Coastal Technologies

CTI VP Norman Mansson Presents Case Studies on De-Bottlenecking

CTI Admin - Wednesday, October 19, 2016

Evaporator and Crystallizer
De-Bottlenecking

The back end of evaporators and crystallizers contain the mist eliminator, which prevents entrained liquid with dissolved solids (as well as some suspended solids) from being carried over with the steam to the following effect steam chest, where it can foul the steam side of the tubular heat exchanger or the space within a plate type evaporator.

Increased production capacity may require redesigning the mist eliminators to prevent loss of product and increased contamination of downstream condensate.

This paper presents (3) different cases where mist eliminators were replaced to increase the capacity of the evaporation process as well as improve performance.

Click here for more information.

Evaporator and Crystallizer De-Bottlenecking

CTI Admin - Tuesday, June 28, 2016

The back end of evaporators and crystallizers contain the mist eliminator, which prevents entrained liquid with dissolved solids (as well as some suspended solids) from being carried over with the steam to the following effect steam chest, where it can foul the steam side of the tubular heat exchanger or the space within a plate type evaporator.

The desire for increased production capacity requires evaluation of the likely resulting increases in vapor flow and higher pressure drop due to the changes in the process conditions. Without redesigning the mist eliminators, there can be loss of product and increased contamination of downstream condensate.

This paper presents (3) different cases where mist eliminators were replaced to increase the capacity of the evaporation process as well as improve performance.


Case #1

Evaporator De-Bottlenecking

The Problem:

For Effect 6 of an old, rising film, black liquor evaporator in a Florida Kraft paper mill, the existing horizontal flow chevron mist eliminator became the bottle-neck when process conditions (including a greater steam rate) changed, resulting in a high pressure drop, physical deterioration, and liquor re-entrainment. Furthermore, when the evaporator was originally designed, no provision was made to be able to remove the heat exchanger for re-tubing without having to remove the mist eliminators.

The Solution:

Since vapor head space was sufficient, an AIROL® 430H125 horizontal flow chevron (3-pass design with 1.25” vane spacing) was installed to provide the highest efficiency and the best direct drainage, and to lower the pressure drop to less than the original design before the process change. The AIROL® 430H125 was selected because the optimum vane spacing and number of directional passes still allowed sufficient opening to minimize fouling. Rather than hanging closely mounted mist eliminators, we designed new support beams and re-positioning to allow for the future removal of the heat exchanger without interference with the chevrons. A resulting deck surface on the mist eliminator outlet sides permits maintenance personnel to work without having to install scaffolding. All sections were made in the largest possible sub-assemblies, pre-fitted and verified to minimize field labor. By removing the top flanged vapor head, the old internals and the new large sub-assemblies were replaced quickly, allowing the retrofit to be done within a tight outage schedule, in less than the allocated time frame.

Start-up and full production evaluation confirmed that both condensate quality and pressure drop were within the levels expected. Not only were energy savings realized from the lower pressure drop, but improved condensate quality meant that additional condensate treatment was no longer necessary before reusing that water, and the 65% black liquor, which had been re-entraining, could now be used directly.


Case #2

Crystallizer Process

Capacity-Boosting Retrofit

The Problem:

When the down-stream cyclonic separator was no longer sufficient for the increased production rate of L-Threonine (an amino acid used in the biosynthesis of proteins), and the crystallizer vapor head had insufficient volume for the addition of an internal mist eliminator, the crystallizer manufacturer and plant management needed a solution to boost capacity and minimize pressure drop. They focused on inserting a compact in-line chevron mist eliminator in the vapor line connecting ducts at the top of 180° elbows.

The Solution:

CTI was selected as the vendor for this application, in part due to our extensive experience with L-Lysine evaporation applications, as well as our past successful record with the evaporation manufacturer.

CFD modeling indicated sufficient pressure drop was needed to assure uniform flow distribution. The vessel, with stiffening, was subsequently designed to run at full vacuum, due to the operating conditions, and FEA proved the design would meet ASME Code purposes.

