The document discusses ammonia synthesis catalysts including their formulation, production, and operation. Key points include:
1) Ammonia synthesis catalysts are typically based on magnetite that is reduced to form a porous iron structure. Promoters like alumina and potash boost activity and stability.
2) Catalyst production involves melting components to control precursor phases before milling to size.
3) The reaction favors high pressure and low temperature. Typical conditions are 350-530°C and 100-600 bar. Temperature and pressure balance kinetics and equilibrium.
High Temperature Shift Catalyst Reduction ProcedureGerard B. Hawkins
High Temperature Shift Catalyst Reduction Procedure
The catalyst, as supplied, is Fe2O3. This reduces to the active form, Fe3O4, in the presence of hydrogen when process gas is admitted to the reactor.
1. The mildly exothermic reactions are:
3 Fe2O3 + H2 ========= 2 Fe3O4 + H2O
3 Fe2O3 + CO ========= 2 Fe3O4 + CO2
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Theory of Carbon Formation in Steam Reforming
Contents
1 Introduction
2 Underpinning Theory
2.1 Conceptualization
2.2 Reforming Reactions
2.3 Carbon Formation Chemistry
2.3.1 Natural Gas
2.3.2 Carbon Formation for Naphtha Feeds
2.3.3 Carbon Gasification
2.4 Heat Transfer
3 Causes
3.1 Effects of Carbon Formation
3.2 Types of Carbon
4 What are the Effects of Carbon Formation?
4.1 Why does Carbon Formation Get Worse?
4.1.1 So what is the Next Step?
4.2 Consequences of Carbon Formation
4.3 Why does Carbon Form where it does?
4.3.1 Effect on Process Gas Temperature
4.4 Why does Carbon Formation Propagate Down the Tube?
4.4.1 Effect on Radiation on the Fluegas Side
4.5 Why does Carbon Formation propagate Up the Tube?
5 How do we Prevent Carbon Formation
5.1 The Role of Potash
5.2 Inclusion of Pre-reformer
5.3 Primary Reformer Catalyst Parameters
5.3.1 Activity
5.3.2 Heat Transfer
5.3.3 Increased Steam to Carbon Ratio
6 Steam Out
6.1 Why does increasing the Steam to Carbon Ratio Not Work?
6.2 Why does reducing the Feed Rate not help?
6.3 Fundamental Principles of Steam Outs
TABLES
1 Heat Transfer Coefficients in a Typical Reformer
2 Typical Catalyst Loading Options
FIGURES
1 Hot Bands
2 Conceptual Pellet
3 Naphtha Carbon Formation
4 Heat Transfer within an Reformer
5 Types of Carbon Formation
6 Effect of Carbon on Nickel Crystallites
7 Absorption of Heat
8 Comparison of "Base Case" v Carbon Forming Tube
9 Carbon Formation Vicious Circle
10 Temperature Profiles
11 Carbon Pinch Point
12 Carbon Formation
13 Effect on Process Gas Temperature
14 How does Carbon Propagate into an Unaffected Zone?
15 Movement of the Carbon Forming Region
16 Effect of Hot Bands on Radiative Heat Transfer
17 Effect of Potash on Carbon Formation
18 Application of a Pre-reformer
19 Effect of Activity on Carbon Formation
High Temperature Shift Catalyst Reduction ProcedureGerard B. Hawkins
High Temperature Shift Catalyst Reduction Procedure
The catalyst, as supplied, is Fe2O3. This reduces to the active form, Fe3O4, in the presence of hydrogen when process gas is admitted to the reactor.
