Catalyst Catastrophes in Syngas Production - I
The Hazards
Review incidents by reactor
Purification….
Through the various unit operations to
Ammonia synthesis
Nickel Carbonyl
Pre-reduced catalysts
Discharging catalysts
Conclusion
The Benefits and Disadvantages of Potash in Steam ReformingGerard B. Hawkins
Why do we include potash ?
What are the benefits ?
What are the disadvantages ?
Catalyst Deactivation
Carbon Deposition : Thermodynamics & Kinetics
Carbon formation margin
Reaction chemistry (Tube inlet)
Hydrocarbons undergo cracking reactions on hot surfaces at the tube inlet
Products of catalytic cracking reactions can form polymeric carbon
- Process effects of pre-reforming
- Process benefits of pre-reforming
- Effect of Pre-reformer Inlet Temp on Primary Reformer Efficiency
- Services for Pre-reforming
Pre-Reforming Problems
- Features: Impact of Sulfur
- High Temperature Operation
- Catalyst Deactivation
- Which is Better - High or Low Inlet Temperatures ?
- Pre Reformer Loading
- Pre-Reformer Installation
- Pre-reformer Startup
- Catalyst Drying
- Catalyst Heating
- Reduction
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
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.
The Benefits and Disadvantages of Potash in Steam ReformingGerard B. Hawkins
Why do we include potash ?
What are the benefits ?
What are the disadvantages ?
Catalyst Deactivation
Carbon Deposition : Thermodynamics & Kinetics
Carbon formation margin
Reaction chemistry (Tube inlet)
Hydrocarbons undergo cracking reactions on hot surfaces at the tube inlet
Products of catalytic cracking reactions can form polymeric carbon
- Process effects of pre-reforming
- Process benefits of pre-reforming
- Effect of Pre-reformer Inlet Temp on Primary Reformer Efficiency
- Services for Pre-reforming
Pre-Reforming Problems
- Features: Impact of Sulfur
- High Temperature Operation
- Catalyst Deactivation
- Which is Better - High or Low Inlet Temperatures ?
- Pre Reformer Loading
- Pre-Reformer Installation
- Pre-reformer Startup
- Catalyst Drying
- Catalyst Heating
- Reduction
Look at two main types
Explain mechanisms
Explain prevention of cracking
Three main types
1 Carbon cracking
2 Boudouard carbon formation
3 CO reduction
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.
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
(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
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
Common poisons include
Sulfur
Chlorides and other halides
Metals including arsenic, vanadium, mercury, alkali metals (including potassium)
Phosphates
Organo-metalics
Catalyst Catastrophes in Syngas Production - II
Contents
Review of incidents by reactor
Primary reforming
Secondary reforming
HTS
LTS
Methanator
Reactor loading
Support media
Some general comments on alternative actions when a plant gets into abnormal operation
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
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
Pre-reforming
Flow-schemes
Feed-stocks
Catalyst handling, loading & start-up
Benefits of a pre-reformer
Case studies
Effects upon primary reformer
Data analysis
Reactor temperature profiles
Catalyst management
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
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
Market Segment by Regions, this report splits Global into several key Regions, with sales (consumption), revenue, market share and growth rate of Refinery Fluid Catalytic Cracking Unit in these regions, from 2011 to 2021 (forecast), like
North America
China
Europe
Japan
Southeast Asia
India
Split by product types, with sales, revenue, price, market share and growth rate of each type, can be divided into
Type 1
Type 2
Type 3.
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
(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
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
Common poisons include
Sulfur
Chlorides and other halides
Metals including arsenic, vanadium, mercury, alkali metals (including potassium)
Phosphates
Organo-metalics
Catalyst Catastrophes in Syngas Production - II
Contents
Review of incidents by reactor
Primary reforming
Secondary reforming
HTS
LTS
Methanator
Reactor loading
Support media
Some general comments on alternative actions when a plant gets into abnormal operation
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
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
Pre-reforming
Flow-schemes
Feed-stocks
Catalyst handling, loading & start-up
Benefits of a pre-reformer
Case studies
Effects upon primary reformer
Data analysis
Reactor temperature profiles
Catalyst management
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
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
Market Segment by Regions, this report splits Global into several key Regions, with sales (consumption), revenue, market share and growth rate of Refinery Fluid Catalytic Cracking Unit in these regions, from 2011 to 2021 (forecast), like
North America
China
Europe
Japan
Southeast Asia
India
Split by product types, with sales, revenue, price, market share and growth rate of each type, can be divided into
Type 1
Type 2
Type 3.