A higher efficiency AIROL® 430H100 horizontal flow chevron (3-pass with 1” vane spacing) was selected and inserted in a short, straight section of ducting. One turning vane was added to the inlet elbow and included as part of the mist eliminator housing to minimize the required field work. Additionally, since this was a crystallizer application with a down-stream turbo compressor, and the user had no experience with chevrons in the service, an inlet wash header/nozzle on a withdrawal nozzle was added so the mist eliminator could be washed online without any carryover.

The field installation was accomplished with ease due to the flawless fit-up, and pressure drop was minimized with the added inlet turning vane. The pressure drop and steam condensate quality were confirmed within the specification requirements.


Case #3

Replacing an Existing External 

Inline Mist Eliminator

The Problem:

A planned increase in production capacity at this South Carolina paper mill was projected to cause significant black liquor carry-over from the 1st effect evaporator to the steam chest of the 2nd effect, as well as a high pressure drop.

Previous upgrades adding a new, larger heat exchanger and a now-outdated large external mist eliminator left no room in the vapor head for expansion. Ironically, the existing mist eliminator housing could not be utilized to increase capacity because it was too large. The sudden great expansion of steam entering the transition housing would create poor flow distribution across the mist eliminator, and trying to fit new mist eliminator internals within the housing would result in poor steam flow.

The Solution:

Design improvements during the past (10) years permitted a new mist eliminator to have a smaller cross section and to operate with a lower pressure drop, and Computational Fluid Dynamic modeling (CFD) verified that the addition of turning vanes would assure uniform vapor flow across the new mist eliminator, so the vanes were added to the existing inlet and outlet elbows. An inlet wash system and a top wash header was provided to clean the mist eliminator online without carry-over. 

The transitional housing needed to be designed for full vacuum and 15 psig, and the housing and stiffening design was verified using Finite Element Analysis (FEA). 

The housing with mist eliminator and wash system was delivered completely assembled. The inlet and outlet elbow turning vanes were delivered in a bolt-together/weld together manner with clear instructions. The transitional housing was replaced within the available dimensional limits with vapor duct, flanged connections to match the existing lines, and were field bolted and welded. An existing deck was reconfigured to allow access to the mist eliminators from the side (as before), as well as from a large new top platform from where, with the mist eliminator access cover removed, the top wash header can be removed and serviced, and all (10) chevron modules can be examined and jet washed without removal. The new top platform with railings and ladders were pre-fit, and knocked down for shipment.

CTI Picked by Midrex for World’s Largest Hot Briquetted Iron Plant

CTI Admin - Friday, June 12, 2015

Coastal Technologies, Inc., CTI, a leading global supplier of mist eliminators and separators, has received an order from Midrex Technologies, Inc. for key mist separation equipment to precede process gas compressors for the World’s largest HBI (Hot Briquetted Iron) plant in Corpus Christie, Texas USA. The two million ton per year plant, voestalpine Texas LLC, will reduce iron ore through the MIDREX® Process. It is scheduled for start-up in 2015 and operates using natural gas as the fuel and reductant for the process.

The separation equipment supplied by CTI is a three-stage system designed for extremely high efficiency to protect the compressors and permit long term operation with minimum fouling and maintenance. The separation equipment consists of, stage one, an AIROL® multi-vane inlet diffuser followed by AIROL®130H-1-750 chevron mist eliminators. The third and final stage is a high efficiency mesh mist eliminator capable of removing 99.8% of droplets 5 microns and larger.

Midrex’s Project Procurement Manager, Mr. David Ahwesh stated, “We have a very strong supplier network and COASTAL TECHNOLOGIES is one of the companies in this select group. The voestalpine Texas project is the largest in the world and requires an unprecedented scale of proven parts that must come together in a well-organized fashion.” CTI has previously supplied Midrex Technologies with separation equipment for select customers in India, Saudi Arabia, Russia, Qatar, Malaysia, Oman, Pakistan and Egypt.

