Total quantity or scope of tender
Specifications for Gas Processing Pilot Plant
Detailed Design:
USW has completed a High Level Design. The successful company will work with USW researchers to produce a detailed design capable of achieving the research requirements taking into account the specification below. Advice from industrial partners regarding any specific site requirements will also feed into the detailed design process.
Assembly:
Procurement of appropriate materials, components and sub systems and assembly of these in accordance with the detailed design agreed above. Assembly to comply with appropriate industrial standards for the purpose of use.
Factory Testing:
Factory testing of the whole system, subsystems and components to demonstrate appropriate functionality prior to delivery, to include mechanical and electrical systems and pressure testing. Certification of all testing undertaken and provision of an operating manual and component list. Factory testing to be witnessed by USW and appropriate industrial partners.
Site Commissioning and Training:
Delivery to a site in South Wales and plant commissioning and training USW staff is also expected.
Reactor Dimensions
Approx. 23.1 litres internal volume
The reactor will be a ‘column’ type system e.g. in the order of Diameter: 160 mm, Height: 1150 mm (internal dimensions)
As an Option, please provide an indication of any cost savings should standard pipe dimensions be used, accepting that aspect ratio of the reactor may be adjusted slightly to achieve the required volume.
Please include the following as options:
a site glass across the liquid level to allow visual inspection, approx. 300 mm by 50 mm; or
two smaller visual inspection windows, one above and one below the liquid level; or
no window at all.
The reactor is to contain a mixture of liquid medium mixed with gaseous feedstocks and a packing material under the operating conditions below.
Operating Conditions
Pressure: Capable of operating between 1-10 barg internal pressure. All gas and liquid handling components therefore need to operate in this range.
Temperature: Normal operating temperature of the reactor of 35°C - 65°C, and also for components attached to the reactor. Sub-system components working away from the reactor (not in contact with working fluids) should be able to operate between normal ambient temperature ranges experienced in the UK.
pH: Normal operating conditions of pH 7-8, however the vessel and components in contact process liquids should be capable of operating between pH5 – pH9.
Operational time: The system should be capable of operating 24 hours per day, 7 days per week during the experimental phase. However, it is expected that the system will be operated intermittently during process start up.
Materials of Construction
The column, perforated plates (top and bottom) will be stainless steel 316L with 2B finish.
The packing material will be provided by USW.
Liquid circulation pipework and all fittings will be appropriate for the operating pressure and temperatures defined.
Design temperature and pressure for all materials is 80°C and 12 barg.
Gas Input
Mechanism for the addition of industrial gases into the reactor vessel via the side wall at the base of the reactor. Gases will include hydrogen (both pure and mixed with nitrogen) and carbon dioxide. Low concentrations of ammonia and of other hydrocarbon gases may potentially be present.
The system will initially operate using pressurised bottled gases.
The system should include the ability to mix gases from 2-4 separate sources (e.g. a gas manifold) supplied at pressure (1-10 barg) and the ability to control and record the flow of each gas (i.e. to allow control of gas composition to an accuracy of 0.1% by volume).
Gas temperatures supplied to the system will be between ambient temperature and 80°C.
Required gas flow volumes: 0 – 28 litres / minute of mixed feed gases (i.e. total flow of mixed gas entering the reactor).
Liquid & Gas Mixing
Mechanism for reduction of gas bubble size at the bottom of the reactor (e.g. diffuser or venturi). The aim is to reduce bubble size as far as is practicable whilst achieving the required gas flows above.
Mechanism for removal of liquid from the lower side of the reactor (opposite gas inlet) and recirculating to the top / upper side of the reactor (i.e. a pumped mixing loop). It is anticipated that the liquid stream will contain a significant proportion of gas (which may achieve 40-50% as gas). Variable liquid flow rates of 80 - 250 litres per minute should be capable of being sustained.
The recirculation pipe will have an internal diameter of 34 mm.
Liquid Removal
The biochemical process generates water within the reactor, therefore the ability to remove excess liquid from the reactor is required. This should be via a dedicated liquid removal port. Liquid removal is required to be achieved whilst the main reactor remains at pressure.
