1. Background of Automatic Condensate Acid Drainer
In the sulfuric acid production process, two locations continuously generate condensate acid, while four locations require regular checks to determine whether condensate acid is being produced, thereby assessing the health status of the unit. If not promptly removed, the condensate acid can cause corrosion or blockages in the equipment, impacting the boiler steam system and resulting in prolonged downtime for the sulfuric acid unit.
Traditional sulfuric acid units usually rely on manual checks and discharge of condensate acid at regular intervals, often resulting in significant condensate acid generation during abnormal conditions. As the unit operates under positive pressure, the discharge of condensate acid can cause splashes, increasing safety risks for operators. Moreover, the discharge is not contained, releasing large amounts of acidic gas into the environment. Annually, a single sulfuric acid unit can release approximately 3000m³ of acidic gas into the environment due to uncontained discharge of condensate acid, causing pollution and equipment corrosion.
2. Product Advantages
1) Can be installed at various locations, the bottom of the steam ejector, in the HRS tower, at the outlet of the absorption tower and drying tower, bottom of economizers, and at the heat exchangers.
2) Quickly detects faults and adjusts process parameters, preventing major production losses.
3) Reduces direct contact with sulfuric acid for operators, making their work safer and easier.
4) Eliminates issues with uncontained acidic gas emissions, protecting the environment and preventing equipment damage.
5) Provides precise measurements of condensate acid, offering solid data for production management and improving efficiency.
3. Product Performance
– Discharge Method: Automatic Discharge
– Discharge Medium: Condensate Acid / Oleum
– Fault Diagnosis: Water and steam Leaks / Demister Health Status
4. Product Features
1. Automatic statistics and discharge of condensate acid.
2. Utilizes local and remote independent measurement technologies to output a 4-20mA signal for the DCS system.
3. No acidic gas emissions, reducing annual acidic gas emissions by **3000m³**, thus protecting the environment.
4. Health diagnostics for the demister in the drying tower / intermediate absorption tower.
5. Automatic low-temperature anti-blocking and automatic purging.
6. Automatic operation, simple operation, maintenance-free, easy installation, and corrosion-resistant stainless steel material.
5. Technical Parameters
| Parameter | Description |
|---|---|
| Name | Automatic Acid Condensate Drainer |
| Model | LSA-300A |
| Measuring Volume | 30-100L |
| Level Sensor Resolution | 1mm |
| Response Time | 0.45s |
| Accuracy | ±3mm |
| Measuring Principle | Guided Wave Pulse |
| Sensor Model | LF-001 |
| Origin | Japan |
| Signal | 4-20mA IO-Link*5 |
| Working Temperature | 20-200℃ |
| Instrument Temperature | -20-70℃ |
| Pressure Measurement | 0-60kPa |
| Automatic Functions | Condensate Acid Discharge / Demister Health Diagnosis |
| Automatic Control Valve | Power Solenoid Valve 8327, Discharge Solenoid Valve (Ball Valve) |
| Power Supply | 90-260VAC, 50/60HZ, 24VDC optional |
| Transmitter Output | 1 isolated 4-20mA transmitter, max loop 350Ω, 2 switch signals |
| Process Interface | Flue Gas HG/T20592 DN50 PN1.6MPa, Acid Discharge HG/T20592 DN50 PN1.6MPa |
| Dimensions | 200mm x 200mm x 400mm |
| Weight | 35kg |
6. Working Principle
The Automatic Acid Condensate Drainer uses dry compressed air to push condensate acid out of the tank. The discharge pressure is based on the height of the discharge pipe, calculated using the formula: P = K * ρ * g * h. For example, if the discharge pipe is 3 meters high and the resistance coefficient is 1.2, the pressure needed is P = 1.2 × 1.82 × 9.8 × 3 = 64.2kPa. If the air pressure is lower than this, the acid won’t discharge properly. When connecting multiple devices to the same discharge pipe, they must discharge in sequence to prevent blockages.
7. Precautions
– When operating the Automatic Acid Condensate Drainer, be aware that the equipment may heat up due to high temperatures. After measuring the temperature, avoid direct contact with the tank of the discharge device.
– During use, do not loosen the connecting flanges or the bottom inspection flanges. If there is pressure inside the standard tank, do not disassemble the discharge control valve.
– Ensure that the compressed air used as a power source is sufficiently dried. If water or steam leaks from the boiler, leading to a large amount of condensate acid generation, immediately stop using the Automatic Acid Condensate Drainer.
8. Maintenance
1. During normal operation, carefully inspect all flange connections of the Automatic Acid Condensate Drainer to ensure there is no flue gas or condensate acid leakage. Monitor the on-site pressure and liquid levels to ensure they remain normal. Additionally, periodically check the filtration pressure-reducing valve to confirm normal condensate discharge and verify that its pressure is maintained between 0.45 to 0.55 MPa and that the pressure-reducing valve is between 0.1 to 0.2 MPa. Also, check the sealing performance of the inlet control valve and the acid discharge control valve.
2. Before maintenance, close the pneumatic ball valve and pressure-reducing valve. If the limit switch hasn’t signaled to close, switch to manual mode to release pressure, then close the valve. Ensure the adjustment valve is closed before discharging the acid until the level gauge reads zero.
3. It is strictly forbidden to disassemble or tighten the Automatic Acid Condensate Drainer while the pneumatic ball valve is open. If you observe process liquid leakage at the connecting flange of the Automatic Acid Condensate Drainer, ensure to close the pneumatic ball valve first, and then, after wearing appropriate protective gear, tighten the flange connection bolts.
4. During maintenance, immediately use clean water to wash the surfaces of the disassembled Automatic Acid Condensate Drainer and pneumatic ball valve to remove any residual condensate acid, acid sludge, or other impurities. This is to prevent them from absorbing water and forming diluted sulfuric acid, which could severely corrode the equipment. Continuously rinse until pH test strips confirm that the washing water from the discharge device and ball valve is neutral.
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