Hydrogen Plant Flowsheet - Effects of Low Steam RatioGerard B. Hawkins
Effect of Low Steam Ratio on the Steam Reformer
Effect of Low Steam Ratio on H T Shift & PSA
Effect of Low Steam Ratio on Gross Efficiency
Effect of Low Steam Ratio on Net Efficiency
Alternative schemes for improving heat recovery
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Confined Space Entry
Hazardous Substances In Refineries
Hazards of Air and Oxygen
Hazards of Electricity and Static Electricity
Hazards of Nitrogen and Catalyst Handling
Hazards of Steam
Hazards of Trapped Pressure and Vacuum
Hazards of Water
Hotel Fire Safety
Liquid Hydrocarbon Tank Fires
Safe Handling of Light Ends
Safe Furnace and Boiler Firing
Safe Tank Farms and (Un)loading Operations
Safe Ups and Downs for Process Units
Control of Work
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
This presentation covers frequent and costly incidents related to catalysts mal-operation with the focus of providing the plant operator with recommendations to avoid plant outages and catalyst losses.
Steam Reforming - The Basics of reforming, shapes and carbon:
Steam Reforming Catalysis :
Chemical reactions
Catalyst shape design
Catalyst chemistry
Carbon formation and removal
This slide is about some new green cooling system (refrigeration system) and green refrigerant. For the Ozone layer depletion and green house effect, it is high time to find new refrigerant and refrigeration system.
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
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
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
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
Essentials of Automations: The Art of Triggers and Actions in FMESafe Software
In this second installment of our Essentials of Automations webinar series, we’ll explore the landscape of triggers and actions, guiding you through the nuances of authoring and adapting workspaces for seamless automations. Gain an understanding of the full spectrum of triggers and actions available in FME, empowering you to enhance your workspaces for efficient automation.
We’ll kick things off by showcasing the most commonly used event-based triggers, introducing you to various automation workflows like manual triggers, schedules, directory watchers, and more. Plus, see how these elements play out in real scenarios.
Whether you’re tweaking your current setup or building from the ground up, this session will arm you with the tools and insights needed to transform your FME usage into a powerhouse of productivity. Join us to discover effective strategies that simplify complex processes, enhancing your productivity and transforming your data management practices with FME. Let’s turn complexity into clarity and make your workspaces work wonders!
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
Alt. GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using ...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Enhancing Performance with Globus and the Science DMZGlobus
ESnet has led the way in helping national facilities—and many other institutions in the research community—configure Science DMZs and troubleshoot network issues to maximize data transfer performance. In this talk we will present a summary of approaches and tips for getting the most out of your network infrastructure using Globus Connect Server.
Generative AI Deep Dive: Advancing from Proof of Concept to ProductionAggregage
Join Maher Hanafi, VP of Engineering at Betterworks, in this new session where he'll share a practical framework to transform Gen AI prototypes into impactful products! He'll delve into the complexities of data collection and management, model selection and optimization, and ensuring security, scalability, and responsible use.
Encryption in Microsoft 365 - ExpertsLive Netherlands 2024Albert Hoitingh
In this session I delve into the encryption technology used in Microsoft 365 and Microsoft Purview. Including the concepts of Customer Key and Double Key Encryption.
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Welcome to the first live UiPath Community Day Dubai! Join us for this unique occasion to meet our local and global UiPath Community and leaders. You will get a full view of the MEA region's automation landscape and the AI Powered automation technology capabilities of UiPath. Also, hosted by our local partners Marc Ellis, you will enjoy a half-day packed with industry insights and automation peers networking.
📕 Curious on our agenda? Wait no more!
10:00 Welcome note - UiPath Community in Dubai
Lovely Sinha, UiPath Community Chapter Leader, UiPath MVPx3, Hyper-automation Consultant, First Abu Dhabi Bank
10:20 A UiPath cross-region MEA overview
Ashraf El Zarka, VP and Managing Director MEA, UiPath
10:35: Customer Success Journey
Deepthi Deepak, Head of Intelligent Automation CoE, First Abu Dhabi Bank
11:15 The UiPath approach to GenAI with our three principles: improve accuracy, supercharge productivity, and automate more
Boris Krumrey, Global VP, Automation Innovation, UiPath
12:15 To discover how Marc Ellis leverages tech-driven solutions in recruitment and managed services.
Brendan Lingam, Director of Sales and Business Development, Marc Ellis
SAP Sapphire 2024 - ASUG301 building better apps with SAP Fiori.pdfPeter Spielvogel
Building better applications for business users with SAP Fiori.
• What is SAP Fiori and why it matters to you
• How a better user experience drives measurable business benefits
• How to get started with SAP Fiori today
• How SAP Fiori elements accelerates application development
• How SAP Build Code includes SAP Fiori tools and other generative artificial intelligence capabilities
• How SAP Fiori paves the way for using AI in SAP apps
Climate Impact of Software Testing at Nordic Testing DaysKari Kakkonen
My slides at Nordic Testing Days 6.6.2024
Climate impact / sustainability of software testing discussed on the talk. ICT and testing must carry their part of global responsibility to help with the climat warming. We can minimize the carbon footprint but we can also have a carbon handprint, a positive impact on the climate. Quality characteristics can be added with sustainability, and then measured continuously. Test environments can be used less, and in smaller scale and on demand. Test techniques can be used in optimizing or minimizing number of tests. Test automation can be used to speed up testing.
