This article describes a project on which Koch Modular Process Systems designed and supplied a distillation system to recover ethylene from an olefins plant purge stream.
Enhanced Ammonia Recovery with Built-In Feed Flexibility
Ammonia absorption and recovery projects are not a
unique challenge for the Koch Modular process team. They
have a high level of experience in this area and with an
abundance of existing data, no pilot trials were necessary
to design a solution and then guarantee the ammonia
absorption system performance. However, there were
challenges. The ammonia vapor feed stream was composed
of multiple ammonia-containing streams with a variety of
compositions. The Koch Modular team worked with the
client to agree upon a feed basis for the design of the
system. As often occurs, the ammonia recovery project
was part of an overall major expansion, and the client
requested that the modules be designed to fit indoors both
functionally and spatially into the new facility. This request,
and the overall scale and building configuration presented
some unique design challenges.
Koch Modular Process Systems specializes in designing liquid-liquid extraction equipment for industries such as chemical, pharmaceutical, petrochemical, biotech, and flavors & fragrances. They offer various types of extraction columns including SCHEIBEL, KARR, rotating disc contactors, pulsed columns, and packed columns. Pilot testing of actual feed streams is important for accurate scale-up and process design since extraction involves complex phenomena at the liquid-liquid interface that is difficult to model. They provide extraction solutions tailored to customers' separation challenges.
KMPS’ engineering team designed a modular acetic acid recovery and purification system as a critical component of a greenfield biomass to renewable chemicals plant.
KMPS’ engineering team helped the client design a modular distillation system to recover and purify spent solvents, a process that is vital for the plant’s manufacturing operations. The system was fabricated and delivered under an expedited project schedule to meet a customer specified timeline.
Bio-Based Plastic - A Novel Process Solutions Approach for Successful, Lower Cost Scale-Up.
Koch Modular was initially approached for their demonstrated
optimization expertise in reaction, distillation and filtration unit
operations. One of the technical challenges the company faced
was determining how to compensate for changing byproduct
compositions as a result of evolving feedstock selection,
alongside the need to produce a consistent yield of material.
They also requested guidance with engineering services,
process conceptualization and pilot testing in order to take
their revolutionary, small-scale manufacturing to successful
full-scale production.
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Gerard B. Hawkins
The document discusses using immobilized ionic liquids (IILs) in shale gas sweetening reactions. It proposes immobilizing a cobalt catalyst in the surface ionic liquid layer of a solid supported ionic liquid catalyst. This would create a "homogeneous catalyst" dissolved within the fixed IIL layer. Competing reactions like oxidation of sulfides to sulfones would need to be considered. Related work on using similar approaches for hydroformylation reactions is referenced. The concept aims to develop a solid IIL catalyst for sweetening reactions involving oxidation using techniques from other areas like hydroformylation.
A specialty chemical company hired Koch Modular to design and build a modular distillation system to recover spent solvents. Koch Modular engineered a multi-step distillation process using modular units that provided lower energy usage than the existing system. The modular design allowed for expedited fabrication and installation with minimal disruption to plant operations. The new system increased production capacity by 40% to meet growing market demand.
Operational Problems
Catalytic Reactor Process - Prompt List
- Feed Issues:
- Pipe work type Issues
- Operational Issues
- Vessel Loading
- Vessel Designs
- Wider Process Issues
- Material Issues
- Discharge issues
- Things to look at
- Things to consider trying
Enhanced Ammonia Recovery with Built-In Feed Flexibility
Ammonia absorption and recovery projects are not a
unique challenge for the Koch Modular process team. They
have a high level of experience in this area and with an
abundance of existing data, no pilot trials were necessary
to design a solution and then guarantee the ammonia
absorption system performance. However, there were
challenges. The ammonia vapor feed stream was composed
of multiple ammonia-containing streams with a variety of
compositions. The Koch Modular team worked with the
client to agree upon a feed basis for the design of the
system. As often occurs, the ammonia recovery project
was part of an overall major expansion, and the client
requested that the modules be designed to fit indoors both
functionally and spatially into the new facility. This request,
and the overall scale and building configuration presented
some unique design challenges.
Koch Modular Process Systems specializes in designing liquid-liquid extraction equipment for industries such as chemical, pharmaceutical, petrochemical, biotech, and flavors & fragrances. They offer various types of extraction columns including SCHEIBEL, KARR, rotating disc contactors, pulsed columns, and packed columns. Pilot testing of actual feed streams is important for accurate scale-up and process design since extraction involves complex phenomena at the liquid-liquid interface that is difficult to model. They provide extraction solutions tailored to customers' separation challenges.
KMPS’ engineering team designed a modular acetic acid recovery and purification system as a critical component of a greenfield biomass to renewable chemicals plant.
KMPS’ engineering team helped the client design a modular distillation system to recover and purify spent solvents, a process that is vital for the plant’s manufacturing operations. The system was fabricated and delivered under an expedited project schedule to meet a customer specified timeline.
Bio-Based Plastic - A Novel Process Solutions Approach for Successful, Lower Cost Scale-Up.
Koch Modular was initially approached for their demonstrated
optimization expertise in reaction, distillation and filtration unit
operations. One of the technical challenges the company faced
was determining how to compensate for changing byproduct
compositions as a result of evolving feedstock selection,
alongside the need to produce a consistent yield of material.
They also requested guidance with engineering services,
process conceptualization and pilot testing in order to take
their revolutionary, small-scale manufacturing to successful
full-scale production.
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Gerard B. Hawkins
The document discusses using immobilized ionic liquids (IILs) in shale gas sweetening reactions. It proposes immobilizing a cobalt catalyst in the surface ionic liquid layer of a solid supported ionic liquid catalyst. This would create a "homogeneous catalyst" dissolved within the fixed IIL layer. Competing reactions like oxidation of sulfides to sulfones would need to be considered. Related work on using similar approaches for hydroformylation reactions is referenced. The concept aims to develop a solid IIL catalyst for sweetening reactions involving oxidation using techniques from other areas like hydroformylation.
A specialty chemical company hired Koch Modular to design and build a modular distillation system to recover spent solvents. Koch Modular engineered a multi-step distillation process using modular units that provided lower energy usage than the existing system. The modular design allowed for expedited fabrication and installation with minimal disruption to plant operations. The new system increased production capacity by 40% to meet growing market demand.