CTI is a leader in the process industries offering state-of-the-art mist elimination and separation technology uniquely designed to Customer specifications and process production goals. “We have designed and manufactured proven high quality mist eliminators for industrial process and power applications for over 29 years. Today, that alone is no longer enough,” indicates Norman Mansson, VP CTI. “We must also deliver complex, technically challenging supply solutions that often require a large number of elements to mesh together synchronously to optimize equipment production efficiency. Also, by working closely with our customers in the early design stages, integration of the largest framed mist eliminator assemblies possible within our customer’s vessels during the vessel fabrication process thus maximizing production capacity and efficiency. And finally, because our customer’s work may be located world-wide, there are often logistical challenges.”

In addition to the primary metals industry, CTI is active in chemical, pharma, food related evaporation and crystallizer applications, geothermal steam separation/scrubbing, and marine applications.

Your company can gain the benefits of our results driven performance and savings in energy, steam, chemicals or water.

Please contact Norman Mansson, VP, Coastal Technologies, Inc.
1-803-943-4822
nmansson[at]cti-sc.com



About Midrex Technologies, Inc.:

Midrex Technologies, Inc. is an international process engineering and technology company providing steelmakers with commercially proven solutions for greater profitability and has been the leading innovator and technology supplier for the direct reduction of iron ore for more than 40 years. The company offers eco-friendly technologies for ironmaking that provide high productivity, outstanding product quality, and cost competitiveness. Midrex has built its foundation upon the MIDREX® Direct Reduction Process that converts iron ore into high-purity direct reduced iron (DRI) for use in steelmaking, ironmaking, and foundry applications. Each year, MIDREX® Plants produce about 60 percent of the world's DRI.  

For more information visit www.midrex.com.

Coastal Technologies, Inc. Picked by VALMET for PT OKI “The World’s Largest Pulp Mill”

HDM Admin - Tuesday, April 28, 2015

CTI, a leading mist eliminator company in the pulp and paper industry, has received an order from Valmet for the supply of key mist separation equipment in their evaporator system for OKI Pulp and Paper Mills in South Sumatra, Indonesia. Upon completion, OKI will be the world’s largest pulp mill.

“The design complexity of new Kraft pulp mills has increased considerably over the last five years. VALMET has delivered the majority of evaporation plants during this period of time equipped with CTI Mist Eliminators. Another step forward in the trend of increasing design complexity taken in the OKI project concerned capacity and efficiency. “Our cooperation with Coastal Technologies (CTI), who supplies efficient, large scale mist eliminator solutions, has contributed in meeting our customer’s higher demands in terms of capacity and operation efficiency.” Lars Petersson, Director Recovery Systems, VALMET.

“We have designed and manufactured proven high quality mist eliminators for industrial process and power applications for over 29 years. Today, that alone is no longer enough,” indicates Norman Mansson, VP CTI. “We must also deliver complex, technically challenging supply solutions that often require a large number of elements to mesh together synchronously to optimize equipment production efficiency. Also, by working closely with our customers in the early design stages, integration of the largest framed mist eliminator assemblies possible within our customer’s vessels during the vessel fabrication process thus maximizing production capacity and efficiency. And finally, because our customer’s work may be located world-wide, there are often logistical challenges.”

In the pulp and paper industry, CTI provides mist separation equipment for evaporators, NCG service, bleach plant and lime kiln scrubber service, recovery boiler scrubbers, and in-plant air cleaning scrubbers. Additionally CTI is active in chemical, pharma, and food related evaporation and crystallizer applications, the primary metals industry, geothermal steam separation and scrubbing service, marine SOX and many other industrial applications.

To discover how your company can gain the benefits of our results driven performance and savings in energy, steam, chemicals or water, please contact: Norman Mansson, VP, Coastal Technologies 1-803-943-4822 or
nmansson[at]cti-sc.com.

BRAD ADKINS CELEBRATES 15

CTI Admin - Friday, March 06, 2015

This week marked a very special Anniversary at Coastal Technologies, Inc. Brad Adkins celebrated his fifteenth year at CTI. Not so impressive with Anthony Woods and Don Savage having passed their twentieth anniversaries but it is for everyone Coastal who has watched Brad grow and develop.