1. The mildly exothermic reactions are:
3 Fe2O3 + H2 ========= 2 Fe3O4 + H2O
3 Fe2O3 + CO ========= 2 Fe3O4 + CO2
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
Theory of Carbon Formation in Steam Reforming
Contents
1 Introduction
2 Underpinning Theory
2.1 Conceptualization
2.2 Reforming Reactions
2.3 Carbon Formation Chemistry
2.3.1 Natural Gas
2.3.2 Carbon Formation for Naphtha Feeds
2.3.3 Carbon Gasification
2.4 Heat Transfer
3 Causes
3.1 Effects of Carbon Formation
3.2 Types of Carbon
4 What are the Effects of Carbon Formation?
4.1 Why does Carbon Formation Get Worse?
4.1.1 So what is the Next Step?
4.2 Consequences of Carbon Formation
4.3 Why does Carbon Form where it does?
4.3.1 Effect on Process Gas Temperature
4.4 Why does Carbon Formation Propagate Down the Tube?
4.4.1 Effect on Radiation on the Fluegas Side
4.5 Why does Carbon Formation propagate Up the Tube?
5 How do we Prevent Carbon Formation
5.1 The Role of Potash
5.2 Inclusion of Pre-reformer
5.3 Primary Reformer Catalyst Parameters
5.3.1 Activity
5.3.2 Heat Transfer
5.3.3 Increased Steam to Carbon Ratio
6 Steam Out
6.1 Why does increasing the Steam to Carbon Ratio Not Work?
6.2 Why does reducing the Feed Rate not help?
6.3 Fundamental Principles of Steam Outs
TABLES
1 Heat Transfer Coefficients in a Typical Reformer
2 Typical Catalyst Loading Options
FIGURES
1 Hot Bands
2 Conceptual Pellet
3 Naphtha Carbon Formation
4 Heat Transfer within an Reformer
5 Types of Carbon Formation
6 Effect of Carbon on Nickel Crystallites
7 Absorption of Heat
8 Comparison of "Base Case" v Carbon Forming Tube
9 Carbon Formation Vicious Circle
10 Temperature Profiles
11 Carbon Pinch Point
12 Carbon Formation
13 Effect on Process Gas Temperature
14 How does Carbon Propagate into an Unaffected Zone?
15 Movement of the Carbon Forming Region
16 Effect of Hot Bands on Radiative Heat Transfer
17 Effect of Potash on Carbon Formation
18 Application of a Pre-reformer
19 Effect of Activity on Carbon Formation
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
Calculation of an Ammonia Plant Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES
13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL
14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Methanation catalysts are almost always manufactured and transported in the oxidized form, and therefore they must be reduced in the reactor to give nickel metal in order to make them active. The reduction is usually carried out in process gas and occurs by the two reactions:
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
Calculation of an Ammonia Plant Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES
13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL
14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Methanation catalysts are almost always manufactured and transported in the oxidized form, and therefore they must be reduced in the reactor to give nickel metal in order to make them active. The reduction is usually carried out in process gas and occurs by the two reactions:
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
Distillation Sequences, Complex Columns and Heat Integration
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 SEQUENCING OF SIMPLE COLUMNS
4.1 Sidestream Columns
4.2 Multi-Feed Columns
5 SIMPLE COLUMN SEQUENCING AND HEAT
INTEGRATION INTERACTIONS
5.1 Energy Quantity and Quality
5.2 Heat Integration within the Total Flowsheet
6 COMPLEX COLUMN ARRANGEMENTS
6.1 Indirect Sequence with Vapor Link
6.2 Sidestream Systems
6.3 Pre-Fractionator Systems
7 COMPLEX COLUMNS AND HEAT INTEGRATION
INTERACTIONS
FIGURES
1 DIRECT AND INDIRECT SEQUENCES
2 A SINGLE SIDESTREAM COLUMN REPLACING 2
SIMPLE COLUMNS
3 A TYPICAL MULTI-FEED COLUMN
4 TYPICAL GRAND COMPOSITION CURVE
5 TYPICAL INDIRECT SEQUENCE WITH VAPOUR LINK
6 SIDESTREAM STRIPPER AND SIDESTREAM
RECTIFIER
7 SIMPLEST PRE-FRACTIONATOR SYSTEM
8 SIMPLEST PRE-FRACTIONATOR SYSTEM
9 PETLYUK COLUMN
Bp global experience meoh and dme presentation ndrc presentation and discussi...Steve Wittrig
Presentation made to China National Development and Reform Commission at their request by Scott Charpentier and Steve Wittrig on the global experience and guidance to China for methanol as a transport fuel.
Bp methanol presentation to China ndrc for methanol as fuels 2006Steve Wittrig
Presentation made to China National Development and Reform Commission at their request by Scott Charpentier and Steve Wittrig on the global experience and guidance to China for methanol as a transport fuel.
If it can go wrong – it will
If something looks odd – it is
Apparent safe systems can fail
Issues include
Metal dusting
Methanol or hydrogen fires
Intent changes
Methanation
“Safe Systems”
METHANOL PLANT - SHALE GAS FEED PRETREATMENT
CASE STUDY #091406
Case Background
A Methanol plant operator would like to examine the technical feasibility of using Shale Gas as a feedstock to their Methanol plant.
The first step in the Methanol production process is gas pretreatment. The purpose of gas pretreatment is to make the gas suitable for the downstream processes. There are two groups of compounds that are usually present in natural gas and that should be removed during pretreatment—the associate NGL and the sulfur-containing compounds. Some natural gas reservoirs may also have other trace components that must be removed, but these are not discussed here.
This case study examines the impact of CO2 (Carbon Dioxide) on the pre-treatment section design, performance and efficiency of ACME Methanol Plant’ feed gas pre-treatment section.
Case 1: Normal Shale Gas
Case 2: “Bad Gas”
Case 3: Low CO2
Case 4: High CO2
Typical Stabilizer Chloride Management Problems
What Causes NH4Cl Salts?
Mitigating System Fouling
Operating practices
Problems with Water Injection
Design To Mitigate Salt Formation
Prevention
Remove Nitrogen from the feed
Remove chloride from stabilizer feed
Chloride Guard Bed
Caustic Injection
Water Wash
Summary
In pyrolysis gasoline hydrogenation there is a tendency to form polymeric materials on and in the catalyst bed. These are formed by condensation of gums and diolefins at local areas in the reactor .........
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainl...Gerard B. Hawkins
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainless Steels in Chloride and Caustic Environments
SYNOPSIS
This Maintenance Best Practice Guide is concerned with the performance of carbon and low alloy steels, and austenitic stainless steels, in chloride and caustic containing fluids. Those factors which are known to promote stress corrosion cracking are outlined, and service charts defining environmental boundaries for stress corrosion cracking in caustic and chloride containing fluids are presented.
General guidance on the avoidance of stress corrosion cracking is provided.
