon Beds
Noncondensibles
Distillation Column
CO2 Condenser
Maximum % Purity Argon Carbon Monoxide Helium Hydrogen Krypton Neon Nitrogen Oxygen Nitrous Oxide THC Dew Point F Total hydrocarbons expressed as methane.
99.995 5 1 4 4 0 0 20 4 4 5 -86
POTENTIAL HAZARDS
Safety relief valves Ball valves Lines anchored firmly Expansion & shrinkage of lines Unauthorized personnel Static electricity Flexible hoses Confined space Asphyxiation
SYMPTOMS OF ASPHYXIATION
Headaches Sweating Rapid breathing Increased heart beat Shortness of breath Dizziness Blurred vision Shaking Make it difficult to leave the area
Toxic Atmospheres in confined work spaces Asphyxiating atmospheres in confined work spaces Other hazards present in confined work spaces TOTAL FATALITIES
PREVENTATIVE MEASURES
Exercise caution when entering areas to ensure proper oxygen/ CO2 levels Monitor levels in all such areas An alarm should be sounded if either the oxygen level drops or CO2 levels rises During down time and maintenance use: Entry permits Lock out procedures Confined space entry standards
PREVENTATIVE MEASURES
All equipment using CO2 must be equipped with a properly designed exhaust system System design must ensure that CO2 concentrations in work areas never exceeds the allowable exposure limits Monitors may be set up to not only sound an alarm but turn on ventilation if needed (done by customer only).
3% or 30,000 parts per million (ppm) 5% or 50,000 parts per million (ppm)
15 minute period
COLD CONTACT
Solid (dry ice) and liquid CO2 are normally very cold. Contact with these may result in frostbite Contact could also result in lesions or more serious injury from deep freezing of the tissues Contact should also be avoided with gaseous CO2 coming out of a pressurized container since this gas can also be very cold
PB SIDEARM VAPORIZER
STEAM VAPORIZER
FIGURE 2
UTILITIES
Electrical Phone Lighting
SIGN INFORMATION
Carbon dioxide Causes severe burns Liberates a gas which may cause suffocation Avoid contact with skin and eyes-- do not taste Do not put in stopped or closed containers Use and store only in well ventilated areas Liquid under pressure Emergency phone numbers
CUSTOMER TRAINING
MSDS (Material Safety Data Sheet) General site review Emergency contact information
REFRIGERATION LAWS
RECOVER
To remove refrigerant in any condition from a system and store it in an external container without necessarily testing or processing it in any way.
RECYCLE
To reduce contaminants in used refrigerant by oil separation, non-condensable removal and single or multiple passes through devices which reduce moisture, acidity and particulate matter, such as replaceable core filter-dryers. This term usually applies to procedures implemented at the field job site or in a local service shop.
RECLAIM
To reprocess refrigerant to new product specifications by means which may include distillation. Chemical analysis of the refrigerant is required to determine that appropriate product specifications are met. This term usually implies the use of processor or procedures available only at a reprocessing or manufacturing facility.
FACTORS-RECOVERED REFRIGERANT
Reason system is being serviced Condition of refrigerant and system Equipment manufactures' policies Refrigerant cleaning capability of recycling equipment Feasibility and owner's preference
CONTAMINANT LEVELS
Because there are no means at this time to determine all contaminant levels (other than by laboratory testing), assurance that these contaminant levels are not exceeded can be accomplished by: The proper use and maintenance of refrigerant recovery/recycling equipment that is capable of recycling refrigerants to or below the levels in the table or Laboratory analysis (the appendix to ARI Standard 700 describes laboratory analysis procedures).
1.0 ppm 10 ppm 2.0 percent .02 percent Visually clean Visually clean 2.0 percent
Non Condensable Gas N/A (By Volume) High Boiling Residues 1.0 percent (vol.) Chlorides by Silver Nitrate test Particulate Other Refrigerants No turbidity Visually clean 2.0 percent
SALE OF REFRIGERANTS
Used refrigerants shall not be sold, or used in a different owner's equipment, unless the refrigerant has been analyzed and found to meet requirements of ARI Standard 700 (latest edition), Specifications for Fluorocarbon and Other Refrigerants".