Operational Problems
Catalytic Reactor Process - Prompt List
- Feed Issues:
- Pipe work type Issues
- Operational Issues
- Vessel Loading
- Vessel Designs
- Wider Process Issues
- Material Issues
- Discharge issues
- Things to look at
- Things to consider trying
Graphical Representation of Liquid-Liquid Phase EquilibriaGerard B. Hawkins
Graphical Representation of
Liquid-Liquid Phase Equilibria
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GRAPHICAL REPRESENTATIONS OF PHYSICAL
PROPERTIES
4.1 Use of Composition Diagrams
4.2 Ternary Systems with Immiscible Liquids
4.3 Graphical Design Using Ternary Diagrams
APPENDICES
A INTERPOLATION AND CORRELATION OF THE LINES
FIGURES
1 TRIANGULAR CO-ORDINATES
2 TYPE 1 SYSTEM: ONE PAIR OF PARTIALLY MISCIBLE LIQUIDS
3 TYPE 2 SYSTEM: TWO PAIR OF PARTIALLYMISCIBLE LIQUIDS
4 DESIGN OF COUNTERCURRENT EXTRACTION SYSTEM WITHOUT REFLUX – TYPE 1 SYSTEM
5 BLOCK DIAGRAM OF REFLUXED LIQUID-LIQUID EXTRACTION
6 DESIGN OF COUNTERCURRENT SYSTEM WITH REFLUX
7 CONSTRUCTION OF THE CONJUGATE LINE
Mechanical Constraints on Thermal Design of Shell and Tube ExchangersGerard B. Hawkins
Mechanical Constraints on Thermal Design of Shell and Tube Exchangers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 STANDARD DIMENSIONS
4.1 Shell Diameters
4.2 Tube Lengths
4.3 Tube Diameters
4.4 Tube Wall Thicknesses
5 CLEARANCES
5.1 Tube Pitch
5.2 Pass Partition Lane Widths
5.3 Minimum 'U' Bend Clearance
5.4 Tube-to-Baffle Clearance
5.5 Baffle-to-Shell Clearance
5.6 Bundle-to-Shell Clearance
6 TUBESHEET THICKNESS
7 END ZONE LENGTHS
8 TUBE COUNTS
8.1 Program Correlations
8.2 Use of Tube count Tables
8.3 Graphical Layout
8.4 Use of Computer Programs
8.5 Tie Rods
TABLES
1 HEAT EXCHANGER SHELLS - GEOMETRICAL DATA
FOR INLET & OUTLET BRANCHES: PIPE WITH ANSI
150 FLANGE
2 HEAT EXCHANGER SHELLS - GEOMETRICAL DATA
FOR INLET & OUTLET BRANCHES: PIPE WITH ANSI
300 FLANGE
3 TEMA TIE ROD STANDARDS
FIGURES
1 DEFINITION OF TUBE PITCH, LIGAMENT THICKNESS & PASS PARTITION LANE WIDTH
2 DEFINITION OF PASS PARTITION LANE WIDTH FOR U-TUBES
3 BUNDLE TO SHELL CLEARANCES FOR DIFFERENT BUNDLE TYPES
4 ESTIMATED TUBESHEET THICKNESS FOR FIXED TUBE CONSTRUCTION
5 ESTIMATED TUBESHEET THICKNESS FOR U-TUBE CONSTRUCTION
6 END ZONE
7 EXAMPLE OF OPTU3 GRAPHICAL OUTPUT
Koch Modular Process Systems shares our experience supporting companies successfully commercializing their novel technologies across the chemical processing industries including most recently the advanced plastics and rare earth metals recycling and biochemical markets.
Taking a new technology from concept to commercialization can be a daunting process for any company and especially formidable for emerging companies.
Whether you are an established company or a start-up, successfully navigating process development and scale-up challenges can directly impact your ability to achieve critical success factors such as: conceptualization, project funding, pilot testing, design development & optimization, and ultimately construction and start up. Success factors which can directly impact your ability to deliver a commercial-scale production unit on time and on budget while achieving time to market and meeting commitments to your stakeholders.
Chris Rentsch, Process Development Manager at Koch Modular, will walk through Koch Modular’s modularLAUNCH: Delivery Model. Furthermore, he will share real world examples and discuss critical success factors during each phase of process development and the pitfalls to be on the lookout for, which have the potential to sideline your project.
This document discusses the advantages of modular process systems for chemical engineering projects. Modular systems can contain anything from filtration systems to cleanrooms to entire refineries. They are built off-site using industrial techniques, then shipped and assembled on-site. This allows construction to begin before permits are obtained, dramatically reducing project timelines. Modular systems also improve quality control and reduce costs compared to on-site construction. As a result, more complex chemical processes are now being offered using modular approaches.
VLE Data - Selection and Use
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 DIAGRAMMATIC REPRESENTATION OF IDEAL
AND NON-IDEAL SYSTEMS
4.1 Ideal Mixtures
4.2 Non-Ideal Mixtures
5 REVIEW OF VLE MODELS
5.1 Ideal Behavior in Both Phases
5.2 Liquid Phase Non-Idealities
5.3 High Pressure Systems
5.4 Special Models
6 SETTING UP A VLE MODEL
6.1 Define Problem
6.2 Select Data
6.3 Select Correlation(s)
6.4 Produce Model
7 AVOIDING PITFALLS
7.1 Experimental Data is Better than Estimates
7.2 Check Validity of Fitted Model
7.3 Check Limitations of Estimation Methods
7.4 Know Your System
7.5 Appreciate Errors and Effects
7.6 If in Doubt – Ask
8 A CASE STUDY
8.1 The Problem
8.2 The System
8.3 Data Available
8.4 Selected Correlation
8.5 Simulation
8.6 Selection of Model
9 RECOMMENDED READING
10 VLE EXPERTS IN GBHE
APPENDICES
A USE OF EXTENDED ANTOINE EQUATION
B USE OF WILSON EQUATION
C USEFUL METHODS OF ESTIMATING
D EQUATIONS OF STATE FOR VLE CALCULATIONS
TABLES
1 SUMMARY OF VLE METHODS
2 LIST OF USEFUL REFERENCES
FIGURES
1 VAPOR-LIQUID EQUILIBRIUM - IDEAL SOLUTION
BEHAVIOR
2 VAPOR-LIQUID EQUILIBRIUM - A GENERALISED
Y-X DIAGRAM
3 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE
4 VAPOR-LIQUID EQUILIBRIUM - MAXIMUM BOILING
AZEOTROPE
5 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE -TWO LIQUID PHASES
6 SENSITIVITY TO ERROR IN VLE DATA (BASED ON FENSKE EQUATION)
7(a) FITTING WILSON 'A' VALUES TO VLE DATA - CASE A
7(b) FITTING WILSON 'A' VALUES TO VLE DATA - CASE B
7(c) FITTING WILSON 'A' VALUES TO VLE DATA - CASE C
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
Selection of Heat Exchanger Types
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 FACTORS INFLUENCING SELECTION
5.1 Type of Duty
5.2 Temperatures and Pressures
5.3 Materials of Construction 5.4 Fouling
5.5 Safety and Reliability
5.6 Repairs
5.7 Design Methods
5.8 Dimensions and Weight
5.9 Cost
5.10 GBHE Experience
6 TYPES OF EXCHANGER
6.1 Shell and Tube Exchangers
6.2 Cylindrical Graphite Block Heat Exchangers
6.3 Cubic Graphite Block Heat Exchangers
6.4 Air Cooled Heat Exchangers
6.5 Gasketed Plate and Frame
6.6 Spiral Plate
6.7 Tube in Duct
6.8 Plate-fin
6.9 Printed Circuit Heat Exchanger (PCHE)
6.10 Scraped Surface/Wiped Film Exchangers
6.11 Welded or Brazed Plate
6.12 Double Pipe
6.13 Electric Heaters
6.14 Fired Process Heaters
TABLE
(1) ADVANTAGES AND DISADVANTAGES OF DIFFERENT SHELL AND TUBE DESIGNS
FIGURES
1 ESTIMATED MAIN PLANT ITEM COSTS
2 ESTIMATED INSTALLED COSTS
3 TEMA HEAT EXCHANGER NOMENCLATURE
4 F ‘CORRECTION FACTORS' : TEMA E SHELL WITH EVEN NUMBER OF PASSE
5 SHELL AND TUBE HEAT EXCHANGER HEAD TYPES
6 GENERAL ARRANGEMENT OF A CYLINDRICAL GRAPHITE BLOCK HEAT EXCHANGER
7 EXPLODED VIEW OF A CUBIC GRAPHITE BLOCK
HEAT EXCHANGER
8 TYPICAL AIR COOLED HEAT EXCHANGER
9 GENERAL VIEW OF ONE END OF A 3-STREAM
PLATE-FIN HEAT EXCHANGER
10 TYPICAL PCHE PLATE
11 VICARB ‘COMPABLOC' EXCHANGER
12 ‘BROWN FINTUBE' MULTITUBE HEAT EXCHANGER
13 FIRED HEATER : SCHEMATICS AND NOMENCLATURE
General Water Treatment For Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CHOICE OF COOLING SYSTEM
4.1 ‘Once through' Cooling Systems
4.2 Open Evaporative Recirculating Systems
4.3 Closed Recirculating Systems
4.4 Comparison of Cooling Systems
5 MAKE-UP WATER QUALITY
6 FOULING PROCESSES
6.1 Deposition
6.2 Scaling
6.3 Corrosion
6.4 Biological Growth
7 CONTROL OF THE COOLING SYSTEM
7.1 ‘Once through' Cooling Systems
7.2 Closed Recirculating Systems
7.3 Open Evaporative Cooling Systems
TABLES
1 RELATIVE IMPORTANCE OF FOULING PROCESSES AND INSTALLED COSTS
2 WATER QUALITY PARAMETERS
FIGURES
1 PREDICTION OF CALCIUM CARBONATE SCALING
2 CALCIUM SULFATE SOLUBILITY
3 CALCIUM PHOSPHATE SCALING INDEX
Physical Properties for Heat Exchanger Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 COMPONENT PROPERTIES
4.1 General
4.2 Use of Component Properties for Mixtures
5 INPUT OF MIXTURE CURVES
5.1 General
5.2 Generation of the Mixture Curves
5.3 Selection of Temperature Points
5.4 Extrapolation
6 IMMISCIBLE CONDENSATES
FIGURES
1 TEMPERATURE POINTS SELECTED FOR EQUAL ENTHALPY CHANGE
2 TEMPERATURE POINTS SELECTED FOR GOOD
FIT TO CURVE
This document discusses a modular construction project called "Chill" that was completed successfully to address scheduling concerns for a larger project. The Chemours company was initially concerned about working with a modular contractor for various reasons relating to space, access, and construction. However, Koch Modular Process Systems was able to address all of Chemours' concerns through their modular design. This included removing temporary steel supports after installation, minimizing interior bracing, and ensuring proper access, egress, and safety features. As a result, the modular facility was delivered ahead of schedule and under budget compared to traditional construction. Chemours was so satisfied that they hired Koch Modular for two additional projects.