Cast White Metal Bearings
1 SCOPE
2 BACKING MATERIAL
3 SURFACE
4 THICKNESS
5 CLEANING PROCEDURE
6 TINNING
7 WHITE METAL
8 BOND SOUNDNESS
9 WITNESSED INSPECTION
10 MACHINING
11 FINAL INSPECTION OF BOND FOR SEAL RINGS
APPENDIX
A - METHOD OF CALCULATING REFLECTANCE RATIO
(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENTGerard B. Hawkins
(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENT; Case Study: #0978766GB/H
CASE STUDY OVERVIEW
Syn Gas Sour Shift: Process Flow Diagram
AGR: Acid Gas to VULCAN SYSTEMS Sour Gas Shift
DESIGN BASIS:
ACID GAS REACTOR CATALYST SPECIFICATION
SOUR SHIFT CASE
SHIFT REACTOR CATALYST SPECIFICATIONS
COS REACTOR CATALYST SPECIFICATIONS
SWEET SHIFT CASE
SHIFT REACTOR CATALYST SPECIFICATIONS
PERFORMANCE SIMULATION RESULTS
SOUR SHIFT SECTION
1 Cases Considered
2 Catalyst Used
3 Client Requirements
4 Oxygen and Olefins
5 HCN
6 NH3
7 Arsine
8 Input Data Sour Shift Unit
9 Activity (PROPRIETARY)
10 Results
ADIABATIC SWEET SHIFT SECTION: HTS Reactor followed by LTS Reactor
1 Catalyst Used
2 Inlet Operating Temperature HTS Reactor
3 Feed Flow Rate, Inlet Operating Pressure and Feed Composition HTS Reactor
4 Inlet Operating Conditions LTS Reactor
5 Client Requirements
6 Results: Standard Case as Presented to the Client
7 Results: Inlet Operating Pressure HTS Reactor = 25.2 bara
8 Results: Addition of 100 kmol/h N2
COS HYDROLYSIS SECTION FOR SWEET SHIFT CASE
1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure
2 Inlet H2S and COS Levels
3 Equilibrium H2S and COS Levels (COS Hydrolysis Reaction)
4 Client Requirements
5 Results
H2S REMOVAL SECTION AFTER AGR UNIT
(2 Absorbent Beds (VULCAN VSG-EZ200) in Lead/Lag Arrangement)
1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure
2 Inlet H2S and COS Levels
3 Client Requirements (All Cases)
4 Results
ISOTHERMAL SWEET SHIFT SECTION: Alternative Approach
VULCAN Simulation Input Data
1 Enthalpy method
2 Cases considered
3 Feed stream data
4 Kinetics
5 Catalyst
6 Catalyst Activity relative to standard
7 Catalyst size and packing details
8 Catalyst pressure drop parameters
9 Catalyst Volume
10 Standard die-off rate
11 BFW Rate
12 Vapor fraction
13 Steam Temperature
14 Steam Pressure
15 Boiling Model
16 Volumetric UA
Isothermal Shift Simulations Results
APPENDIX
Characteristics of Acid Gas Removal Technologies
Design and Operation of NHT Strippers to Protect Catalytic Reformers Gerard B. Hawkins
Common Reformer Problems
Purpose of NHT Stripper
Typical Design
Instrumentation of NHT Stripper
Other Design Issues
Indications of Problems in the NHT
Response to Reformer Upsets
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
DEACTIVATION OF METHANOL SYNTHESIS CATALYSTS
CONTENTS
1 INTRODUCTION
2 THERMAL SINTERING
3 CATALYST POISONING
4 REACTANT INDUCED DEACTIVATION
5 SUMMARY
TABLES
1 DEACTIVATION PROCESSES ON METHANOL SYNTHESIS CATALYSTS
2 MELTING POINT, HUTTIG AND TAMMANN TEMPERATURES OF COPPER, IRON AND NICKEL
3 SINTERING RATE CONSTANTS CALCULATED INLET AND OUTLET SIDE STREAM UNIT FOR VULCAN VSG-M101
4 COMPARISON BETWEEN CALCULATED S∞ AND DISCHARGED MEASUREMENTS ON VULCAN VSG-M101
5 EFFECT OF POSSIBLE CONTAMINANTS AND POISONS ON CU/ZNO/AL2O3 CATALYSTS FOR METHANOL SYNTHESIS
6 GUARD SCREENING TEST RESULTS ON METHANOL MICRO-REACTOR. EFFECT OF DEPOSITED METALS ON METHANOL ACTIVITY
FIGURES
1 THE HΫTTIG AND TAMMANN TEMPERATURES OF THE COMPONENTS OF A SYNTHESIS CATALYST
2 A SCHEMATIC REPRESENTATION OF TWO CATALYST SINTERING MECHANISMS
3 SIDE STREAM DATA FOR VULCAN VSG-M101. INLET TEMPERATURE 242 OC, PRESSURE 1500 PSI, GAS COMPOSITION 6% CO, 9.2% CO2, 66.9% H2, 2.5% N2 AND 15.4% CH4, SPACE VELOCITY 17,778 HR-1. MEAN OUTLET TEMPERATURE 280 OC
