Dead Sea Works
Drying Furnaces Temperature control improvements
Drying furnaces has special features that has to be taken when coming to deal with its performaces in general and specifically with its thermal, Fuel and product quality (dryness).
We participated in few of this kind for different customers:
Advanced Temperature Control of fertilizers granulation plant – fuel oil firing.
Product (fertilizer) dryer temperature and load control, changing from fuel oil to Natural Gas firing
The Potash Filtering section is dealing with very large quantities of slurry and the quality of this section operation has significant impact on the economics of the whole production.
This comes to light in the production rate, quality of product as well as the rate of breakdowns in the process.
Conducting careful process analysis, together with the client engineers and the production team brought number of improvements such as using unusual means to control process parameters, as well as some inovative process control techniques implementations.
- Better stability in the filtering process by reducing variability in cake thickness.
- Higher production per filter unit.
- Significant saving in water and electricity consumptions.
- Reduce number of filter units in operation.
Color Dosing in Potash Granulation Plant
Potash fertilizers are expected to be red to help the user to make out these.
The dosing of color onto the product was not accurate enough which caused the product not to confirm with the spec, Different types of red showed up, customer unsatisfaction, over usage of expensive coloring material.
Following our work – with the customer:
- The control of the dye improved and is done automatic in RATIO to the quantity of material (Potash) in processs, rather then manually as it used to be.
- Control system was improved and was tuned to the proper range of action.
- Inherent mechanical problems were identified and were addressed by maintenance.
pH control is considered by the majority of Process Control Experts as the most difficult one topic control job.
Careful study the unique situation in each project together with cautious implementation of advance process control techniques brings excellent results to the full satisfaction of the projects’ goals.
pH control is found in Processes, in effluent treatment plants in scrubbers and more.
Haifa Oil Refineries (ORL), Haifa Oil Refineries (ORL), Machteshim - Adama, Machteshim - Adama, Periclase, Periclase, Rotem Amfert Fertilizers, Rotem Amfert Fertilizers, Rotem Amfert Fertilizers, Water Treatment, Water Treatmentalex
Wet Scrubber Process Control
Wet Scrubbing plays important role in Gas Cleaning operations.
As such it is widely used where gases that are released to the atmosphere have to meet the environment standards.
In the DSW case we had to take care of the brine collected at the system bottom to meet the required pH values as well to be suitable to be released to the sewage.
In refining projects, sour gases were treated to reduce the sulfur content down to acceptable levels.
Cristalizers Density Control stabilysing
In the process of Potash (KCl) production Carnallite [KMgCl3·6(H2O)] and water are fed into crystallizers. Instability in the Carnallite rate of feed requires the water to follow and maintain the proper ratio between these two streams.
Examining the system and instrumentation we found some mistakes in the control strategy implementation.
We redesigned the control strategy.
Number of readings outside the required values dropped dramatically.
Stage II of this project brought significant savings in water consumption and reduced the Potash lost considerably.
Process Control Improvement in Potash Granulation Unit
To unify the granulation process product it was required to balance the feed rate from all raw material sources.
The plant was not designed to allow direct controlling of these streams. With the aid of the plant staff it was made possible.
Significant improvements were observed.
Drying Furnace Firing convertion to Natural gas
The availability of Natural Gas brought the need to adapt the control systems for optimal performance.
The advantages of firing Natural Gas are significant:
- Minimum Environment signature.
- Easy to handle.
- Cheaper then other energy sources.
We participated in such conversion for three (3) Product Dryers where we took care of the control strategy as well as the proper implementation and final loops tuning.
Natural Gas Firing Skid.
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Potash Hot extraction stabilizing
Instability in “Hot Extraction” operation cause (among other things):
- Instability in all Tanks Levels and hence reduction of production rate.
- Bottle Necks: production means are not equally loaded which causes production losses even with no mechanical failures.
With the expected new Drying Furnace and new Sivanite Filters situation is expected to worsen.
Checking all parts of the process enabled us to improve the control performance and as a result to that – the stability both in feed rates and in tanks level.