The “Green site” project

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The aim of this sub-action has been the assembly of the pilot plant in tight accordance to the project design. The construction of the skid is started on 27 September 2012. The assembly is started on the 24th January and ended on the 28th March 2013.
The supporting structure of plant was studied considering the following requirements:
Small dimension and easy to transport;
Arrangement of process equipment that facilitates the control and the operations management;
Easy to read and calibration of test equipment.

The skid has plan dimensions 6.05 x 2.45 m, total height 2.5 m. The total weight of the structure including mounted equipment is about 3.7 t. The skid consists of structural elements in Stainless Steel AISI 304 tubular framework with high thickness, reinforcement sections and sheet metal. Under the basement 18 supports to calibrate the level. Main front includes the process equipment and separation of pollutants, such as accumulation tank CO2, extractor, separator gravimetric, cyclonic separator. There are pressure gauges with a large diameter. There are the main valves for regulating the process. Front Back includes equipment such as oxidizer, heaters, process pumps, flowmeters.
Aisle with aluminium gangway for access to circuit hydraulic lines to process, cooling water circuit, control valves and adjustment process (linked operation to the logic of automation), pressure transmitter, under the gangway is installed conduit for electrical. Front Cabinet: in the short side of the skid, on the opposite side of the inlet of gangway, is obtained the position for housing electrical panel In the final stage of construction of the skid, with the skid still in the workshop of construction, were mounted major equipment such as storage of CO2, extractor E1, gravimetric separator S1, cyclone separator S2, heaters H1, H2, H3, H4, H5, condensation units C1, C2, C3, C4, C5, C6, collectors of the cold water feed and return.
In assembly phase were mounted in succession: process pumps, flow meters, safety valves, valves for manual adjustment, regulation valves to control automatic slaved to instrumentation for controlling and adjusting the process parameters (analyzers-temperature transmitters, gauges-flow transmitters, etc.), pressure transmitters.

Being a pilot plant with special features and unusual has studied the construction of piping “in the field” according to the hydraulic diagram, the location of equipment and instrumentation, with the constant support of process engineer and of technical department. The way of the piping has been studied in order to optimize the spaces, choosing the shortest distance, thinking of maintaining a space of accessibility to the electrical system. Has been adopted a tubing ¼ “ thickness 1.24 mm with two different materials: a) AISI 316 L (ASTM A269 – EN10216), for the lines at high pressure (300 bar) and temperatures below 260 °C b) INCONEL (ASTM B444, UNS N066255) for the lines at high pressure (300 bar) and temperatures until to 410 ° C (line oxidation process)
Particular attention was taken to the construction of the pipe, taking care of the cleaning of the end of the tubing after cutting and blowing compressed air to inside of the pipe ensuring the internal cleaning of the pipe to avoid the presence of small metal shavings, which can prevent the regular operation of valves and process equipment. The fixing of the pipes has been achieved with specific media to be fixed to the frame with platelet support.
We have realized the cooling circuit with copper pipe and installation of valves and solenoid valves. The pipes, where provided, were coated the thermal insulation material: polyurethane insulation for no very hot pipe; rock wool for pipe working at high temperature. Been included in the vessel are special seals U with internal spiral wire. The following hydraulic tests were successful.

It was still tested another type of seal in extractor E1 because the former have determined some difficulty in extraction of the head of the vessel.
The panel has been mounted on head of the skid and secured with additional structural support. Then It was connected all the electromechanical equipment, valves and instrumentation. Special metal sheaths have been provided for the wiring of electrical cables coming out of the heater. Electric cables high heat resistance have been used for the connection of heating resistances of oxidiser O1. Were performed on all hydraulic TEST vessel under pressure. One at a time, all of the vessel were filled with water and brought to pressure. The test was attended by an inspector certification of SGS. All tests were positive. After the hydraulic and electrical assembling the technical department completed the assembly drawings with indication of the final equipment position and the reference to P&I.

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