4 TEMPERATURE DEPENDENCE OF THE RATE OF SINTERING
5 MECHANISM OF SULFUR RETENTION
6 CORRELATION OF SULFUR CAPACITY WITH TOTAL SURFACE AREA
7 EFFECT OF DEPOSITED (NI+FE) PPM ON METHANOL SYNTHESIS CATALYST ACTIVITY
8 DISCHARGED (FE + NI) DEPOSITION LEVELS ON METHANOL SYNTHESIS PLANT SAMPLES
9 EPMA ANALYSIS OF DISCHARGED LABORATORY SAMPLE OF POISONED VULCAN VSG-M101
10 THE EFFECT OF CO2 ON SYNTHESIS CATALYST DEACTIVATION
REFERENCES
SMR PRE-REFORMER DESIGN
Case Study #0618416GB/H
Contents
1. SMR Pre-Reformer Design
2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation
Technical Review and Commentary on Proposed Design
APPENDIX
A. Operating / Mechanical Data
B. Materials Specifications
C. Fabrication and Inspection Requirements
D. Weights
E. Nozzle Data
F. Instrument Connections
G. Manholes
Batch Distillation
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THE DESIGN
4.1 General
4.2 Choice of batch/continuous operation
4.3 Boiling point curve and cut policy
4.4 Method of design
4.5 Scope of calculations required for design
5 SIMPLE BATCH DISTILLATION
6 FRACTIONAL BATCH DISTILLATION
6.1 General
6.2 Approximate methods
6.3 Rigorous design - use of a computer model
6.4 Other factors influencing the design
6.4.1 Occupation
6.4.2 Choice of Batch Rectification or Stripping
6.4.3 Batch size
6.4.4 Initial estimate of cut policy
6.4.5 Liquid Holdup
6.4.6 Total reflux operation and heating-up time
6.4.7 Column operating pressure
6.5 Optimum Design of the Batch Still
6.6 Special design problems
7 GENERAL ASPECTS OF EQUIPMENT DESIGN
7.1 Kettle reboilers
7.2 Column Internals
7.3 Condensers and reflux split boxes
8 PROCESS CONTROL AND INSTRUMENTATION IN
BATCH DISTILLATION
9 MECHANICAL DESIGN FEATURES
10 BIBLIOGRAPHY
APPENDICES
A McCABE - THIELE METHOD - TYPICAL EXAMPLE
Pumps for Ammonium Nitrate Service
Engineering Design Guide: GBHE-EDG-MAC-1503
CONTENTS
1 SCOPE
SECTION ONE: INTEGRATION OF PUMPS INTO THE PROCESS
2 PROPERTIES OF FLUID
2.1 Decomposition
2.2 Combustion
2.3 Detonation
2.4 Deliquescence
2.5 Density
2.6 Viscosity
2.7 Vapor Pressure
2.8 Freezing Point
2.9 Specific Heat
2.10 Surface Tension
2.11 Thermal Conductivity
3 CALCULATION OF DUTY
3.1 Centrifugal Pumps
4 CHOICE OF PUMP TYPE
4.1 Centrifugal Pumps
4.2 Rotary Pumps
4.3 Reciprocating Pumps
5 LINE DIAGRAMS
5.1 Centrifugal Pumps with Mechanical Seals
5.2 Vertical Suspended Cantilever Shaft Pumps for
Melt Service
5.3 Horizontal Self-Priming Pumps
5.4 Reciprocating Pumps
5.5 Seal Water Supply System
6 LAYOUT
6.1 Vertical Cantilever Shaft Pumps - Tank Proportions
SECTION TWO: CONSTRUCTION FEATURES OF PUMPS
7 SEALS FOR CENTRIFUGAL PUMPS
7.1 Below 30% AN
7.2 30-45% AN
7.3 45-90% AN
7.4 Above 90% AN
8 PACKED GLANDS FOR RECIPROCATING PUMPS
8.1 Below 90% AN
9 SEAL WATER SUPPLY SYSTEMS
10 CONSTRUCTION FEATURES OF CENTRIFUGAL PUMPS
10.1 Casing
10.2 Rotor
10.3 Bearing Lubrication
10.4 Coupling
10.5 Baseplate
11 CONSTRUCTION FEATURES OF VERTICAL CANTILEVER SHAFT IMMERSED PUMPS
11.1 Motor
11.2 Insulation and Jacketing
11.3 Rotor
11.4 Bearing Lubrication
11.5 Preservation
12 CONSTRUCTION FEATURES OF RECIPROCATING PLUNGER PUMPS
12.1 Speed Limits
12.2 Casing and Gearbox
12.3 Couplings
13 MATERIALS OF CONSTRUCTION
13.1 Recommended Materials
13.2 Forbidden Materials
APPENDIX A: BEARING LUBRICANTS
FIGURES
2.5.1 DENSITY OF AMMONIUM NITRATE SOLUTIONS
2.5.2 DENSITY OF AMMONIUM NITRATE SOLUTIONS
2.6 KINEMATIC VISCOSITY OF AMMONIUM NITRATE SOLUTIONS
2.7.1 WATER VAPOR PRESSURE ABOVE AMMONIUM NITRATE SOLUTIONS
2.7.2 AMMONIA VAPOR PRESSURE FOR AM!AMMONIUM NITRATE MELT
2.8 FREEZING POINT OF AMMONIUM NITRATE SOLUTIONS
2.9 SPECIFIC HEAT OF AMMONIUM NITRATE SOLUTIONS
4 SELECTION OF PUMP TYPE
5. 1 RECOMMENDED LINE DIAGRAM CENTRIFUGAL PUMPS WITH MECHANICAL SEALS