Fixed Bed Reactor Scale-up Checklist
The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
• Literature data.
• Lab testing.
• Calculation.
• Modeling.
• Semi-tech testing.
• Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor
Air / Steam Regeneration Procedure for Primary Reforming CcatalystGerard B. Hawkins
GBH Enterprises specializes in refinery process catalysts, including performance evaluation, analysis, and development of new technologies. The document provides procedures for air/steam regeneration of primary reforming catalysts either during shutdown or startup. During shutdown, steaming should continue for two hours before introducing a small amount of air to burn off carbon deposits, monitored by CO2 levels. During startup, normal heating with steam is followed by the same air regeneration process once temperatures reach 1300-1325°F, before removing air and resuming steam for two hours prior to introducing feed gas.
Critical Variables in Catalytic Reforming and Unit Monitoring Best PracticesGerard B. Hawkins
This document discusses optimization strategies for catalytic reforming processes in oil refineries. It outlines best practices for identifying and monitoring critical variables, and provides examples of critical variables like catalyst activity and recycle gas composition. The document also discusses principles of reformer optimization like defining objectives, layered management practices, and optimizing operations. Overall it provides guidance on monitoring performance, catalyst management, and using online optimization to improve profitability of refinery catalytic reforming units.
The Selection of Flocculants and other Solid-Liquid Separation AidsGerard B. Hawkins
The use of chemical additives, such as flocculants, is a common step in solid-liquid separation operations. The correct selection of agent is an essential part of the design of such processes. Many excellent reviews and guides deal with this topic, and the interested reader is referred to works such as [l-4]. In particular the Harwell-Warren Spring Report “The Use and Selection of Flocculants" provides a good overview on the application of coagulants and flocculants. This section does not attempt to reproduce a detailed treatment of that kind; instead it is our intention to state a few general rules and principles concerning methods of choosing an additive, and to illustrate briefly their application in practice.
The types of agents employed in solid-liquid separation fall into three principal classes:
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF AQUEOUS ORGANIC EFFLUENT STREAMS
CONTENTS
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 IPU
3.2 AOS
3.3 BODs
3.4 COD
3.5 TOC
3.6 Toxicity
3.7 Refractory Organics/Hard COD
3.8 Heavy Metals
3.9 EA
3.10 Biological Treatment Terms
3.11 BATNEEC
3.12 BPEO
3.13 EQS/LV
3.14 IPC
3.15 VOC
3.16 F/M Ratio
3.17 MLSS
3.18 MLVSS
4 DESIGN/ECONOMIC GUIDELINES
5 EUROPEAN LEGISLATION
5.1 General
5.2 Integrated Pollution Control (IPC)
5.3 Best Available Techniques Not Entailing Excessive Costs (BATNEEC)
5.4 Best Practicable Environmental Option (BPEO)
5.5 Environmental Quality Standards(EQS)
6 IPU EXIT CONCENTRATION
7 SITE/LOCAL REQUIREMENTS
8 PROCESS SELECTION PROCEDURE
8.1 Waste Minimization Techniques (WMT)
8.2 AOS Stream Definition
8.3 Technical Check List
8.4 Preliminary Selection of Suitable Technologies
8.5 Process Sequences
8.6 Economic Evaluation
8.7 Process Selection
APPENDICES
A DIRECTIVE 76/464/EEC - LIST 1
B DIRECTIVE 76/464/EEC - LIST 2
C THE EUROPEAN COMMISSION PRIORITY CANDIDATE LIST
D THE UK RED LIST
E CURRENT VALUES FOR EUROPEAN COMMUNITY ENVIRONMENTAL QUALITY STANDARDS AND CORRESPONDING LIMIT VALUES
F ESTABLISHED TECHNOLOGIES
G EMERGING TECHNOLOGY
H PROPRIETARY/LESS COMMON TECHNOLOGIES
J COMPARATIVE COST DATA
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
This document provides instructions for loading and starting up molecular sieve adsorbents and adsorption units. It discusses inspecting the vessel before loading, loading support material at the bottom and molecular sieves, then support material at the top. An initial regeneration is recommended after closing to ensure the molecular sieves are highly active. Safety precautions are outlined to prevent moisture contamination.
Hydrogen Compressors
Engineering Design Guide
1 SCOPE
2 PHYSICAL ROPERTIES
2.1 Data for Pure Hydrogen
2.2 Influence of Impurities
3 MATERIALS OF CONSTRUCTION
3.1 Hydrogen from Electrolytic Cells
3.2 Pure Hydrogen
4 DESIGN
4.1 Pulsation
4.2 Bypass
5 TESTING OR COMMISSIONING RECIPROCATING COMPRESSORS
6 LUBRICATION
7 LAYOUT
8 REFERENCES
FIGURES
1 MOLLIER CHART - HYDROGEN
2 COMPRESSIBILITY CHART
3 NELSON DIAGRAM
4 WATER CONTENT IN HYDROGEN FOR OIL-LUBRICATED COMPRESSORS AS GRAMM/M2 SWEPT CYLINDER AREA
This document presents a case study and methods to re-establish a condemned boiler. It includes an introduction, contents listing, acknowledgements, abstract on the Hindustan Storage & Distribution Company where the boiler is located, specifications and diagrams of the boiler, scope of dismantling and repair work, results of dismantling, scope of work after renovation including flue gas analysis and boiler tuning.
This is a presentation on the design of plant for producing 20 million standard cubic feet per day (0.555 × 106 standard m3/day) of hydrogen (H2) of at least 95% purity from heavy fuel oil (HFO) with an upstream time of 7680 hours/year applying the process of partial oxidation of the heavy oil feedstock.
