Environmental Technology

SELAS-LINDE GmbH

Contents.
3 Introduction

SELAS-LINDE GmbH

Company history

Thermal oxidation

Sub-X technology

Flameless thermal oxidation

Technology center

10

Selected references

12

Contact

Sub-X is a registered trademark of The Linde Group Cover photo: Thermal oxidation unit for aqueous waste liquids in Germany

Introduction.
SELAS-LINDE GmbH a wholly-owned subsidiary of The Linde Group, Engineering Division is one of the worlds leading suppliers of process plants in the fields of: Process furnaces for the chemical and petrochemical industry: Pyrolysis furnaces for ethylene production EDC cracking furnaces Cracking furnaces for special chemicals, such as acetic acid and freon Reformers Steam reformers for hydrogen and synthesis gas production Fired heater units for refineries: Crude oil heaters Vacuum oil heaters Visbreaker Platformer HDS heaters Reboilers Superheaters Special-purpose furnace equipment: Furnaces for iron direct reduction processes Steam superheaters Waste recovery units for gas turbines Environmental technology In addition to these fields, SELAS-LINDE is also a leader in the design and construction of plants for oxidizing gaseous and liquid wastes, including waste heat recovery, flue gas treatment, byproduct recovery for: Halogenated hydrocarbons PCBs Pesticides, herbicides Dioxins Pharmaceutical wastes Aqueous salt-laden wastes Nitrogen-bound organics Vaporisation of cryogenic fluids Submerged combustion vaporiser systems (Sub X) for: LNG LPG Nitrogen Ethylene Range of Services SELAS-LINDE GmbH offers a wide range of services, tailored to customer specifications: Studies Project management Basic and detail engineering Procurement of services and materials Construction, revamp and commissioning Supervision of fabrication and construction Start-up supervision After-sales service Project financing

SELAS-LINDE GmbH.
SELAS-LINDE has extensive experience in the conceptual and detailed design and construction of turn-key plants, but also offers its customers all these services individually. The world-wide cooperation and exchange of information with Linde, the connection with the Fired Heaters Division within Linde Impianti, Italia (LII), Rome and the sister company, Selas Fluid Processing Corporation (SFPC), Blue Bell, PA, USA, ensure state of the art technology and project execution. Efficient engineering work by experienced specialists and the use of the most modern 3D CAD systems (PDS) result in optimal design and reliable long-term operation of all SELAS-LINDE plants. Materials and equipment are procured worldwide in close cooperation with competent suppliers and business associates. SELAS-LINDE has decades of experience as a general contractor managing the complex logistics of plant procurement and construction. Proven project management and control systems guarantee strict adherence to cost, schedule and quality requirements. Contracts are executed in compliance with all relevant international standards and rules, accompanied by continuous quality-assurance activities. SELAS-LINDE is certified under ISO 9001 since February 2000. After a contract has been completed, SELASLINDE remains a reliable partner for its customers, with its flexible and efficient after-sales service. Proof of SELAS-LINDEs capability and know-how is the successful completion and commissioning of more than 2000 plants since the foundation of this company.