5.2 RECOMMENDED LINE DIAGRAM: VERTICAL SUSPENDED CANTILEVER PUMPS
5.3 RECOMMENDED LINE DIAGRAM: HORIZONTAL SELF
PRIMING PUMPS
5.4 RECOMMENDED LINE DIAGRAM: RECIPROCATING PLUNGER PUMPS
5.5 RECOMMENDED LINE DIAGRAM SEAL: WATER PUMPS AND INJECTION PUMP SYSTEMS
7.2 TYPICAL ARRANGEMENT OF SEAL WITH NO INJECTION FLUSH
7.3 TYPICAL ARRANGEMENT OF CRANE TYPE 52B WITH 'J' SEAT INCORPORATING TETRALIPS INBOARD AND OUTBOARD
7.4 TYPICAL ARRANGEMENT OF LABYRINTH SEAL FOR VERTICAL SUSPENDED CANTILEVER SHAFT PUMPS
8.1 TYPICAL ARRANGEMENT OF SOFT PACKED GLAND FOR RECIPROCATING PLUNGER PUMPS FOR DELIVERY PRESSURES UP TO 10 BAR G.
12 TEMPERATURES ATTAINED ON DISSOLUTION OF ANHYDROUS CAUSTIC SODA
TABLES
13.1 MATERIALS OF CONSTRUCTION CENTRIFUGAL PUMPS
13.2 MATERIALS OF CONSTRUCTION VERTICAL CANTILEVER
SHAFT IMMERSED PUMPS
13.3 MATERIALS OF CONSTRUCTION RECIPROCATING PLUNGER PUMPS
Introduction
VULCAN Series VHT-S101
Catalyst storage, handling, charging
Health and safety precautions
Start-up of VHT-S101 hydrogenation catalyst
Operation of VHT-S101 hydrogenation catalyst
Shut-down of VHT-S101 hydrogenation catalyst
Sulfiding of hydrodesulfurization catalysts
Catalyst Discharge
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
Revamp objectives
Revamp Philosophy
Revamp options
Semi-Regenerative Reforming Unit
Typical Flow Scheme
Continuous Reforming Unit
Typical Flow Scheme
Revamp to Hybrid Operation
What may be achieved?
Typical C5+ Yield at Decreasing Pressure
Changes Required for Full Conversion
Typical Benefits of Full Conversion
Revamping of Existing Continuous Reforming Units
Fired Heaters Revamp
Burners
Reactor Options
Regeneration Section
Summary
Methanator Water Wash Procedures
To avoid nickel carbonyl formation, it is preferable to heat the catalyst above 400oF in nitrogen or some other CO free gas. If this is impractical and the catalyst must be heated with process gas, low pressure, high rate heating should be employed. The gas must be vented at a height and ideally flared. Care should be taken to ensure all methanator and local drains are shut.
Similar to Ammonia Synthesis Catalyst Chemistry and Operator Training (20)
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy GasesGerard B. Hawkins
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
This Process Safety Guide has been written with the aim of assisting process engineers, hazard analysts and environmental advisers in carrying out gas dispersion calculations. The Guide aims to provide assistance by:
• Improving awareness of the range of dispersion models available within GBHE, and providing guidance in choosing the most appropriate model for a particular application.
• Providing guidance to ensure that source terms and other model inputs are correctly specified, and the models are used within their range of applicability.
• Providing guidance to deal with particular topics in gas dispersion such as dense gas dispersion, complex terrain, and modeling the chemistry of oxides of nitrogen.
• Providing general background on air quality and dispersion modeling issues such as meteorology and air quality standards.
• Providing example calculations for real practical problems.
SCOPE
The gas dispersion guide contains the following Parts:
1 Fundamentals of meteorology.
2 Overview of air quality standards.
3 Comparison between different air quality models.
4 Designing a stack.
5 Dense gas dispersion.
6 Calculation of source terms.
7 Building wake effects.
8 Overview of the chemistry of the oxides of nitrogen.
9 Overview of the ADMS complex terrain module.
10 Overview of the ADMS deposition module.
11 ADMS examples.
12 Modeling odorous releases.
13 Bibliography of useful gas dispersion books and reports.
14 Glossary of gas dispersion modeling terms.
Appendix A : Modeling Wind Generation of Particulates.