Graphical Representation of Liquid-Liquid Phase EquilibriaGerard B. Hawkins
Graphical Representation of
Liquid-Liquid Phase Equilibria
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GRAPHICAL REPRESENTATIONS OF PHYSICAL
PROPERTIES
4.1 Use of Composition Diagrams
4.2 Ternary Systems with Immiscible Liquids
4.3 Graphical Design Using Ternary Diagrams
APPENDICES
A INTERPOLATION AND CORRELATION OF THE LINES
FIGURES
1 TRIANGULAR CO-ORDINATES
2 TYPE 1 SYSTEM: ONE PAIR OF PARTIALLY MISCIBLE LIQUIDS
3 TYPE 2 SYSTEM: TWO PAIR OF PARTIALLYMISCIBLE LIQUIDS
4 DESIGN OF COUNTERCURRENT EXTRACTION SYSTEM WITHOUT REFLUX – TYPE 1 SYSTEM
5 BLOCK DIAGRAM OF REFLUXED LIQUID-LIQUID EXTRACTION
6 DESIGN OF COUNTERCURRENT SYSTEM WITH REFLUX
7 CONSTRUCTION OF THE CONJUGATE LINE
Mechanical Constraints on Thermal Design of Shell and Tube ExchangersGerard B. Hawkins
Mechanical Constraints on Thermal Design of Shell and Tube Exchangers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 STANDARD DIMENSIONS
4.1 Shell Diameters
4.2 Tube Lengths
4.3 Tube Diameters
4.4 Tube Wall Thicknesses
5 CLEARANCES
5.1 Tube Pitch
5.2 Pass Partition Lane Widths
5.3 Minimum 'U' Bend Clearance
5.4 Tube-to-Baffle Clearance
5.5 Baffle-to-Shell Clearance
5.6 Bundle-to-Shell Clearance
6 TUBESHEET THICKNESS
7 END ZONE LENGTHS
8 TUBE COUNTS
8.1 Program Correlations
8.2 Use of Tube count Tables
8.3 Graphical Layout
8.4 Use of Computer Programs
8.5 Tie Rods
TABLES
1 HEAT EXCHANGER SHELLS - GEOMETRICAL DATA
FOR INLET & OUTLET BRANCHES: PIPE WITH ANSI
150 FLANGE
2 HEAT EXCHANGER SHELLS - GEOMETRICAL DATA
FOR INLET & OUTLET BRANCHES: PIPE WITH ANSI
300 FLANGE
3 TEMA TIE ROD STANDARDS
FIGURES
1 DEFINITION OF TUBE PITCH, LIGAMENT THICKNESS & PASS PARTITION LANE WIDTH
2 DEFINITION OF PASS PARTITION LANE WIDTH FOR U-TUBES
3 BUNDLE TO SHELL CLEARANCES FOR DIFFERENT BUNDLE TYPES
4 ESTIMATED TUBESHEET THICKNESS FOR FIXED TUBE CONSTRUCTION
5 ESTIMATED TUBESHEET THICKNESS FOR U-TUBE CONSTRUCTION
6 END ZONE
7 EXAMPLE OF OPTU3 GRAPHICAL OUTPUT
Koch Modular Process Systems shares our experience supporting companies successfully commercializing their novel technologies across the chemical processing industries including most recently the advanced plastics and rare earth metals recycling and biochemical markets.
Taking a new technology from concept to commercialization can be a daunting process for any company and especially formidable for emerging companies.
Whether you are an established company or a start-up, successfully navigating process development and scale-up challenges can directly impact your ability to achieve critical success factors such as: conceptualization, project funding, pilot testing, design development & optimization, and ultimately construction and start up. Success factors which can directly impact your ability to deliver a commercial-scale production unit on time and on budget while achieving time to market and meeting commitments to your stakeholders.
Chris Rentsch, Process Development Manager at Koch Modular, will walk through Koch Modular’s modularLAUNCH: Delivery Model. Furthermore, he will share real world examples and discuss critical success factors during each phase of process development and the pitfalls to be on the lookout for, which have the potential to sideline your project.
This document discusses the advantages of modular process systems for chemical engineering projects. Modular systems can contain anything from filtration systems to cleanrooms to entire refineries. They are built off-site using industrial techniques, then shipped and assembled on-site. This allows construction to begin before permits are obtained, dramatically reducing project timelines. Modular systems also improve quality control and reduce costs compared to on-site construction. As a result, more complex chemical processes are now being offered using modular approaches.
VLE Data - Selection and Use
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 DIAGRAMMATIC REPRESENTATION OF IDEAL
AND NON-IDEAL SYSTEMS
4.1 Ideal Mixtures
4.2 Non-Ideal Mixtures
5 REVIEW OF VLE MODELS
5.1 Ideal Behavior in Both Phases
5.2 Liquid Phase Non-Idealities
5.3 High Pressure Systems
5.4 Special Models
6 SETTING UP A VLE MODEL
6.1 Define Problem
6.2 Select Data
6.3 Select Correlation(s)
6.4 Produce Model
7 AVOIDING PITFALLS
7.1 Experimental Data is Better than Estimates
7.2 Check Validity of Fitted Model
7.3 Check Limitations of Estimation Methods
7.4 Know Your System
7.5 Appreciate Errors and Effects
7.6 If in Doubt – Ask
8 A CASE STUDY
8.1 The Problem
8.2 The System
8.3 Data Available
8.4 Selected Correlation
8.5 Simulation
8.6 Selection of Model
9 RECOMMENDED READING
10 VLE EXPERTS IN GBHE
APPENDICES
A USE OF EXTENDED ANTOINE EQUATION
B USE OF WILSON EQUATION
C USEFUL METHODS OF ESTIMATING
D EQUATIONS OF STATE FOR VLE CALCULATIONS
TABLES
1 SUMMARY OF VLE METHODS
2 LIST OF USEFUL REFERENCES
FIGURES
1 VAPOR-LIQUID EQUILIBRIUM - IDEAL SOLUTION
BEHAVIOR
2 VAPOR-LIQUID EQUILIBRIUM - A GENERALISED
Y-X DIAGRAM
3 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE
4 VAPOR-LIQUID EQUILIBRIUM - MAXIMUM BOILING
AZEOTROPE
5 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE -TWO LIQUID PHASES
6 SENSITIVITY TO ERROR IN VLE DATA (BASED ON FENSKE EQUATION)
7(a) FITTING WILSON 'A' VALUES TO VLE DATA - CASE A
7(b) FITTING WILSON 'A' VALUES TO VLE DATA - CASE B
7(c) FITTING WILSON 'A' VALUES TO VLE DATA - CASE C
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
Selection of Heat Exchanger Types
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 FACTORS INFLUENCING SELECTION
5.1 Type of Duty
5.2 Temperatures and Pressures
5.3 Materials of Construction 5.4 Fouling
5.5 Safety and Reliability
5.6 Repairs
5.7 Design Methods
5.8 Dimensions and Weight
5.9 Cost
5.10 GBHE Experience
6 TYPES OF EXCHANGER
6.1 Shell and Tube Exchangers
6.2 Cylindrical Graphite Block Heat Exchangers
6.3 Cubic Graphite Block Heat Exchangers
6.4 Air Cooled Heat Exchangers
6.5 Gasketed Plate and Frame
6.6 Spiral Plate
6.7 Tube in Duct
6.8 Plate-fin
6.9 Printed Circuit Heat Exchanger (PCHE)
6.10 Scraped Surface/Wiped Film Exchangers
6.11 Welded or Brazed Plate
6.12 Double Pipe
6.13 Electric Heaters
6.14 Fired Process Heaters
TABLE
(1) ADVANTAGES AND DISADVANTAGES OF DIFFERENT SHELL AND TUBE DESIGNS
FIGURES
1 ESTIMATED MAIN PLANT ITEM COSTS
2 ESTIMATED INSTALLED COSTS
3 TEMA HEAT EXCHANGER NOMENCLATURE
4 F ‘CORRECTION FACTORS' : TEMA E SHELL WITH EVEN NUMBER OF PASSE
5 SHELL AND TUBE HEAT EXCHANGER HEAD TYPES
6 GENERAL ARRANGEMENT OF A CYLINDRICAL GRAPHITE BLOCK HEAT EXCHANGER
7 EXPLODED VIEW OF A CUBIC GRAPHITE BLOCK
HEAT EXCHANGER
8 TYPICAL AIR COOLED HEAT EXCHANGER
9 GENERAL VIEW OF ONE END OF A 3-STREAM
PLATE-FIN HEAT EXCHANGER
10 TYPICAL PCHE PLATE
11 VICARB ‘COMPABLOC' EXCHANGER
12 ‘BROWN FINTUBE' MULTITUBE HEAT EXCHANGER
13 FIRED HEATER : SCHEMATICS AND NOMENCLATURE
General Water Treatment For Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CHOICE OF COOLING SYSTEM
4.1 ‘Once through' Cooling Systems
4.2 Open Evaporative Recirculating Systems
4.3 Closed Recirculating Systems
4.4 Comparison of Cooling Systems
5 MAKE-UP WATER QUALITY
6 FOULING PROCESSES
6.1 Deposition
6.2 Scaling
6.3 Corrosion
6.4 Biological Growth
7 CONTROL OF THE COOLING SYSTEM
7.1 ‘Once through' Cooling Systems
7.2 Closed Recirculating Systems
7.3 Open Evaporative Cooling Systems
TABLES
1 RELATIVE IMPORTANCE OF FOULING PROCESSES AND INSTALLED COSTS
2 WATER QUALITY PARAMETERS
FIGURES
1 PREDICTION OF CALCIUM CARBONATE SCALING
2 CALCIUM SULFATE SOLUBILITY
3 CALCIUM PHOSPHATE SCALING INDEX
Physical Properties for Heat Exchanger Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 COMPONENT PROPERTIES
4.1 General
4.2 Use of Component Properties for Mixtures
5 INPUT OF MIXTURE CURVES
5.1 General
5.2 Generation of the Mixture Curves
5.3 Selection of Temperature Points
5.4 Extrapolation
6 IMMISCIBLE CONDENSATES
FIGURES
1 TEMPERATURE POINTS SELECTED FOR EQUAL ENTHALPY CHANGE
2 TEMPERATURE POINTS SELECTED FOR GOOD
FIT TO CURVE
This document discusses a modular construction project called "Chill" that was completed successfully to address scheduling concerns for a larger project. The Chemours company was initially concerned about working with a modular contractor for various reasons relating to space, access, and construction. However, Koch Modular Process Systems was able to address all of Chemours' concerns through their modular design. This included removing temporary steel supports after installation, minimizing interior bracing, and ensuring proper access, egress, and safety features. As a result, the modular facility was delivered ahead of schedule and under budget compared to traditional construction. Chemours was so satisfied that they hired Koch Modular for two additional projects.
