Country: North Dakota;
Client: Dakota Gas Company;
Temperature Service: -100°F;
Dakota Gasification Company owns and operates the Great Plains Synfuels Plant, a coal gasification complex in North Dakota that produces pipeline-quality synthetic natural gas and related products.
K-Flex flexible elastomeric foam insulation (K-Flex® HT EPDM-based base layer to withstand 250°F vessel steaming cycles and K-Flex® LS NBR/PVC-based additional layers) with a protective polymeric jacket (K-Flex IN CLAD) was the choice for cold service insulation in the rectisol area, an area that has operating temperatures down to -100°F. The elastomeric system was a replacement for a previously installed PUR with metal jacketing system that had resulted in significant ice accumulation. Benefits from the FEF system included the ability for both on-site and off-site fabrication to achieve maximum project time compression, a dust-free product for a clean working environment, a flexible and conformable product for installation of complex valves and flanges, easy handling and transportation up scaffolding floors, and the ability to cut from jumbo rolls to reduce inventory volumes and off-site warehouse space needed. The K-Flex FEF system’s microcellular closed cell structure and low water vapor permeability plus the polymeric jacket’s high emissivity and 100% sealability has provided excellent thermal performance, with key benefits being no ice accumulation and proper process temperature control. Since the project’s completion, DGC has achieved lower process temperatures under the same chiller load, improving the gas purification process and extending the life of the catalyst by reducing sulfur levels.
Thermal performance elements from the K-Flex FEF system include:
· No ice accumulation, improving personnel safety by eliminating the risk of falling ice.
· Consistent surface temperature, indicating a properly installed and highly efficient thermal system with no thermal bridges. The high emissivity polymeric jacket allows for accurate, non-destructive insulation inspection.
· Lower process temperatures achieved under the same chiller load, improving the gas purification process and extending the life of the catalyst by reducing sulfur levels.
Thermal Imaging Data
Ambient Temperature: 69°F;
Approximate Process Temperature: -100°F;
Section AR1 (FEF System) Surface Temperature: 62°F;
Section AR4 reflects PUR + Metal system;
Process Temperature Data
Approximate 10°F lower process temperature for FEF system (right of gap) vs. PUR + metal system (left of gap).
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