APPENDIX B TABLE OF PROPERTY VALUES FOR SPECIFIC CHEMICALS
Ammonia Plant Technology
Pre-Commissioning Best Practices
GBHE-APT-0102
PICKLING & PASSIVATION
CONTENTS
1 PURPOSE OF THE WORK
2 CHEMICAL CONCEPT
3 TECHNICAL CONCEPT
4 WASTES & SAFETY CONCEPT
5 TARGET RESULTS
6 THE GENERAL CLEANING SEQUENCE MANAGEMENT
6.6.1 Pre-cleaning or “Physical Cleaning
6.6.2 Pre-rinsing
6.6.3 Chemical Cleaning
6.6.4 Critical Factors in Cleaning Success
6.6.5 Rinsing
6.6.6 Inspection and Re-Cleaning, if Necessary
7 Systems to be treated by Pickling/Passivation
Ammonia Plant Technology
Pre-Commissioning Best Practices
Piping and Vessels Flushing and Cleaning Procedure
CONTENTS
1 Scope
2 Aim/purpose
3 Responsibilities
4 Procedure
4.1 Main cleaning methods
4.1.1 Mechanical cleaning
4.1.2 Cleaning with air
4.1.3 Cleaning with steam (for steam networks only)
4.1.4 Cleaning with water
4.2 Choice of the cleaning method
4.3 Cleaning preparation
4.4 Protection of the devices included in the network
4.5 Protection of devices in the vicinity of the network
4.6 Water flushing procedure
4.6.1 Specific problems of water flushing
4.6.2 Preparation for water flushing
4.6.3 Performing a water flush
4.6.4 Cleanliness criteria
4.7 Air blowing procedure
4.7.1 Specific problems of air blowing
4.7.2 Preparation for air blowing
4.7.3 Performing air blowing
4.7.4 Cleanliness checks
4.8 Steam blowing procedure
4.8.1 Specific problems of steam blowing
4.8.2 Preparation for steam blowing
4.8.3 Performing steam blowing
4.8.4 Cleanliness checks
4.9 Chemical cleaning procedure
4.9.1 Specific problems of cleaning with a chemical solution
4.9.2 Preparation for chemical cleaning
4.9.3 Performing a chemical cleaning
4.9.4 Cleanliness criteria
4.10 Re-assembly - general guideline
4.11 Preservation of flushed piping
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
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
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...Gerard B. Hawkins
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs)
FOREWORD
CONTENTS
1 INTRODUCTION
2 THE NEED FOR VOC CONTROL
3 CONTROL AT SOURCE
3.1 Choice or Solvent
3.2 Venting Arrangements
3.3 Nitrogen Blanketing
3.4 Pump Versus Pneumatic Transfer
3.5 Batch Charging
3.6 Reduction of Volumetric Flow
3.7 Stock Tank Design
4 DISCHARGE MEASUREMENT
4.1 By Inference or Calculation
4.2 Flow Monitoring Equipment
4.3 Analytical Instruments
4.4 Vent Emissions Database
5 ABATEMENT TECHNOLOGY
5.1 Available Options
5.2 Selection of Preferred Option
5.3 Condensation
5.4 Adsorption
5.5 Absorption
5.6 Thermal Incineration
5.7 Catalytic Oxidation
5.8 Biological Filtration
5.9 Combinations of Process technologies
5.10 Processes Under Development
6 GLOSSARY OF TERMS
7 REFERENCES
Appendix 1. Photochemical Ozone Creation Potentials
Appendix 2. Examples of Adsorption Preliminary Calculations
Appendix 3. Example of Thermal Incineration Heat and Mass Balance
Appendix 4. Cost Correlations
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
EMERGENCY ISOLATION OF CHEMICAL PLANTS
CONTENTS
1 Introduction
2 When should Emergency Isolation Valves be Installed
3 Emergency Isolation Valves and Associated Equipment
3.1 Installations on existing plant
3.2 Actuators
3.3 Power to close or power to open
3.4 The need for testing
3.5 Hand operated Emergency Valves
3.6 The need to stop pumps in an emergency
3.7 Location of Operating Buttons
3.8 Use of control valves for Isolation
4 Detection of Leaks and Fires
5 Precautions during Maintenance
6 Training Operators to use Emergency Isolation Valves
7 Emergency Isolation when no remotely operated valve is available
References
Glossary
Appendix I Some Fires or Serious Escapes of Flammable Gases or Liquids that could have been controlled by Emergency Isolation Valves
Appendix II Some typical Installations
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
Burner Design, Operation and Maintenance on Ammonia Plants
Brief History
Reformer Burner Types/Design
Types of Reformers
Combustion Characteristics
Excess Air/Heater Efficiency
Maintenance, Good Practice
Low Nox Equipment
Summary
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...Gerard B. Hawkins
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates
1 Executive Summary
2 Claus Process
2.1 Partial Combustion Claus
2.2 Split Flow Claus
2.3 Sulfur Recycle Claus
3 Zinc Titanates
4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10%
4.1 Process
4.2 ASPEN Modeling Results
4.3 Cost of Zinc Titanate Bed Installation
4.3.1 Basis of Costing
4.3.2 Zinc Titanate Beds
4.3.3 Regen Cooler
4.3.4 Blowers
4.3.5 Results
4.4 Alternative Debottlenecking Technology for Partial Combustion Claus
4.5 Cost of 10% Debottlenecking Using COPE Process
5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates
6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate
7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems
7.1 Selectox
7.2 SuperClaus99
7.3 Superclaus 99.5
7.4 SCOT Process
7.5 Zinc Titanate as a Claus Tail Gas Treatment
7.6 H2S Removal Efficiency With Zinc Titanate
8 Effects on COS and CS2 Formation
9 Questions for further Investigation
FIGURES
Figure 1 Claus Unit and TGCU
Figure 2 Claus Process
Figure 3 Typical Claus Sulfur Recovery Unit
Figure 4 Two-Stage Claus SRU
Figure 5 The Super Claus Process
Figure 6 SCOT
Figure 7 SCOT/BSR-MDEA (or clone) TGCU
REFERENCES: PATENTS
US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT
US4394297_ZINC_TITANATE_CATALYST
US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
Connector Corner: Automate dynamic content and events by pushing a buttonDianaGray10
Here is something new! In our next Connector Corner webinar, we will demonstrate how you can use a single workflow to:
Create a campaign using Mailchimp with merge tags/fields
Send an interactive Slack channel message (using buttons)
Have the message received by managers and peers along with a test email for review
But there’s more:
In a second workflow supporting the same use case, you’ll see:
Your campaign sent to target colleagues for approval
If the “Approve” button is clicked, a Jira/Zendesk ticket is created for the marketing design team
But—if the “Reject” button is pushed, colleagues will be alerted via Slack message
Join us to learn more about this new, human-in-the-loop capability, brought to you by Integration Service connectors.