Fixed Bed Reactor Scale-up Checklist
The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
• Literature data.
• Lab testing.
• Calculation.
• Modeling.
• Semi-tech testing.
• Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor
Air / Steam Regeneration Procedure for Primary Reforming CcatalystGerard B. Hawkins
GBH Enterprises specializes in refinery process catalysts, including performance evaluation, analysis, and development of new technologies. The document provides procedures for air/steam regeneration of primary reforming catalysts either during shutdown or startup. During shutdown, steaming should continue for two hours before introducing a small amount of air to burn off carbon deposits, monitored by CO2 levels. During startup, normal heating with steam is followed by the same air regeneration process once temperatures reach 1300-1325°F, before removing air and resuming steam for two hours prior to introducing feed gas.
Critical Variables in Catalytic Reforming and Unit Monitoring Best PracticesGerard B. Hawkins
This document discusses optimization strategies for catalytic reforming processes in oil refineries. It outlines best practices for identifying and monitoring critical variables, and provides examples of critical variables like catalyst activity and recycle gas composition. The document also discusses principles of reformer optimization like defining objectives, layered management practices, and optimizing operations. Overall it provides guidance on monitoring performance, catalyst management, and using online optimization to improve profitability of refinery catalytic reforming units.
The Selection of Flocculants and other Solid-Liquid Separation AidsGerard B. Hawkins
The use of chemical additives, such as flocculants, is a common step in solid-liquid separation operations. The correct selection of agent is an essential part of the design of such processes. Many excellent reviews and guides deal with this topic, and the interested reader is referred to works such as [l-4]. In particular the Harwell-Warren Spring Report “The Use and Selection of Flocculants" provides a good overview on the application of coagulants and flocculants. This section does not attempt to reproduce a detailed treatment of that kind; instead it is our intention to state a few general rules and principles concerning methods of choosing an additive, and to illustrate briefly their application in practice.
The types of agents employed in solid-liquid separation fall into three principal classes:
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF AQUEOUS ORGANIC EFFLUENT STREAMS
CONTENTS
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 IPU
3.2 AOS
3.3 BODs
3.4 COD
3.5 TOC
3.6 Toxicity
3.7 Refractory Organics/Hard COD
3.8 Heavy Metals
3.9 EA
3.10 Biological Treatment Terms
3.11 BATNEEC
3.12 BPEO
3.13 EQS/LV
3.14 IPC
3.15 VOC
3.16 F/M Ratio
3.17 MLSS
3.18 MLVSS
4 DESIGN/ECONOMIC GUIDELINES
5 EUROPEAN LEGISLATION
5.1 General
5.2 Integrated Pollution Control (IPC)
5.3 Best Available Techniques Not Entailing Excessive Costs (BATNEEC)
5.4 Best Practicable Environmental Option (BPEO)
5.5 Environmental Quality Standards(EQS)
6 IPU EXIT CONCENTRATION
7 SITE/LOCAL REQUIREMENTS
8 PROCESS SELECTION PROCEDURE
8.1 Waste Minimization Techniques (WMT)
8.2 AOS Stream Definition
8.3 Technical Check List
8.4 Preliminary Selection of Suitable Technologies
8.5 Process Sequences
8.6 Economic Evaluation
8.7 Process Selection
APPENDICES
A DIRECTIVE 76/464/EEC - LIST 1
B DIRECTIVE 76/464/EEC - LIST 2
C THE EUROPEAN COMMISSION PRIORITY CANDIDATE LIST
D THE UK RED LIST
E CURRENT VALUES FOR EUROPEAN COMMUNITY ENVIRONMENTAL QUALITY STANDARDS AND CORRESPONDING LIMIT VALUES
F ESTABLISHED TECHNOLOGIES
G EMERGING TECHNOLOGY
H PROPRIETARY/LESS COMMON TECHNOLOGIES
J COMPARATIVE COST DATA
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
This document provides instructions for loading and starting up molecular sieve adsorbents and adsorption units. It discusses inspecting the vessel before loading, loading support material at the bottom and molecular sieves, then support material at the top. An initial regeneration is recommended after closing to ensure the molecular sieves are highly active. Safety precautions are outlined to prevent moisture contamination.
Hydrogen Compressors
Engineering Design Guide
1 SCOPE
2 PHYSICAL ROPERTIES
2.1 Data for Pure Hydrogen
2.2 Influence of Impurities
3 MATERIALS OF CONSTRUCTION
3.1 Hydrogen from Electrolytic Cells
3.2 Pure Hydrogen
4 DESIGN
4.1 Pulsation
4.2 Bypass
5 TESTING OR COMMISSIONING RECIPROCATING COMPRESSORS
6 LUBRICATION
7 LAYOUT
8 REFERENCES
FIGURES
1 MOLLIER CHART - HYDROGEN
2 COMPRESSIBILITY CHART
3 NELSON DIAGRAM
4 WATER CONTENT IN HYDROGEN FOR OIL-LUBRICATED COMPRESSORS AS GRAMM/M2 SWEPT CYLINDER AREA
This document presents a case study and methods to re-establish a condemned boiler. It includes an introduction, contents listing, acknowledgements, abstract on the Hindustan Storage & Distribution Company where the boiler is located, specifications and diagrams of the boiler, scope of dismantling and repair work, results of dismantling, scope of work after renovation including flue gas analysis and boiler tuning.
This is a presentation on the design of plant for producing 20 million standard cubic feet per day (0.555 × 106 standard m3/day) of hydrogen (H2) of at least 95% purity from heavy fuel oil (HFO) with an upstream time of 7680 hours/year applying the process of partial oxidation of the heavy oil feedstock.
T.H. Chemicals wants to produce nitrogen, oxygen, and argon from air using cryogenic distillation. Cryogenic air separation is the dominant technology for producing large quantities of high-purity liquified gases. The process involves compressing and cooling air, removing impurities via membrane separation, further cooling the air using heat exchangers, and fractionating the components in distillation columns. Oxygen is recovered from the bottom of the low pressure column at 99.49% purity, nitrogen from the top at 99.275% purity, and argon from the middle. Heat integration occurs between the condenser and reboiler to improve efficiency.