Ethylene cracking furnace, Jilin Petrochemical Company, Jilin/China

Linde AG Engineering Division Munich, Germany

Selas Fluid Processing Corp. and T-Thermal Division Philadelphia, USA

SELAS-LINDE GmbH and T-Thermal Division Munich, Germany

Bertrams Heatec AG

Fired Heater Division within Linde Impianti (Licence of SL) Rome, Italy

Pratteln, Switzerland

SELAS LINDE GmbH T-Thermal Division within Linde CryoPlants Ltd. Aldershot, UK

Company history.
SELAS-LINDE has a long tradition in furnace design, which dates back to the early thirties in the USA. The original company, Selas Corporation of America (in Pennsylvania), was involved in the technology of fired process furnaces from an early date and developed this technology continuously. Starting in 1948, the company of Ernst Kirchner in Hamburg was developing its product line for fired industrial furnaces. After the death of the companys founder in 1970, the fired industrial furnaces section was separated and sold to Selas Corporation of America. This acquisition was then renamed to Selas-Kirchner GmbH. In 1973, Selas Corporation of America and Linde AG, Process Engineering and Contracting Division, signed a license agreement for the planning, manufacturing, and erection of pyrolysis furnaces for producing olefins. This also meant that the Selas, Kirchner, and Linde technologies in the field of fired process-furnace plants for the chemical and refinery industries were combined. Over the following years, step by step Lindes Process Engineering and Contracting Division acquired ever larger shares of Selas-Kirchner and of the fired process-furnace plant division of Selas Corporation of America. In 1985, Linde AG became the sole owner of Selas-Kirchner, Germany, and of the Process Furnaces division of Selas Corporation. This division now operates under the name Selas Fluid Processing Corporation (SFPC) in Blue Bell, USA. On January 1st, 1999, Selas-Kirchner GmbH was renamed to SELAS-LINDE GmbH. SELAS-LINDE GmbH and Selas Fluid Processing Corporation now market the entire know-how of the Selas, Kirchner and Linde furnace technologies exclusively throughout the world under the trademark Selas. Since its acquisition of T-Thermal in 1992, SELASLINDE possesses the extensive know-how and leading technology for thermal oxidation of gaseous and liquid wastes, in addition to its already available technology in the field of environmental engineering. Furthermore SELAS-LINDE designs, supplies and constructs plants for the vaporisation of cryogenic liquids. Today SELAS-LINDE is one of the leading global contractors in all above mentioned fields.

Thermal oxidation.
A pollution free environment SELAS-LINDE has committed, as a company, to provide the equipment, service and technical support to resolve complex disposal problems. By tailor-made combustion technology, SELASLINDE can safely destroy nearly any kind of liquid and gaseous effluent encountered in industry. Since building our first thermal waste oxidation system in 1952, we have supplied over 500 installations world-wide to many of the leading process and manufacturing companies. In a technology where experience and expertise are critical, SELAS-LINDE is an acknowledged world leader.

Thermal oxidation unit in Saint Clair du Rhne, France

Guaranteed destruction efficiencies Thermal oxidation is the most direct, efficient, complete and final method for the disposal of especially hazardous liquid and gaseous industrial effluent. For some wastes it is the only practicable solution. Destruction efficiencies of SELAS-LINDE waste oxidation systems well exceeds the most demanting requirements anywhere in the world including the European legislative limits. We have successfully dealt with virtually every kind of hazardous and toxic waste. One example among many, a specially designed thermal system was selected for the US Army program to destroy the nations stockpile of obsolete chemical weapons, including nerve agents.

Catalytic oxidation plant in Antwerp, Belgium

Sub-X technology.
SELAS-LINDEs exclusive Sub-X system is a major advance in the safe treatment of hazardous wastes, particularly aqueous wastes bearing metals, salts or halogens. This versatile, integrated chemical waste destructor, using a high intensity Vortex burner, makes full use of the energy contained in the waste streams. Combustible gaseous and liquid wastes, along with non-combustible aqueous wastes, can be destroyed simultaneously. Frequently, valuable by-products can be removed from the waste streams. Examples include recovery of catalyst oxides after destruction of the carrier liquid and recovery of sodium iodide for process re-use. SELAS-LINDE is also a world leader in the oxidation of fluorinated liquid and vapour waste streams with the option of hydrofluoric acid or calcium fluoride recovery. The Sub-X design is also utilised for the destruction of chlorinated, brominated and iodinated waste streams. Some of the main features of the proprietary Sub-X system are defined in fig. 2. Finely atomized waste is mixed with combustion air and injected into the integral Vortex Fuel spray Internal recirculation of inert gases Flame envelope