Gas Outlet
Gas outlet port approximately 50 mm from the top of the reactor connected to a foam trap / liquid trap vessel (approx. 4 litres in volume) including level sensor and actuated valve for liquid removal. Final gas outlet should also include a variable back pressure valve to allow pressure within the reactor to be controlled and maintained.
Reactor Heating
Include provision to maintain temperature within the reactor including heat source, insulation and mechanism to circulate heating fluid if used. Normal operating temperature is approx. 37 °C, however the ability to change and maintain temperature between 35 °C and 65 °C is required. Temperature within the reactor should be capable of being maintained at a set point to +/- °1 C.
Process Monitoring
Separate cost item - USW has / will procure the following components directly and supply to the appointed contractor:
pH probe and controller
digital mass flow controllers to measure gas input volumes
digital mass flow meter to measure gas output volume
digital output gas monitors for CO2, H2 and CH4 to measure gas outlet quality
The appointed contractor will be required to source components appropriate for the monitoring of:
liquid temperature in the reactor
liquid recirculation flow rate
process operating pressure
liquid levels in the main reactor and liquid / foam trap
The contractor is to allow for the incorporation of all of the above components on to the reactor in such a way that allows the continuous / near continuous monitoring of
Process pH
Individual gas input volumes
Gas output volume
Gas output composition (CO2, H2, CH4)
Liquid temperature in the reactor
Liquid recirculation flow rate
Process operating pressure
As a minimum, all data is to be available for inspection via a user interface with the capability to export data in standard digital formats.
As an optional item please indicate any additional costs associated with providing a cloud based platform allowing the secure on-line storage and inspection of process monitoring data to a limited number of authorised users.
Process Control
The ability to control the following via a user interface:
Reactor Temperature: 30°C to 65 °C
Pressure: Automated control of gas regulators (0-12 bar)
Gas Input Volume: 0 – 500 litres / hour of mixed input gas comprising of H2 0-100%, CO2 0-100%, N 0-100% and all mixtures in between (controlled using mass flow controllers). Ideal operating conditions are approximately 20% CO2 and 80% H2 by volume.
Liquid flow rate in the recirculation line
On / Off (including automated control and manual emergency shut down)
As an optional item please indicate any additional costs associated with providing a secure cloud based platform allowing the control of the above parameters from remote locations using mobile and pc devices.
Process Automation
All valves, flow controllers and other means of controlling system be operated via the control system, i.e. no exclusively manual control other than safety shut down and manual emptying / drainage of the reactor. Manual over-ride of all safety critical control points is to be included.
Process Safety
The chosen provider is to provide advice relating to the H&S requirements of the final system, and is to incorporate the requirements of industrial partners into the final design.
As a minimum the system will include:
Emergency Shut off valve(s) for gas supply,
Emergency Shut down control for all mechanical/electronics associated with the reactor,
Automated safe shutdown procedure to ensure that the reactor is left in a safe condition should an alarm condition occur,
Circuit breakers for system malfunction (e.g. overheat / overfill)
As an option, please indicate any additional costs to include a remote alarm facility to notify operator of failure via mobile device.
Factory testing certification to be provided by the manufacturer to include pressure testing, electronic and mechanical testing.
The reactor and ancillary equipment should be skid / frame mounted to allow transportation. Appropriate support mechanisms should also be included as required.
The plant will be located within a well ventilated, covered area. Initial discussions with industrial partners have indicated that ATEX rating of electronic components is not required. This can be discussed with the appointed contractor prior to finalizing the design.
Please provide an Option of an additional cost for Zone 1 ATEX compliance.
Delivery & Installation
Delivery to a testing location located within South Wales within 12-14 Weeks of agreeing the detailed design. To include unloading from transportation.
Methods for moving the unit into position are to be provided.
Operator instruction & training.
Single phase and three phase power will be available on site. Power requirements to be determined during detailed design.
Drainage will be provided on site.
Technical Support
6 months of technical support post-delivery including 2 No. site visits and end of the phone technical advice.
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