This document summarizes the start-up of the world's largest ammonia plant in Bontang, Indonesia with a nameplate capacity of 2,000 metric tons per day. Some key milestones included mechanical completion in January 2000, first ignition of reformers in January 2000, and completion of performance testing in May 2000. The plant layout was optimized for efficiency and utilized proven ammonia production technologies. It achieved a low specific energy consumption of 6.89 Gcal/MT of ammonia produced.
This document summarizes the start-up of the world's largest ammonia plant in Bontang, Indonesia with a nameplate capacity of 2,000 metric tons per day. Some key milestones included mechanical completion in January 2000, first ignition of reformers in January 2000, and completion of performance testing in May 2000. The plant layout was optimized for efficiency and utilized proven ammonia production technologies. It achieved a low specific energy consumption of 6.89 Gcal/MT of ammonia produced.
The document summarizes the start-up of the world's largest ammonia plant in Bontang, Indonesia with a nameplate capacity of 2,000 metric tons per day. Key points include:
- The plant was a joint venture between Mitsui, Tomen Corp., and PT Talang Gumbaru Andhika and used Haldor Topsoe technology.
- Mitsubishi Heavy Industries constructed the plant over 34 months, achieving mechanical completion in January 2000 and completing performance tests in May 2000.
- The compact design integrated waste heat recovery and utilized local natural gas and seawater to achieve low energy consumption.
"Replacement of vapor compression system of domestic refrigerator by an eject...IRJET Journal
This document summarizes research on replacing vapor compression refrigeration systems with ejector refrigeration systems. It discusses how ejector refrigeration systems use low-grade waste heat as the power source, have fewer moving parts than compressors, and can help reduce greenhouse gas emissions. The document provides details on the design and testing of ejector refrigeration systems using various working fluids. It analyzes the performance of these systems and the impact of parameters like heat source temperature, refrigerant type, and ejector design on the system coefficient of performance.
The document summarizes the installation of an S-50 ammonia synthesis converter and waste heat boiler downstream of an existing S-200 converter at an ammonia plant. This is done as part of an energy savings project and is expected to increase conversion per pass by 35.5% compared to 28.3% for the S-200 alone, as well as increase steam generation. The installation included placing the S-50 converter foundation, loading it with catalyst, connecting it via insulated pipelines to the existing system, and commissioning it along with instrumentation and controls. The result is higher efficiency ammonia production and energy recovery from waste heat.
Carbon Sequestration Final Proposal (LINKEDIN)Alex Rojas
This report proposes a design to capture and store carbon dioxide emissions from Cornell University's power plant. The major components are a water spray cooler to lower the temperature of flue gas from the plant, a series of MEA columns to separate CO2 from the flue gas, and a pipeline to transport CO2 16.5 miles to a storage site near another power plant. The total estimated cost is $80 million to capture 65,000 lbs/hr of CO2, and the project would take 5.5 years to construct with storage lasting 125 years. Risks like pipeline failures and groundwater displacement are also analyzed.
Review of Vapour Absorption System and Vapour Compression System.IRJET Journal
This document reviews and summarizes literature on vapour absorption and vapour compression refrigeration systems. It discusses the basic principles and components of vapour absorption systems, including single effect and double effect cycles. It also discusses vapour compression systems and their four main components: evaporator, compressor, condenser, and expansion device. The document summarizes several research papers on improving the efficiency of these systems through various parameters and working fluids. It concludes that further research is needed on smaller vapour absorption systems and the energy analysis of compression-absorption systems.
IRJET- Review of Vapour Absorption System and Vapour Compression System.IRJET Journal
This document reviews and summarizes literature on vapour absorption and vapour compression refrigeration systems. It discusses the basic principles and components of vapour absorption systems, including single effect and double effect cycles. It also discusses vapour compression systems and their four main components: evaporator, compressor, condenser, and expansion device. The document summarizes several research papers on improving the efficiency of these systems through various parameters and working fluids. It concludes that further research is needed on smaller vapour absorption systems and the energy analysis of compression-absorption systems.
The document discusses energy efficiency improvements in the Pali textile cluster in India. It describes how the MSME sector is an important part of the Indian economy but faces challenges in adopting energy efficiency. The Bureau of Energy Efficiency initiated a project to implement energy efficient technologies like air preheaters and economizers in boiler systems in five MSME clusters, including Pali. Air preheaters and economizers allow for waste heat recovery from flue gases which can improve boiler efficiency and reduce fuel consumption. Cost-benefit analyses are provided for installing these technologies in typical textile processing units, finding potential savings of 1% of fuel costs for every 6 degree Celsius rise in feed water temperature from an economizer.
The document discusses the history and evolution of fluid catalytic cracking (FCC) units from their inception in 1915 up to modern times. FCC units now process about 5.3 million barrels of feedstock per day in the US alone to produce gasoline and other products. Technological improvements over the decades include developments in catalyst materials, unit designs, operating conditions, and products to optimize the catalytic cracking process.
Practical Implementation Of Renewable Hydrogen & Fuel Cell Installations in t...guest083950
Paper presented at the conference Detail Design in Architecture 8 at University of Wales Institute Cardiff, on the 4th September 2009.
Authors: Gavin D. J. Harper & Ross Gazey
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1) Around 47% of the thermal energy used in cement production is wasted, with 35% of that waste heat recoverable to generate up to 30% of a plant's electricity needs.
2) Waste heat recovery reduces operating costs and increases profits, but has not been widely implemented except in China where most installations use steam turbines.
3) New organic Rankine cycle technology provides an alternative to steam turbines for cement plant waste heat recovery, offering efficiencies at lower temperatures without complex vacuum systems.
Study of Thermoelectric Air Conditioning for AutomobilesIRJET Journal
This document discusses the study of using thermoelectric air conditioning for automobiles as an alternative to traditional HVAC systems. It begins by introducing thermoelectric modules, which can act as heat pumps using the Peltier effect to produce a temperature difference when current flows through them. Unlike traditional HVAC systems, thermoelectric air conditioning does not require compressors or pumps. The document then discusses the methodology, working principles based on the Peltier and Seebeck effects, configuration of thermoelectric modules, and aims to introduce a new HVAC system using thermoelectric modules to overcome disadvantages of existing systems such as environmental impact, energy efficiency, and cost.
This document discusses using cold boiler feed water from membrane deaerators for heat recovery in refineries. Specifically, it proposes supplying cold boiler feed water to waste heat streams to replace steam duty currently used in deaerators. As an example, it describes using cold feed water in the heat exchanger of a hydrocracker hydrogen production unit, which could recover more waste heat and reduce steam usage by 8.8 Gcal/h in the deaerator. Overall, maximizing heat recovery from waste streams with cold boiler feed water can significantly improve energy efficiency in refineries.
This document summarizes a study on an adsorption refrigeration system for truck cabin cooling using engine exhaust heat. The proposed system uses two adsorbers, two condensers and an evaporator connected with two control valves. Experimental testing of a 1 kW prototype showed a cooling capacity of 1-1.2 kW and a COP of 0.4-0.45. The system uses a compact design with minimal components, making it portable for truck integration. Graphs show the system's refrigeration capacity, COP and heating time vary with exhaust gas temperature. The study concludes the proposed system can provide refrigeration without impacting engine efficiency and is a viable option for truck cabin cooling.
Similar to A Modular C2 Splitter - Hydrocarbon Engineering April 2017 (20)
Koch Modular Process Systems presented on extractive distillation. Extractive distillation involves adding a high-boiling solvent to a binary mixture to alter the relative volatility of the components and allow separation via distillation. It can be considered for mixtures that form azeotropes or have low relative volatility. Examples were given of mixtures like acetone/methanol and THF/water that can be separated through extractive distillation using appropriate solvents. Attendees were encouraged to evaluate extractive distillation for difficult separation challenges.