And...
Speakers:
Akshay Agnihotri, Product Manager
Charlie Greenberg, Host
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
Builder.ai Founder Sachin Dev Duggal's Strategic Approach to Create an Innova...Ramesh Iyer
In today's fast-changing business world, Companies that adapt and embrace new ideas often need help to keep up with the competition. However, fostering a culture of innovation takes much work. It takes vision, leadership and willingness to take risks in the right proportion. Sachin Dev Duggal, co-founder of Builder.ai, has perfected the art of this balance, creating a company culture where creativity and growth are nurtured at each stage.
LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
Slack (or Teams) Automation for Bonterra Impact Management (fka Social Soluti...Jeffrey Haguewood
Sidekick Solutions uses Bonterra Impact Management (fka Social Solutions Apricot) and automation solutions to integrate data for business workflows.
We believe integration and automation are essential to user experience and the promise of efficient work through technology. Automation is the critical ingredient to realizing that full vision. We develop integration products and services for Bonterra Case Management software to support the deployment of automations for a variety of use cases.
This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
"Impact of front-end architecture on development cost", Viktor TurskyiFwdays
I have heard many times that architecture is not important for the front-end. Also, many times I have seen how developers implement features on the front-end just following the standard rules for a framework and think that this is enough to successfully launch the project, and then the project fails. How to prevent this and what approach to choose? I have launched dozens of complex projects and during the talk we will analyze which approaches have worked for me and which have not.
Let's dive deeper into the world of ODC! Ricardo Alves (OutSystems) will join us to tell all about the new Data Fabric. After that, Sezen de Bruijn (OutSystems) will get into the details on how to best design a sturdy architecture within ODC.
DevOps and Testing slides at DASA ConnectKari Kakkonen
My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
JMeter webinar - integration with InfluxDB and GrafanaRTTS
Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overview
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
To view the webinar recording, go to:
https://www.rttsweb.com/jmeter-integration-webinar
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
Speakers:
👨🏫 Andras Palfi, Senior Product Manager, UiPath
👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
Neuro-symbolic is not enough, we need neuro-*semantic*Frank van Harmelen
Neuro-symbolic (NeSy) AI is on the rise. However, simply machine learning on just any symbolic structure is not sufficient to really harvest the gains of NeSy. These will only be gained when the symbolic structures have an actual semantics. I give an operational definition of semantics as “predictable inference”.
All of this illustrated with link prediction over knowledge graphs, but the argument is general.
Neuro-symbolic is not enough, we need neuro-*semantic*
Ammonia Synthesis Catalyst Chemistry and Operator Training
1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation
Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst
Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing &
Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology - Ammonia Catalyst / Process
Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New
Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Ammonia Synthesis Catalyst (VSG-A101)
Chemistry and Operator Training
by:
Gerard B. Hawkins
Managing Director, CEO
2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation
Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst
Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing &
Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology - Ammonia Catalyst / Process
Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New
Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
VSG-A101 Ammonia Synthesis Chemistry and Catalysis
Reaction stoichiometry and thermodynamics
Ammonia synthesis catalyst fundamentals
Molecular mechanism and kinetics
Activation and deactivation
Alternative catalyst technologies
Reaction stoichiometry and thermodynamics
NH3 synthesis reaction
N2 + 3 H2 2 NH3 DH700°K = - 52 kJ/mol
Equilibrium position favors NH3 synthesis at
• High pressure
• Low temperature
Pressure depends on capital and operating cost
Temperature depends on the balance of kinetics/equilibrium
P & T also depend on available catalyst activity
3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation
Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst
Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing &
Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology - Ammonia Catalyst / Process
Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New
Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
0
5
10
15
20
25
30
35
40
50 75 100 125 150
Pressure bara
NH3concentration%
380 C
400 C
420 C
4. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation
Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst
Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing &
Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology - Ammonia Catalyst / Process
Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New
Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
VSG-A101 Ammonia synthesis catalyst fundamentals
