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The leakage of caustic, toxic, or corrosive substances such as Sulfuric Acid, Ethylene, or Sodium Hydroxide can quickly pose deadly health risks to employees and the surrounding environment for countless years after the initial leakage occurs. These environmentally compromising chemicals may continue to pose substantial health threats to immediate environment and local communities. Such dangers used to make selecting the appropriate sealing solution for your operations a difficult task, as numerous factors such as: temperature fluctuation, fluid pressure, facility location, corrosive mediums, fire safety, and operating environment had to be taken into consideration. With the DeltaV-Seal, selection is made easy as it is given by the connected flanges.
While it is not always difficult to select a compatible seal material for the processing of a single chemical, one of the biggest difficulties for chemical production is selecting the right material which is compatible with a mixture of chemicals. The DeltaV-Seal™ is the ideal sealing solution that satisfies the needs of the Chemical Industry. Its material is matched to the flange for the highest quality sealing performance, making it just as effective at tolerating the exact same substances as the pipe does through various levels of operations. Utilizing a smarter seal not only means superior sealing performance, but it also means a client can operate without ever having to clean a flange or having to maintain it, for the entire operational lifespan of the flange connection.
The reactor is a vessel used to house a chemical reaction in the petrochemical industry. In the chemical process multiple substances are fed into a tank/vessel where a chemical reaction occurs. In industry reactors vary in size from a few cm3 to the vast structures that are often depicted in photographs of industrial plants. Two main types of reactors are in use today: Batch Reactors (which are most used for reactions, carried out in laboratories) vs Continuous Reactors which are used in production. These are continuously fed chemical reactants from a single entry point, allowing the reaction to take place, and then withdrawing the products at alternate point. Due to the nature of mixed reactants, choosing a seal with versatility and superior sealing strengths is paramount, containing chemicals both before and after reactor processing.
Cyclones for Refineries & Petrochemical Plants are a technology that uses cyclonic separation (via vortexes) as the method of removing particulates from a stream of liquid or gas without the utilization of filters. Maintaining an air tight seal in this process ensures the internal separation process is functioning and optimal strength and efficiency. A loss in pressure due to leak can disrupt the process, cause loss of product, reducing operating efficiency, as well as expose workers and the environment to potentially dangerous substances.
Catalytic cracking units
One of the most important conversion processes used in petroleum refineries, these units are used to convert the complex hydrocarbons into simpler molecules in order to increase the quality and quantity of lighter hydrocarbon fractions of petroleum crude oil into highly demanded gasoline, olefinic gases, and other petroleum based products. This process can result in the production of highly combustible kerosene, gasoline, LPG, heating oil, and petrochemical feedstocks. Micro leak or fugitive emissions can occur in piping that leads to or from the Catalytic Cracking Units due to weak flange gaskets. These leaks can result in an explosion, loss of product, and/or environment problem, however these challenges are all eliminated through a superior sealing strength.
Preventing nitrous gas leakage at a Thermowell instrument flange joint
On a Thermowell instrument coupling flange joint a previous semi-metallic gasket required maintenance intervention 7 times in three-and-a-half years. Switching from a semi-metallic gasket to the DeltaV-Seal prevents the emissions of NOx, protecting the environment and will saving the operator the cost of regular maintenance interventions.
Corporate environmental responsibility ‘done right’ with long-term methane mitigation by design
Methane is one of the most potent greenhouse gases and avoiding leakage is a priority when using methane systems. Methane also ignites easily, so there are clear and immediate HSE incentives for maintaining absolute process integrity. Traditional pipeline gaskets often leak and need frequent maintenance, which must be considered when choosing seals for a methane system.
Gasket ensures a long-lasting seal
In manufacturing fertilizer, ammonium nitrate is added to the process, and traditional, spiral wound and Gylon gasket technology often deteriorate in these conditions, resulting in leaks. This is problematic because when ammonium nitrate leaks, it crystalizes and expands like ice, resulting in costly repair and safety hazards.
In conversation with: Odd Skagestad, GE Healthcare Lindesnes
I am a departmental engineer in the technical engineering department with equipment responsibility for pipes, valves, gaskets and tanks. In addition, I am responsible for pipes and mechanical disciplines in a number of projects. I’ve been employed at Lindesnes for almost 20 years
DeltaV-Seal™ reduces greenhouse emissions
In fertilizer production, high-quality phosphorus fertilizers require nitric acid as a key ingredient, which is usually synthesized via the Ostwald process on-site (oxidizing of ammonia before combining with water). This form of nitric acid synthesis is a cornerstone of any modern fertilizer production facility. However, this process can cause nitrous oxide to leak from the nitric acid lines, and it is 296 times more potent than carbon dioxide.
DeltaV-Seal™ prevents leaks and pipe corrosion
In district heating and cooling, generic spiral wound gaskets frequently cannot cope with the cyclical temperature conditions and often fail, leading to leakages and corrosion of the pipeline. This causes expensive maintenance and lower overall performance.
DeltaV-Seal™ prevent fires, promote safe environment
The use of hot oil systems in manufacturing presents challenges when traditional gaskets breakdown and cause leakage. As liquids in the system are kept at a temperature above their flash point, when they escape they can cause fires and even explosions in the facility.
Bespoke gasket solution for waste plastic synthesis to kerosene
Recycling plastic into hydrocarbons requires extreme pressures and temperatures, challenging the performance of traditional gaskets. Before contacting Pipeotech, a university had been utilizing Kammprofile gaskets which consistently failed at around 80 Bar G pressure during trial operations. Ensuring a reliable seal was essential to confirm proof of concept, and this was made possible with Pipeotech’s engineering expertise and the DeltaV-Seal™ flange gasket.