Product purification and recovery remains a priority for chemical engineers, today. Designing separations processes to accomplish the above is a challenge, especially as streams get more complex in composition. Though often overlooked, liquid-liquid extraction (LLE) is a powerful separation technique for both organic and aqueous liquids. Whereas distillation technology relies on relative volatility differences among chemicals, LLE exploits the differences in relative solubilities of compounds in two immiscible liquids, to perform the key separation. Distillation may not be feasible when boiling points are nearly identical or for other reasons, economic and technical. When distillation is not a viable solution, LLE is a great alternative to achieve product purification and recovery.
According to the Construction Industry Institute, modularization entails the large-scale transfer of stick-build construction effort from the jobsite to one or more local or distant fabrication shops/yards in order to exploit one or more strategic advantages. Nonetheless, the majority of projects today still do not exploit these strategic advantages to their fullest potential.
Modular Construction has many advantages over conventional stick-build construction. These benefits include shorter schedules, lower cost overall cost, minimal plant site interruption and many more. Strengthen your knowledge of when and why to choose modularization as a project delivery model.
Koch Modular Process Systems, LLC (Koch Modular) provides process control system and automation solutions for standalone turnkey applications or integration within a customer's existing PLC, DCS, or SCADA infrastructure. Koch Modular engineers work directly with the customer to design a custom solution specific to meet their plant, industry, standards, and needs. Koch Modular can also assist in modification of existing control systems to upgrade or integrate enhanced functionality.
In most chemical engineering curriculums, distillation and liquid-liquid extraction (LLE) do not receive equal billing. Yet, this powerful separations technology is in place across the CPI, pharmaceutical and oil/gas industries. Discover how to design an LLE column with industry experts Don Glatz and Brendan Cross as they discuss specific examples and separations challenges.
This document discusses various methods for breaking azeotropes in distillation operations. An azeotrope is a mixture that boils as a single composition in liquid and vapor phases, making separation via simple distillation impossible. The easiest type to break is a heterogeneous azeotrope, using a combination of distillation and decantation into separate phases. Pressure swing distillation and azeotropic distillation using an additional entrainer component are effective for homogeneous azeotropes. Other techniques include extractive distillation, liquid-liquid extraction, and newer membrane technologies. Determining the best approach requires substantial experience, as pilot testing is usually needed to account for real feedstock variations not seen in
Equilibrium data and related information gathered from a liquid-liquid extraction laboratory “shake test” can provide information for process feasibility and column-type selection in the scaleup of liquid-liquid extraction processes
Most chemical engineers have had the experience of dealing with problematic separations, and most have a general understanding of distillation processes. When it comes to liquid-liquid extraction (LLE) processes (Figure 1), however, the details of how these processes work are often less clear. Most academic chemical engineering degree programs do not heavily emphasize liquid-liquid extraction, and most chemical engineering graduates did not receive more than a few days of instruction on generating equilibrium data for LLE in their degree programs.
The document outlines a module assembly factory acceptance test procedure with 7 steps: 1) The project manager determines representatives for inspection; 2) Schedules inspections with client and vendor; 3) Compiles drawings and specifications for inspection; 4) Representatives take inspection package and conduct factory acceptance test; 5) Representatives issue punch list after each visit; 6) Repeat steps until unit is acceptable for shipment; 7) KMPS signs acceptance document upon successful completion.
KMPS is requesting feedback from a customer on a recently completed project through a project report card survey. The survey asks the customer to rate various aspects of the project such as proposal development, process design, piping and layout design, major equipment, electrical and instrumentation controls, module assembly, shipment and installation, and overall project execution. The customer is asked to provide a rating from 1 to 5 and any additional comments for each section to help KMPS improve its work processes and products.
This document provides modular project documentation for a mass transfer system, including a project schedule, process diagrams, equipment drawings, 3D models, and instrumentation diagrams. KMPS is an engineering company that has designed and built modular process systems for chemical companies for over 20 years.
Glass-lined KARR® Column used for extracting an organic acid from a solvent/monomer feed stream, using water as the solvent. This column is used to extract >90 of the acid prior to neutralization in a second KARR® Column supplied previously, thus minimizing the use of base and generation of salts.
This document discusses liquid-liquid extraction columns and provides steps for evaluating and improving their performance. It begins by explaining that over time, the original understanding of column designs can be lost. The six steps provided aim to revisit the design basis and identify optimization opportunities. The steps include generating new liquid-liquid equilibrium data, obtaining a material balance, calculating the current number of theoretical stages, evaluating how process changes affect performance, pilot testing options, and implementing modifications. Understanding liquid-liquid equilibrium curves and distribution coefficients is important for evaluating column performance.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive function. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
Distillation may be the chemical process industries workhorse for separating the components of a liquid mixture. However, extraction comes to the forefront when separations are either difficult or impossible to economically handle by ordinary distillation.
A reference guide to DeltaV DCS controls and operation. This easy, intuitive, and interoperable Distributed
Control System (DCS) harnesses predictive
technologies to connect your people, processes, and
production.
The document outlines the 18 step process for completing a modular assembly project. It describes the key stages as equipment fabrication, steel fabrication, receiving purchased equipment, piping fabrication, equipment installation, loading out modules for shipment, site installation, and fitting up split modules. Contact information is provided for KMPS Construction.
Koch Modular Process Systems, LLC. (KMPS) Extraction Technology Group specializes in the design and supply of liquid-liquid extraction equipment engineered to fulfill the chemical, pharmaceutical, petrochemical, biotech and flavor & fragrance industries’ increasingly challenging purification requirements. Our extractor design expertise includes SCHEIBEL® Columns, KARR® Columns, rotating disc contactor (RDC) columns, pulsed, packed (SMVP) and sieve tray.
At KMPS, we don’t just sell extraction equipment; we supply solutions to your difficult separation applications.
KMPS also provides replacements parts, repair services and troubleshooting assistance for all types of extraction columns. A qualified technician or engineer can be provided on-site for both mechanical and process related support.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
Home security is of paramount importance in today's world, where we rely more on technology, home
security is crucial. Using technology to make homes safer and easier to control from anywhere is
important. Home security is important for the occupant’s safety. In this paper, we came up with a low cost,
AI based model home security system. The system has a user-friendly interface, allowing users to start
model training and face detection with simple keyboard commands. Our goal is to introduce an innovative
home security system using facial recognition technology. Unlike traditional systems, this system trains
and saves images of friends and family members. The system scans this folder to recognize familiar faces
and provides real-time monitoring. If an unfamiliar face is detected, it promptly sends an email alert,
ensuring a proactive response to potential security threats.
Software Engineering and Project Management - Software Testing + Agile Method...Prakhyath Rai
Software Testing: A Strategic Approach to Software Testing, Strategic Issues, Test Strategies for Conventional Software, Test Strategies for Object -Oriented Software, Validation Testing, System Testing, The Art of Debugging.
Agile Methodology: Before Agile – Waterfall, Agile Development.
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
Generative AI Use cases applications solutions and implementation.pdfmahaffeycheryld
Generative AI solutions encompass a range of capabilities from content creation to complex problem-solving across industries. Implementing generative AI involves identifying specific business needs, developing tailored AI models using techniques like GANs and VAEs, and integrating these models into existing workflows. Data quality and continuous model refinement are crucial for effective implementation. Businesses must also consider ethical implications and ensure transparency in AI decision-making. Generative AI's implementation aims to enhance efficiency, creativity, and innovation by leveraging autonomous generation and sophisticated learning algorithms to meet diverse business challenges.
https://www.leewayhertz.com/generative-ai-use-cases-and-applications/
Supermarket Management System Project Report.pdfKamal Acharya
Supermarket management is a stand-alone J2EE using Eclipse Juno program.
This project contains all the necessary required information about maintaining
the supermarket billing system.
The core idea of this project to minimize the paper work and centralize the
data. Here all the communication is taken in secure manner. That is, in this
application the information will be stored in client itself. For further security the
data base is stored in the back-end oracle and so no intruders can access it.