Brad came to CTI in 2000. He was twenty-three. He was like any 23 year old, a work in progress. We have seen him develop over the years to one of our most accomplished fabricators in the plant. His ability to communicate and manage under pressure has taken him to the position of Shop Lead.

We have seen him grow personally as well. We have experienced his milestones of dating, marriage and the birth of his children.

Brad is the perfect embodiment of the Coastal Technology focus for employment. We want bright, talented, personable leaders and followers who want to grow professionally and personally and grow old with us.

Congratulations to Brad and keep up the great work.

CTI Exhibits at CAPCA Fall Conference

CTI Admin - Thursday, November 20, 2014

Norman Mansson and Louis Peeples man the Coastal Technologies, Inc. booth at the Fall 2014 Carolina Air Pollution Control Association (CAPCA) Trade Show in Myrtle Beach, South Carolina. CAPCA provides its members two forums each year to discuss air quality topics and exchange information of professional value.

Of particular interest this year was the presentation on the National Ambient Air Quality Standards (NAAQS). The 2013 NAAQS may have a direct and dramatic effect on business. Particulate Matter (PM) Standards were last revised in 2006. Due to significant research into heath matters affected by particulate matter, the standards were reviewed and revised in 2013.

Coastal Technologies, Inc. Supplies Uniquely Designed Chevron Vane Mist Eliminators to Alberta Oil Sands

CTI Admin - Tuesday, October 28, 2014

Hampton, SC—Coastal Technologies, Inc. (CTI), a worldwide provider of high-performance industrial mist eliminators, coalescors, and separation solutions, will supply its uniquely designed chevron vane mist eliminators to the water conservation efforts in Canada's Alberta oil sands.

The Alberta oil sands form the world's third-largest hydrocarbon basin, with 97% of its land mass located in northern Alberta. Today's technology supports growing production in areas like this by improving energy efficiency and reliability, along with reducing impact on air, water, and land. With these advanced techniques, 173 billion bbls of water can be recovered. Two hydrocarbon extraction processes are used: oil extraction after shallow open pit mining and the in situ steam extraction process for deeper resources. CTI’s experience in the oil sands goes back ten years to the early extraction process after the open pit mining.

The in situ Steam Assisted Gravity Drainage (SAGD) is now primarily used for thermal heavy oil production and is the fastest-growing extraction method. This recovery operation employs a pair of horizontal wells, one for steam injection and one for oil drainage production. Heat from steam turns the semisolid bitumen to liquid. Most of the effort and cost of using the SAGD method goes into producing the required steam without make-up water. For every barrel of oil produced, three to four times that quantity of water is needed for the steaming operation, resulting in over 90% of water plantwide being recycled for reuse. Once the heavy oil and condensed steam, known as produced water, is brought to the surface, the SAGD facility is left with the complex task of recycling the produced water to make more steam while minimizing the strain on make-up water resources and waste disposal.

That's where Coastal Technologies, Inc., a world leader in high-performance steam separators and mist eliminators, comes in. CTI has supplied its equipment to the Alberta oil sands projects to help minimize the need for large quantities of water and ensure that the distillate quality provided by evaporation systems meets or exceeds the boiler feed water requirement. CTI's high-efficiency horizontal-flow AIROL130H100, AIROL440H100, and AIROL140H-1-750 mist eliminators allow high-quality distillate to be assured from the evaporator. The mist eliminator also protects the downstream compressor against erosion from brine droplets in the outlet steam vapor. And thanks to mist eliminators' unique containment devices, maintenance and inspection are safe and easy.

Separators are also used following the Once Through Steam Generators (OTSG) that produce 75 to 80% quality steam. The steam separators upgrade that percentage to 99%+ steam quality, which is directed into the reservoir steam wells to liquefy the heavy bitumen oil. Years of experience with geothermal steam-production power plant applications around the world qualify CTI in this area.