VSG-A101 Ammonia Synthesis Catalyst - Formulation
Based on magnetite (Fe3O4) precursor
Defined form and crystal structure
Magnetite requires controlled reduction
Pre-reduction or in situ reduction
Oxygen is removed from the crystal lattice without shrinkage
Produces extremely porous metallic iron structure
Key in achieving a high activity catalyst
Promoters boost catalyst performance
VSG-A101 Ammonia Synthesis Catalyst - Requirements
High catalyst activity
Low sensitivity to catalyst poisons
High thermal resistance
Reasonable reduction time
High mechanical strength and abrasion resistance
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VSG-A101 Ammonia Synthesis Catalyst - Production
Unique manufacturing process
Catalyst is not made via pelleting or extrusion
Components are mixed including promoters
Feed is melted in an electric arc furnace
Solidified melt is milled to give required shape and size distribution
Melt conditions are key to produce required Fe3O4 precursor phases and
morphology
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Catalyst Type
Vulcan VSG-A101 Comp J Comp J Comp H Comp H
Fe 0.5 - 0.6 - 80 - 80
Fe3O4 67 - 69.5 95 12 - 13 94.5 ~10
Al2O3 2.2 - 2.6 2.5 3.3 2.1 2.8
CaO 1.4 1.8 2 2.5 1.5 2
K2O 0.6 - 0.8 0.8 1 0.6 0.8
SiO2 < 0.5 0.25 0.3 <0.2 <0.2
MgO - 0.25 0.3 - -
Co - - 1 1.3
Cl <0.0001 <0.001 <0.001 <0.001 <0.001
S <0.0001 <0.001 <0.001 <0.001 <0.001
VSG-A101 Ammonia Synthesis Catalyst - Incorporation of Promoters
Certain metal oxides promote activity and improve stability
Small and controlled amounts
Alumina and potash are the most important
Al2O3 is a ‘structural’ promoter
Restricts growth of iron crystallites during reduction and operation
Increases thermal stability
Alkali metals are ‘electronic promoters’
Greatly increase activity of the iron particles
K particularly effective
Other promoters include CaO, SiO2
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Contaminants in the magnetite raw material
Must be considered and controlled during manufacture
Ensures optimum concentration of promoters
Ammonia Synthesis Catalyst - Effect of Promoters and Stabilizers
Al2O3 - stabilizes the internal surface
SiO2 - stabilizes activity in presence of oxygen compounds during normal
operation and reduction
K2O - increases intrinsic activity of Fe particles
CaO - protects the K promoter against neutralization and increases the stability
against poisoning by sulfur
Typical Operating Conditions
Temperature 360 - 530°C (680 – 986°F)
Pressure 100 - 600 bara
Space velocity 1000 - 5000 hr-1
Poisons limits
Oxygen and oxygen compounds normally 3 ppmv
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Typical Converter Temperatures
Converter Heat Recovery
Heat recovered is that available from synthesis exotherm across synthesis beds
Catalyst bed temperatures usually similar
Bed 1 410 – 520°C ΔT = 110 °C
Bed 2 415 – 480°C ΔT = 65 °C
Bed 3 410 – 450°C ΔT = 40 °C
Total Bed ΔT = Converter ΔT = 215 °C
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VSG-A101 Ammonia Synthesis Chemistry
Reaction Progress across Beds
VSG-A101 Ammonia Synthesis Catalyst - Effect of Size on Activity
Smaller pellets have higher activity
Reaction is subject to diffusion limitations
Film diffusion and pore diffusion effects
Thus, smaller means higher production (closer ATE) or lower catalyst volume
But higher pressure drop
use either axial-radial or radial flow beds to minimize
Basis of many converter internal retrofits
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VSG-A101 Ammonia Synthesis Catalyst - Effect of Size on Activity
Ammonia Synthesis Catalyst - Catalyst Size Options
Size Grade Size
A 1.5 - 3.0 mm
B 3.0 - 4.5 mm
C 3.0 - 6.0 mm
D 6.0 - 10.0 mm
G 14.0 - 20.0 mm
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Molecular mechanism and kinetics
Ammonia Synthesis Mechanism
Dissociative adsorption of H2
Dissociative adsorption of N2 - believed to be the Rate Determining Step (RDS)
Multi-step hydrogenation of adsorbed N2 Desorption of NH3
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Ammonia Synthesis Kinetics
Detailed studies on intrinsic reaction rate
Influential work by Temkin et al.
Actual rate subject to diffusion limitations
Film diffusion and pore diffusion effects
Activation and deactivation
Catalyst Reduction
Depends on catalyst type
E.g. pre-reduced or oxide form
E.g. VSG-A101, Comp H, Comp J
Raise T in first bed to 350°C* (300°C #
), then slowly upwards @ 10°C/h
Control exit H2O level
Maintain downstream beds at 350°C* (300°C#
)
NH3 synthesis initiates as the catalyst reduces
Once H2O falls, heat 2nd
bed and repeat
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VSG-A101 Deactivation – Background
Temperature
Re-crystallization of iron surface occurs slowly
Thermal sintering process
Minimize operating temperature
Commensurate with maintenance of conversion
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VSG-A101 Deactivation - Common Poisons
Oxygenated species (H2O, CO, CO2)
Converted to H2O
Sintering/re-organization of catalyst surface
Temporary
Low level/short duration (days)
Permanent
High levels/weeks to months
Sulfur
Incorporation of Ca promoter enhances stability of catalyst
Arsenic, Antimony and Phosphorus
Chlorine
Formation of volatile metal chlorides
Lead to KCl formation and loss of K from catalyst
Physical foulants (Fe scale, etc)
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Summary
Thermodynamics, kinetics and reaction mechanism considered
Features of ammonia synthesis catalysts
Activation and deactivation parameters discussed
Brief consideration of non-Fe based commercial catalyst