Air vanes

Fuel and atomizing fluid

Combustion air

Air nozzle

Secondary air inlet

Air fuel zone

Combustion chamber
Fig. 1: Vortex burner

burner. Most conventional burners cannot handle this mixture, but the Vortex has the necessary turbulence and swirl action to oxidize the mixture efficiently. Usually the reaction chamber is vertical. When aqueous wastes containing inorganic compounds are present, they are injected into the fully developed flame zone just below the burner. The generated molten salts flow down the refractory wall to the quench chamber. Hot gases pass through a water-cooled downcomer tube and are quenched in the Sub-X quench tank. The integral tank is a primary scrubber recovering a high percentage of acids and particulates. The tank also acts as a safety device: if quench water supply is lost, the water in the tank will serve as a heat sink and liquid seal until the malfunction is corrected. In the treatment of chlorinated wastes, the rapid quenching of flue gases in a matter of milli-seconds virtually eliminates the gasphase dioxin reformation reactions and hence the unit is able to achieve dioxin levels < 0.1 ng/Nm (TEQ). Other auxiliaries, including downstream exhaust gas treatment and product recovery equipment, can increase the versatility and profitability of the Sub-X system.

Vortex burner assembly

Combustion air inlet

Firebrick

Non-combustible waste inlet Annulus (where hot gases pump quench water)

Insulating brick

Quench water inlet

Exhaust Downcomer

Fig. 2: Sub-X system

Flameless thermal oxidation.

Flameless thermal oxidation (FTO) is a process that thermally reacts combustible gases and/or atomized liquids with an oxidizing agent to convert combustible compounds to their oxidized state, and release heat without flame. This is accomplished by heating the compounds to reaction temperature under controlled conditions in a specially designed reactor that absorbs and dissipates the heat of the reaction. This maintains a stable oxidation zone at a precise temperature and residence time sufficient to compensate for variations in fume flow and composition. The FTO reactor Figure 1 depicts the basic FTO system. The reactor is made up of a refractory lined, cylindrical vessel (material of construction varies with application) with a centered inlet diptube. This vessel is approximately half full of randomly packed inert ceramic pieces to form a uniform matrix below and around the diptube. A preheat burner or electric heating elements heat the ceramic matrix to operating temperature at start-up only. During standard operation the matrix temperature is maintained by the incoming combustible mixture entering from the top of the diptube. As the mixture flows down the diptube it passes through a series of mixing baffles to ensure uniform composition of the gases. The pre-mixed reactants enter the ceramic matrix, and expand radially outward from the end of the diptube. Each fume, air, and fuel mixture has a particular reaction speed based on the composition and temperature. As the slowing velocity of the pre-mixed reactants reaches the oxidation speed, heat transfer into the mixture from the hot matrix and free radical oxidation begins. The location of the reaction wave is held in place by controlling the air and fuel mixed with the fumes (fig. 2). FTO technology has repeatedly demonstrated a destruction efficiency of 99.99 %+, virtually undetectable thermal NOx and CO emissions, and dioxin and furan emissions that are less than 1/10 of the stringent European emissions standard of 0.1 ng/m TEQ. This unique performance assures regulatory compliance with a high degree of reliability.

Fuel Fume Air Inlet diptube

Clean gas outlet

Hot ceramic matrix

Ellipsoidal reaction envelope

Principle of operation (fig. 2)

FTO reactor (fig. 1)