Alberta Oil Sands Project

Suncor Energy Inc., Tar Island, Fort McMurray,
Alberta Open Pit Extraction  2003 not rated
JACOS (Japan Canada Oil Sands Ltd) pilot facility, SAGD  2013  7,000 bbl/day
Penngrowth Energy Corp. Lindberg Thermal Plant, Phase I, SAGD  2013 12,500 bbl/day
JACOS Expansion Project, SAGD  2014 20,000 bbl/day


For more information on Coastal Technologies, Inc., please call 803-943-4822 or visit 
www.cti-sc.com

About Coastal Technologies, Inc.

Coastal Technologies, Inc. was founded in 1986 to provide high-quality and innovative solutions to customers' mist separation problems. The company has operated and improved its manufacturing facilities continuously since that time in keeping with its corporate mission of excellent customer service and ever-increasing product value and selection. CTI represents over a century of engineering, manufacturing, and management experience and stands ready to respond to the full scope and magnitude of any mist separation problem.

Contacts:
Norman Mansson
nmansson@cti-sc.com

Louis Peeples
lpeeples@cti-sc.com

phone: 803-943-4822


Coastal Technologies, Inc. USA Announces Sales and Project Managers for Expanding Worldwide Market

CTI Admin - Tuesday, October 28, 2014

Hampton, SC—Coastal Technologies, Inc. USA (CTI), a worldwide provider of high-quality industrial mist eliminators, coalescors, and separation solutions, is pleased to announce the appointment of John Louis Peeples III as a Sales and Project Management professional dedicated to the expanding global market.

Peeples joined CTI in April 2014, bringing almost 25 years of multinational engineering and management experience. He began his career with Westinghouse Electric working nationally before progressing with Westinghouse to Saudi Arabia with ISCOSA Industries & Maintenance, Ltd. Peeples' next move was to Singapore as Managing Director with Westinghouse Industry Service Asia Pte Ltd (WISAPL). Most recently, while located at facilities in Munich and Bristol, he was Vice President International for Baldor Electric with responsibility for all worldwide sales and production outside of North America. Peeples has won numerous commendations for his outstanding success in Europe, the Middle East, and Asia.

“Louis is a remarkable fit for our division offering mist eliminator and separator products to industry worldwide," remarked Harry Wechsler, CTI President. "He has many years of experience in Asia and is well versed in the culture, economy, and needs of our clients. We are very excited.”

Coastal Technologies, Inc. is a midsize engineering design and fabrication facility. Two-thirds of Coastal’s sales are shipped out of the United States. Its founders and personnel are ingenious, committed to quality, and loyal. Many employees have been with the company since its founding in 1986. CTI is ISO 9001:2008 registered; among the many industry recognitions it has received is the US Department of Commerce's Export Achievement Certificate for accomplishments in the global market.

Coastal's primary products are mist eliminators, retainer frames, and housings that can be conformed to best respond to customers’ applications and processes. Coastal recognizes that pollution from industrial processes is a major threat to air quality in industrialized areas worldwide. Additionally, the company acknowledges that ineffective process separation and equipment can be a huge profit loss. With these facts in mind, Coastal works closely with clients to solve these issues.

Norman Mansson, Vice President of Sales and Marketing, remarked that “Louis, who is equally happy to be addressed as John, combines his professionalism and passion with a laid-back, easygoing demeanor that makes it easy for him to connect with anyone. We think everyone who comes into contact with him will agree!”

Coastal is entering an exciting time in its history with not only the appointment of Peeples but also the recent addition of a new and experienced Office Manager, Kathy Scoggins, and a Special Projects guru, Christine Seabrook. We thank all of our customers for their continued support, and we look forward to continuing our relationship with you.

Please feel free to contact any member of Coastal's senior management team with questions or concerns:

Harry Wechsler, President and Owner hwechsler@cti-sc.com
Norman Mansson, Vice President and Owner nmansson@cti-sc.com
John Louis Peeples III, Sales and Project Management    lpeeples@cti-sc.com
Dave Gillan, Engineering and Quality Control              dgillan@cti-sc.com
Kathy Scoggins, Office Manager kscoggins@cti-sc.com

For more information about Coastal Technologies, Inc., please call 803-943-4822 or visit 
www.cti-sc.com.