Digital Twins Computer Networking Paper Presentation.pptxaryanpankaj78
A Digital Twin in computer networking is a virtual representation of a physical network, used to simulate, analyze, and optimize network performance and reliability. It leverages real-time data to enhance network management, predict issues, and improve decision-making processes.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELijaia
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
Accident detection system project report.pdfKamal Acharya
The Rapid growth of technology and infrastructure has made our lives easier. The
advent of technology has also increased the traffic hazards and the road accidents take place
frequently which causes huge loss of life and property because of the poor emergency facilities.
Many lives could have been saved if emergency service could get accident information and
reach in time. Our project will provide an optimum solution to this draw back. A piezo electric
sensor can be used as a crash or rollover detector of the vehicle during and after a crash. With
signals from a piezo electric sensor, a severe accident can be recognized. According to this
project when a vehicle meets with an accident immediately piezo electric sensor will detect the
signal or if a car rolls over. Then with the help of GSM module and GPS module, the location
will be sent to the emergency contact. Then after conforming the location necessary action will
be taken. If the person meets with a small accident or if there is no serious threat to anyone’s
life, then the alert message can be terminated by the driver by a switch provided in order to
avoid wasting the valuable time of the medical rescue team.
Zener Diode and its V-I Characteristics and Applications
A Modular C2 Splitter - Hydrocarbon Engineering April 2017
1. A MODULAR
C2 SPLITTERStan Lam, Koch Modular
Process Systems LLC, USA, describes a
project where the company designed and
supplied a distillation system that enabled
ethylene recovery from purge gas streams.
A
typical olefins plant produces several purge gas streams,
which are usually flared or used as fuel. Some of those
streams contain valuable components such as ethylene
and propylene.
This article describes a project on which Koch Modular Process
Systems designed and supplied a distillation system to recover
ethylene from one of those purge streams, while overcoming some
special challenges with heat integration.
Project objective
The design objective of the ethylene recovery unit (ERU) was to
recover >90% of the ethylene from a 2000 lb/hr purge gas stream.
Challenges
The customer, a major polyethylene producer in Texas, US, had
decided on using distillation as the recovery process. There were
several challenges, including the following:
n There was a shortage of cooling water and all cooling duties
had to be provided by air.
n The temperature throughout the distillation column was below
the freezing point of water, so steam was not to be used as the
heat source for the reboiler.
n Air would be too warm to be used for cooling at the column
condenser.
n The low process temperatures required the use of a refrigerant.
After a screening of refrigerants, Koch Modular concluded that
Freon-12 and ammonia were the most economically feasible
refrigerants. After this, Freon-12 was ruled out because its use was
scheduled to be prohibited in 2010, even though it was still permitted
for use with existing equipment at the original time of planning (2008).
Simulation
Process simulations were performed using the PD-Plus simulator,
licensed from Deerhaven Technical Software. The recommended
equation of state for hydrocarbons at high pressure was
Soave Redlich-Kwong (SRK). Koch Modular utilised both
2. Reprinted from April 2017 HYDROCARBON
ENGINEERING
Peng-Robinson (P-R) and SRK to trial-fit operating data and
found that both models fitted the operating data well. The
SRK method was eventually selected as the process engineer
that was leading the project (and the author of this article)
was more familiar with it.
Feed and product specification
The feed stream composition was as follows:
nn Methane: 7 vol%.
nn Ethylene: 84 vol%.
nn Ethane and other hydrocarbons: balance.
The required product purity was 95 vol% ethylene at
2000 psig. Most of the ethylene loss took place in the
overhead vent gas stream, which consisted mainly of methane.
Process flow diagram
The flow diagram in Figure 1 is typical of an
ethylene/ethane distillation system. It consisted of a
distillation column with a pasteurisation section (C-1), a
reboiler (E-2), condenser (C-1) and a reflux drum (T-1). A
special requirement was that the recovered ethylene must
be in gaseous form at 2000 psig, even though the distillation
column would only operate at 350 psig. Consequently,
Koch Modular had to use a high pressure pump (P-2) to send
the liquid ethylene to an evaporator (E-3) operating at
2000 psig. The basic flow diagram is shown in Figure 1 and
demonstrates how the process simulation was modelled.
Flow diagram with heat integration
As explained in the ‘Challenges’ section of this article, steam
could not be used in the reboiler. Koch Modular had to
select a heat transfer fluid that would condense at a high
enough temperature as a heat source for the reboiler and
ethylene evaporator, and evaporate at a low enough
temperature to be a coolant for the column condenser (E-1)
without freezing. Ammonia met all of these requirements.
Hence, the refrigeration unit would also serve as a heat
pump. While its main function was to provide the cooling
duty for the column condenser, the condensation of the
ammonia vapours also provided heat to the reboiler and
ethylene evaporator with no potential freezing.
Air was used as the coolant for the refrigeration unit. No
cooling water or steam is required to operate the ERU. Once
the ethylene was recovered, the balance of the
hydrocarbons would be vented to the flare. However, after
the pressure let-down and due to the Joule-Thomson effect,
the vent gas was at a very low temperature. To make use of
the ‘cold’ from this stream, a knock-back condenser (E-4) was
used to minimise the loss of ethylene in the vent gas.
Even after leaving E-4, the vent gas temperature was still
too low for the carbon steel piping of the flare system. So,
another heat exchanger (E-5) was then added to heat the gas
to an acceptable temperature while also providing additional
cooling to the refrigerant. The flow diagram with heat
integration is shown in Figure 2.
Distillation equipment
Typically, distillation columns are equipped with either
fractionation trays or packing. For a gas flowrate of
2000 lb/hr, the diameter of the distillation column was only
2 ft. Due to the small equipment size, it was decided that a
modular construction approach would be the most cost and
schedule effective. The most economical distillation device
would be structured packing. Under normal circumstances, it
would result in the most compact distillation column and
the smallest modules. However, it had been widely reported
that the use of structured packing in high pressure
hydrocarbon distillation had been unsuccessful. Hence,
Koch Modular took the conservative approach of using trays
of cartridge design. The cartridge trays were installed in the
column, prior to shipping, while it was still in a horizontal
position. This eliminated the need for field installation,
which would have required additional site labour and the use
of a very tall crane. Figure 3 demonstrates the installation of
cartridge trays in a distillation column in a shop.
Figure 1. Basic flow diagram.
Figure 2. Flow diagram including heat integration
with the refrigeration unit.
Figure 3. Cartridge tray installation.
3. Reprinted from April 2017HYDROCARBON
ENGINEERING
Modular construction
All of the equipment, piping, and instruments, etc., were
installed in two modular frames. The unit was first
electronically modelled using the 3D modeller AutoPLANT.
This allowed Koch Modular to build a virtual unit in the design
office that the customer could walk through until they were
totally satisfied with the equipment and piping layout,
accessibility, ease of maintenance, plant safety requirements,
etc. A 3D model of the ERU is shown in Figure 4.
The unit was then built in the assembly shop, inspected,
pressure tested and shipped to the jobsite. The customer
only had to lift the modules from the trucks and place them
on pre-installed anchor bolts, connect the piping tie-ins and
wire their control system to the instrument junction boxes.
With this modular construction approach, the requirement
for site labour was minimised.
Start-up
The process start-up was uneventful. Customers usually
require some company assistance when starting up new
distillation systems. However, in this case, the customer’s
engineers were able to start-up the system independently
and meet the product specifications without any assistance.
The ERU has been in operation since 2010 and has not
encountered any problems.
Economics
The cost of the ERU to the customer was US$2.8 million and
the estimated installation cost was US$1 million, making a total
installed cost of US$3.8 million. At the time of start-up, the
price of ethylene was approximately US$0.60/lb. Based on
8000 hrs/y, the value of recovered ethylene was over
US$8.5 million/y, providing a substantial return on investment.
Since this project, Koch Modular has been awarded two
further orders from the same customer, one for a similar
modular system in 2012 and one for an engineering design
package in 2014 that enabled the customer to perform its
own construction.
Conclusion
Koch Modular has demonstrated that valuable hydrocarbons
such as ethylene and propylene can be recovered from
olefins plants' purge gas streams, but some innovative heat
integration techniques are required to make the process
feasible.
Figure 4. A 3D model of the ethylene recovery unit.