Constant flow Constant composition Constant total flow

Constant velocity Constant reaction speed

P 0.5 m/s 0.5 m/s

Mixer

CH4
20C flow

reaction wave

Air

1000C CO2 H2O O2 N2

Expanded, hot combustion product

Fume

O2 N2

Trim fuel

Constant reaction speed

Technology center.
When expanding the technology of specialized combustion related process and emission control equipment, pilot testing is often the only prudent way to confirm suitability of a design. SFPC and SL have always relied on research and development testing as the basis for their system guarantees. In the early 1950s the test facility was used strictly for proprietary projects. Due to customer demand, contract research was introduced. Over the years, more than 800 projects have been initiated by major chemical, petro-chemical, pharamceutical, aircraft, building products, steel and mining companies, as well as the U.S. Army, Navy and Environmental Protection Agency. Many of the projects resulted in technological breakthroughs, and because of the interaction between the companies, lasting business relationships were formed and became the foundation of our present customer base. The original facility, located in Conshohocken, PA, was constructed in the 1950s. In the year 2000, the facility was completely revamped to make way for the new state-of-the-art technology center. In addition to performing proprietary and contract research, the technology center is a focal point to gather and exchange scientific information with the Linde family of companies world-wide. The new center is equipped with multiple fullscale combustion, incineration, flameless thermal oxidation, and air pollution control systems. The systems are fully automated with abundant data gathering capabilities. Programmable logic controllers (PLC), human-machine interface (HMI) and continuous emission monitoring (CEM) systems are integrated with spread sheet software for down loading and integration with customer software packages. High temperature cameras and high-speed internet connections provide unique opportunities for solving customers needs. Augmenting these systems is our in-house ability to perform computational fluid dynamic (CFD) modeling.

FTO system

Sub-X incinerator

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Selected references.
Hydrofluoric acid recovery in India Process description Fluorinated waste gases are incincerated at high temperature to ensure complete destruction. The Sub-X quench system provides rapid cooling such that dioxin/furan formation is safely avoided. In the quench and the down stream absorber column hydrofluoric acid is recovered. The final caustic scrubber stage removes remaining gaseous emissions and aerosols for compliance with environmental emission limits. The unit is certified for trading with CERs (Certified Emission Reduction) according to the United Nations Framework Convention on Climate Change (UNFCCC). Location Ranjitnagar, Gujarat, India Key performance data Fluorinated waste gas duty 139 kg/h Hydrofluoric acid recovery 99% Hydrofluoric acid production 575 kg/h of 20 wt% acid Emissions NOx TOC < 200 m/Nm < 10 mg/Nm HF < 1 mg/Nm Dioxins & Furans < 0.1 ng/Nm (TEQ)

Standardised system for the treatment of pharmaceutical wastes Process description The units have been developed as standardized systems in co-operation with the end client to treat a wide variety of wastes originating from pharmaceutical processes including chlorinated compounds. Key criteria were flexibility for load changes and easy adaptation to new wastes from regularly changing batch processes. The units consist of a vertical combustion chamber with Sub-X quench and downstream caustic scrubber; European units are equipped additionally with a plume suppression system. Locations La Vallee, France; Ponders End, Great Britain; several locations in the U.S. Key performance data Waste gas Burner duty Emissions CO CH4 TOC 2900 kg/h (4360 kg/h) 3.2 MW (4.5 MW) NOx HCI < 200 mg/Nm < 10 mg/Nm

< 100 mg/Nm < 50 mg/Nm < 20 mg/Nm

Treatment of wastes from an agricultural chemicals plant Process description The system treats aqueous wastes containing salts and waste gases from an upstream agricultural chemicals plant. The unit utilises SELAS-LINDEs proprietary concept for salt containing wastes consisting of a specially designed vertical combustion system with a Sub-X quench able to treat the salt-containing flue gases. A downstream acid gas scrubber removes residual gaseous emissions and aerosols to meet the emission requirements. Location Hangzhou, China Key performance data Waste liquids Waste gas Burner duty Emissions CO TOC Dioxins 800 kg/h 200 kg/h 2.9 MW Dust SO2 < 10 mg/Nm < 50 mg/Nm

< 80 mg/Nm < 10 mg/Nm < 0.1 ng/Nm (TEQ)

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Treatment of sulphur-containing wastes Process description Organic and aqueous wastes containing significant amounts of sulphurbearing compounds are treated in a horizontal combustion system. The heat generated during combustion is recovered by generation of saturated steam in a firetube boiler suitable for the acid gases resulting from combustion. A combined quench and scrubber system removes the acid gases. Location Bhlen, Germany Key performance data Organic waste Aqueous waste Burner duty Steam generation Emissions CO TOC SO2 1,456 kg/h 8,133 kg/h 19.8 MW 17 t/h (saturated at 12 bar) NOx Dust < 200 mg/Nm < 10 mg/Nm