About Coastal Technologies, Inc.

Coastal Technologies, Inc. was founded in 1986 to provide high-quality and innovative solutions to customers' mist separation problems. Since that time, the company has operated and improved its manufacturing facilities continuously in keeping with its corporate mission of excellent customer service and ever-increasing product value and selection. CTI represents over a century of engineering, manufacturing, and management experience and stands ready to respond to the full scope and magnitude of any mist separation problem.

Contact:
Norman Mansson
nmansson@cti-sc.com

Louis Peeples
lpeeples@cti-sc.com

phone: 803-943-4822
fax: 803-943-4744

Anthony Woods Marks 15 Years

CTI Admin - Friday, October 17, 2014

Coastal Technologies, Inc. proudly congratulates Anthony Woods on his fifteenth anniversary with the company.  

Anthony came to CTI in 1999 after a successful fourteen years at Vanguard Plastics where he worked his way up from shop floor to shop management, then came to us as our Production Manager. Anthony excels in the improvement of employee cooperation and acceptance of responsibility. His successful mentoring of young men has yielded many long term CTI employees. This cannot be taught; he is a natural.

Anthony runs a tight ship and holds closely our mission to provide “exceptional products, on time, using a creative, consistent, efficient and continually improving process…” Anthony is an essential member of our management team; we are fortunate to have him aboard and pleased to celebrate this milestone event.

Coastal Technologies Provides Steam Separator/Scrubbers for New Zealand’s Te Mihi Power Station

CTI Admin - Tuesday, January 01, 2013

Coastal Technologies, Inc. (CTI), a worldwide provider of high-quality industrial mist eliminators, coalescers, and separation solutions, has supplied six steam separator/scrubbers to the Te Mihi Power Station in New Zealand.

The two-unit, 166-megawatt geothermal plant, currently undergoing commissioning, is located in New Zealand’s central North Island Taupo Volcano Zone. The Te Mihi Power Station is owned by Contact Energy Ltd., one of New Zealand’s leading developers of sustainable power generation systems.

This is CTI’s third geothermal power project in the region. CTI supplied a steam scrubber for the 50-megawatt McLachlan Power Station, also owned by Contact, in 1996, as well as a steam scrubber for the Mokai Geothermal Power Plant, now owned by Mighty River Power, one of the world’s 10 largest geothermal generation operators.

At Te Mihi, the plant receives low-pressure steam and intermediate-pressure geothermal water that is flashed to steam in a low-pressure flash system and sent to the two steam turbines. This dual flash system uses steam released from the geothermal brine at the two pressure levels. CTI’s steam separator/scrubbers ensure 99.9% steam quality to each of the 83-megawatt Toshiba steam turbines.

The double-flash technology used at Te Mihi produces 20 to 25 percent more electricity than what was produced using the same amount of geothermal fluid by the plant that Te Mihi replaces, the Wairakei Power Station, built in 1958. CTI’s separation equipment also has been installed in wood-drying mills on the North Island, where geothermal heat is used as the energy source.

For more information about Coastal Technologies, Inc., please call 803-943-4822 or visit www.coastaltechnologiesinc.com.

About Coastal Technologies, Inc.

Coastal Technologies, Inc. is an industry-leading provider of mist eliminators, separators, and purification equipment, with world-class capabilities in steam power, evaporation, metallurgy, desalination, and renewable power. CTI entered the geothermal power business in 1992 by supplying separators to MHI geothermal power plants in the Philippines and Indonesia, subsequently expanding the business to North America, Southeast Asia, Costa Rica, New Zealand, and Japan. Today, CTI is a world leader in the design and manufacture of separators and scrubbers, having supplied a total of 36 units.

Contacts:
Norman Mansson
Phone: 803-943-4822
Fax: 803-943-4744
nmansson@cti-sc.com 

Louis Peeples
Phone: 803-943-4822
Fax: 803-943-4744
lpeeples@cti-sc.com


© Coastal Technologies, Inc. Coastal Technologies, Inc. is ISO 9001:2008 CERTIFIED