Modification of the waste-gas absorption system in the paraformaldehyde granule production unit through the design and installation of an advanced chemical scrubber capable of removing ≥95% of formaldehyde vapors and recovering formalin for recycling back into the production process, with the aim of reducing emissions, improving safety, and achieving economic savings.
Accurate characterization of the gas composition under variable operating conditions; design of a multi-stage absorption system for formaldehyde and methanol without clogging; selection of a regenerable absorbent that does not generate undesirable by-products; control of the exothermic reaction temperature; integration without disrupting line pressure; recovery at sufficient purity; protection against toxic and flammable gases in compliance with ATEX requirements; resistance to acidic corrosion; optimization of water and energy consumption; and stable operation across 30–100% of design capacity.
Design and fabrication of a new absorption tower; installation of a plate condenser; system isolation and integration with the suction system; conversion from positive to negative operating pressure; installation of induced-draft fans; implementation of an online environmental monitoring system (GC/FTIR); installation of advanced filters for particles <5 μm; implementation of an HSE system with gas leak detection and emergency ventilation; and obtaining ISO 14001 certification.
A new scrubber system equipped with recovery tanks, pumps, and piping; P&ID documentation and as-built drawings; performance test reports detailing absorption efficiency and recovery rates; before-and-after analysis of outlet gas composition; a digital control system (SCADA/DCS); operation and maintenance (O&M) manuals; and certification of compliance with environmental standards.
Jey Oil Refining Company
Design and development of magnetoactive nanoceramic coatings to inhibit the nucleation and growth of coke deposits in process equipment used in bitumen-producing refineries. Through surface engineering, these coatings prevent the initial adhesion of coke, thereby enhancing equipment efficiency and extending its service life.
Jey Oil Refining Company
Design and manufacture of an industrial turbo-compressor to supply combustion chamber air and plant compressed air by utilizing the heat generated from the combustion of excess gas. The key innovation is the elimination of the power turbine rotor and the splitting of the hot gas flow upstream of the gas-generator turbine inlet, which reduces costs while increasing aerodynamic loading.
Jey Oil Refining Company
Design and fabrication of a compact heat exchanger for preheating the compressed air supplied to the oxidation reactor from 90°C to 200°C, using direct flame heat and combustion products from excess gas. The heat exchanger is installed in the excess-gas burner wall and fabricated from A516 steel plate with minimized welding requirements.