< 50 mg/Nm < 10 mg/Nm < 50 mg/Nm

Treatment of halogenated wastes with sodium iodide recovery Process description The unit treats various liquid wastes, among them salt-containing wastes and Iodine compounds. The integrated approach of the system allows for heat recovery by steam generation in a boiler suitable for salt-laden flue gases and recovery of Sodium Iodide solution. Location Lisbon, Portugal Key performance data Waste liquids 931 kg/h Burner duty 7.0 MW Steam generation 5 t/h (saturated at 10 bar) Sodium lodide recovery 155 kg/h (solution at 8 wt%) Emissions CO TOC Dioxins & Furans < 50 mg/Nm < 10 mg/Nm < 0.1 ng/Nm (TEQ) HCI Dust < 10 mg/Nm < 10 mg/Nm

Treatment of salt brines Process description The system treats waste liquids and gases originating from an upstream insecticide/herbicide plant with high concentrations of phosphorus compounds, chlorides and up to 30 wt% of salts. The unit utilises SELAS-LINDEs proprietary concept for salt-containing wastes consisting of a specially designed vertical combustion system with a Sub-X quench able to treat the salt-containing flue gases. A scrubber and filter system removes residual salt aerosols and other pollutants. Location Lemvig, Denmark Key performance data Waste liquids Process air Burner duty Emissions HCI CO Dioxins 1,000 kg/h 5,000 Nm/h 3.6 MW < 10 mg/Nm < 50 mg/Nm < 0.1 ng/Nm (TEQ) TOC NOx Dust < 20 mg/Nm < 500 mg/Nm < 30 mg/Nm

SELAS-LINDE GmbH Range of activities.

Process furnaces for the chemical and petrochemical industry Pyrolysis furnaces for ethylene production EDC cracking furnaces Cracking furnaces for special chemicals, such as acetic acid and freon Reformers Steam reformers for hydrogen and synthesis gas production Fired heater units for refineries Crude oil heaters Vacuum oil heaters Visbreaker Platformer HDS heaters Reboilers Superheaters Special-purpose furnace equipment Furnaces for iron direct reduction processes Steam superheaters Waste recovery units for gas turbines Environmental Technology Plants for oxidizing gaseous and liquid wastes, including waste heat recovery, flue gas treatment, byproduct recovery for: Halogenated hydrocarbons PCBs Pesticides, herbicides Dioxins Pharmaceutical wastes Aqueous salt-laden wastes Nitrogen-bound organics Vaporisation of cryogenic fluids Submerged combustion vaporiser systems (Sub X) for: LNG LPG Nitrogen Ethylene

Offices/Subsidiaries T-Thermal & Process Heater Technology c/o Linde CryoPlants Ltd. 1 Blackwater Park, Holder Road Aldershot, Hants GU12 4PQ Great Britain Phone: +44.1252.321-811 Fax: +44.1252.321-355 SELAS-LINDE Fired Heaters Divsion c/o Linde Impianti Italia S.p.A. Via Corona Boreale, 86 00054 Fiumicino, Roma Italy Phone: +39.06656.13-1 Fax: +39.06656.13-200 Selas Fluid Processing Corporation T-Thermal Company/Thermatrix Five Sentry Parkway East, Suite 204 Blue Bell, Philadelphia 19422 United States of America Phone: +1.610.8340-300 Fax: +1.610.8340-473

SELAS-LINDE GmbH, A Member of The Linde Group Wolfratshauser Str. 138, 82049 Pullach, Germany Phone +49.89.7447.47-0, Fax +49.89.7447.47-17 E-Mail: selas-linde@linde-le.com, www.selas-linde.com

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