Calculation Example for using JPX Vapor Phase Cleaning during Turnarounds

Calculation Examples

Jayne Products, based on 20 years’ experience in vapor phase clearing uses 4 liters of JPX for 1 cubic meter of column or vessel internal volume.

To calculate the volume requires the following calculation:  

For example

·      Let’s take a crude atmospheric tower that is 30 meters high and has a diameter of 7 meters. Internally, it has 40 trays, all of a bubble-cap design.

·      To calculate the tower volume, without taking account of the dished-ends, use

V= πR²xL    V=π3.5² (30) =1,154m³

The volume of JPX required would be calculated a 1,154 x 4 = 4,616 liters.

1 drum JPX = 208 liters so 4,616 ÷ 208 = 22 drums of JPX. This is equivalent to a liquid circulation: fill column 20% to cover the trays and provide a positive pump suction will require 1,154 x 20% = 230m³ and using 2% concentration of JPX will require 230x .02 or 4.6m³ JPX = total of 22 drums.

We always favor the vapor phase over liquid phase to cut the decontamination time by 2/3 and eliminate the disposal of the circulation solution. 

Application for JPX/JPX-E Refinery Vapor Phase Cleaning

The vast majority of decontamination work is performed by Vapor Phase. The JPX is injected

directly into the purge stream that is used in the normal steam out process during shutdowns. The

JPX is carried throughout the column contacting all surfaces, breaking down the hydrocarbons

into lighter ends that are carried overhead to the flare system and emulsifying the heavier

hydrocarbons to be drained from the column with the condensate.

This Vapor Phase process greatly reduces decontamination time, wastewater generation, and

chemical cost, but provides H²S, Benzene LEL removal, so that the equipment is ready to enter

after a cool down water flushing rinse.

JPX/JPX-E can be applied by circulation to target packed beds that may be more heavily

contaminated or be at risk from Iron Sulfide, pyrophoric materials. Typical circulation solution

concentrations are from 1% to 3%.

A third application type would apply to horizontal vessels that have known sludge

accumulations, such as desalters or gas recycle KO drums.

The vessel is typically filled to 1/3 level and JPX/JPX-E is added to the steam heated water. The

mix is boiled and agitated to provide maximum sludge liquid content. The sludge hot water

slurry is then pumped out of the vessel and the vessel is re-steamed to relief to purge all vapors

in preparation for entry.

An auxiliary step when pyrophoric material is suspect of being present is to add JPX-EE (a mild

oxidizer and solubilizer) to the rinse water; this neutralizes the pyrophoric iron sulfides and

allows them to be rinsed from the internals of the columns.

Struvite Removal Wastewater Lab Testing

We at Jayne Products ask for and receive a great variety of struvite samples as can see in the picture below.

Struvite and Vivianite can range in color, granularity, hardness, composition as well as other variables. 

We offer those with struvite problems free testing on their different samples to prove our products effectiveness.

Our testing typically takes into account the comparison of the struvite to others we have collected so we can asses if will need a stronger concentration dependent upon the amount of struvite.

We also do product testing were we will place 5 grams of struvite in different solutions, 100%, 50%, 30%, 25% and so forth in a beaker with a magnetic stirrer (to resemble a recirculation).

Below is an example of our testing setup. For more information, to contact us or for free samples please visit our website.

www.jayneproducts.com

JPX Chemical Cleaning Set-Up Procedure

Below are both the diagrams for the set up as well as the video to set up for use of JPX line of products into vessels for cleaning.

Please don't hesitate to call us for any help or consultation regarding the use of JPX or the procedure to set up!

JPX Products Chemical Cleaning Set-Up Video

Struvite Removal Wastewater Removal Egg Demo

Our Struvite Removal and Control Product is used primarily in wastewater applications, including both municipal and CAFO operations.

In this video you will notice an Egg is placed in enough Struvite Remover to keep it submerged. The pH of this product is approximately 0.5 but since it is a buffered acid, it has been proven to be:

Non-corrosive to steel
Only Slightly irritating to skin

Meaning, that despite its low pH, and being a great descaler, it is safe, as well as will not damage any equipment in your operation.

The egg in the video proves that it will remove and dissolve scale (egg shell), while not harming the protein (egg), leaving it fully intact and handling both the product and the egg with our bare hands.

For any other questions, information, or for a FREE product sample and consultation please visit our websites.

http://jayneproducts.com/applications/wastewater

http://www.struviteremoval.com

Turnaround and Shutdown Decontamination Chemical Cleaner

JPX is the most cost effective decontamination chemical available. It outperforms well-known and more expensive products. JPX injection into your vessel steam out will:

·      Cut steam out time by 2/3

·      Remove hydrocarbons, H²S and benzene, permitting earlier vessel entry

·      Eliminate internal clean-ups normally required for inspection and repair

·      Reduce the time required for exchanger bundle cleaning

JPX is safe for people, the effluent system, and air quality.

JPX has been used in cokers, crude and vacuum units, FCC, hydrotreaters, hydrocrackers, reformers, contactors, separators, and all varieties of columns:

·      See our steam injection or circulation diagrams for an outline of the JPX cleaning process.

Shell, BP, Arco, Mobil, Chevron, ConocoPhillips, Tesoro, and overseas refineries have saved money by utilizing JPX to decrease down time.

Vapor Phase Application of JPX and JPX-E Chemical Cleaner

 

Vapor Phase Application of JPX and JPX-E

Preparatory:

            Obtain simplified process flow diagram review; with operations, the sequence and priority for equipment decontamination.  Mark up diagram to show JPX injection points and vent locations; show flow path for vapor cleaning through process vessels. 

            Prepare a layout page showing sequence and volumes of JPX (or JPX-E).  Time, temperature, results, and rinse columns will be completed as application proceeds.

Application:

Prior to pumping JPX, verify the following, by physically checking:

1)     Vessel is drained – Condensate not hydrocarbon coming from bottom drain connection.  Do not rely on control instrument levels.  They may be plugged or blocked in.

2)     Vessel is vented to relief system, sometimes called blowdown or vapor recovery system.

3)     JPX injection valves into vessel are open, and that only one flow path for JPX exists.

4)     Check and record vessel temperature.  Depending on system flow and vessel size, temperature should be over 200°F after a couple of hours of steaming.

5)     Check rinse line (reflux line) to be free of H.C. and hot via steam.

Begin pumping JPX into vessel:

Typically one drum per 20 minutes.  After pumping ½ of the calculated JPX required, re-check drain line, any top vent connection and reflux (rinse) line for JPX lemon odor to verify vaporization is adequate.  When completed, JPX injection continue steaming for several more hours; then have operations lower steam rates dropping vessel pressure and perform sniff for LEL, benzene, and H₂S.  If vessel is a column, the overhead accumulator would have JPX injected immediately after column JPX injection and would be sniffed at the same time as column.

If sniff OK, start fresh water rinse, hot water is preferred.  Maximize flow of rinse & continue for several hours until bottom drain is clear of soap emulsion.  Caution, do not use accumulator water or reflux pump as water rinse source.  Accumulator may have sludge emulsion from JPX cleaning and could recontaminate column.

After:

Complete layout page info and discuss with operations.  Flush JPX pumps with water.  Remove empty JPX drums to location for later pick up.