Observability Concepts EVERY Developer Should Know -- DeveloperWeek Europe.pdfPaige Cruz
Monitoring and observability aren’t traditionally found in software curriculums and many of us cobble this knowledge together from whatever vendor or ecosystem we were first introduced to and whatever is a part of your current company’s observability stack.
While the dev and ops silo continues to crumble….many organizations still relegate monitoring & observability as the purview of ops, infra and SRE teams. This is a mistake - achieving a highly observable system requires collaboration up and down the stack.
I, a former op, would like to extend an invitation to all application developers to join the observability party will share these foundational concepts to build on:
The Metaverse and AI: how can decision-makers harness the Metaverse for their...Jen Stirrup
The Metaverse is popularized in science fiction, and now it is becoming closer to being a part of our daily lives through the use of social media and shopping companies. How can businesses survive in a world where Artificial Intelligence is becoming the present as well as the future of technology, and how does the Metaverse fit into business strategy when futurist ideas are developing into reality at accelerated rates? How do we do this when our data isn't up to scratch? How can we move towards success with our data so we are set up for the Metaverse when it arrives?
How can you help your company evolve, adapt, and succeed using Artificial Intelligence and the Metaverse to stay ahead of the competition? What are the potential issues, complications, and benefits that these technologies could bring to us and our organizations? In this session, Jen Stirrup will explain how to start thinking about these technologies as an organisation.
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.
2. The Hazards
Review incidents by reactor
◦ Purification….
◦ Through the various unit operations to
◦ Ammonia synthesis
Nickel Carbonyl
Pre-reduced catalysts
Discharging catalysts
Conclusion
www.gbhenterprises.com
3. Catalysts are pretty reactive! They are designed
to be so!
Under normal conditions they get on and do the
job they were designed to do
However if we give them the opportunity they will
also perform other reactions
◦ many of which generate large amounts of heat
◦ others produce toxic materials
◦ or other dangers to life/equipment
www.gbhenterprises.com
4. Hydrodesulfurization (CoMo NiMo)
◦ can hydro-crack higher hydrocarbons - exothermic
◦ can form carbon from CO2 via reverse shift to CO and
carbon via the Boudourd reaction
Ultra-purification
◦ similar hazards to other copper catalysts
exothermic reduction
exothermic oxidation (both Cu and CuS)
www.gbhenterprises.com
5. Hydrogen plant with two low sulfur feeds:
◦ high hydrogen content
◦ butane
HDS heated to 350°C(662°F) with hydrogen feed
50°C(90°F) exotherm observed – reduction?
Then butane was commissioned
Exotherm developed, went off-scale
◦ ruined catalyst, covered with carbon
◦ could have reached 700°C(1292°F)
www.gbhenterprises.com
6. Avoid high partial pressures of hydrogen on
unsulfided HDS catalysts above 200-300°C(392-
572°F)
Recognize the potential for hydrocracking of higher
hydrocarbons with hydrogen
◦ particularly if HDS catalysts are reduced
www.gbhenterprises.com
7. Nickel carbonyl
Oxidation – exothermic
Can break up when wetted causing high pressure
drop
◦ Note potential damage from rapid drying
www.gbhenterprises.com
9. Significant loss of tubes on start-up
◦ happens every year
Invariably firing > heat removal
Usually deviation from normal start-up procedures
◦ e.g quick recovery from trip condition
Low flow means tube temperature measurements
are unreliable
www.gbhenterprises.com
11. Be super vigilant during start-ups
Have a look (carefully)
‘Stop and Think’ if you deviate from established
procedures
Establish steam flow before flue-gas temperatures
reach 500°C(932°F) to provide heat-sink and
improved temperature indication
www.gbhenterprises.com
12. Above 500°C (932°F) the Boudouard reaction will
go quickly!
2CO → C + CO2
Do not allow steam ratio below 2.5/1.5
Whisker carbon can form within the pores and
cause the outer layer of catalyst to break off -
similar to metal dusting but much faster
www.gbhenterprises.com
13. Lesson
◦ do not run with low S/C ratio trip bypassed
www.gbhenterprises.com
14. Wetting is unusual - although some older plants
loaded catalyst into tubes full of water
Rapid drying is a problem for all catalysts as
steam pressure generated within the pellet can
break it apart
Also if one can break reforming catalysts this way
then all other catalysts are more susceptible
www.gbhenterprises.com
15. A plant underestimated the extent of condensation
in the early part of their start-up and then continued
as normal assuming normal rates of heating would
dry the catalyst
The net effect was a pressure drop build up due to
broken catalyst - particularly in the bottom of the
tubes where catalyst had been flooded with
condensate
www.gbhenterprises.com
17. If you get catalyst wet - dry it carefully
www.gbhenterprises.com
18. In addition to the obvious explosion hazard - Air
addition without combustion can lead to vessel
damage from exotherms in high/low temperature
shift
◦ Air oxidation of HTS catalysts can generate temperatures
of 800°C(1472°F)
Lessons
◦ Prevent air feed until secondary temperature is above the
auto-ignition temperature around 650°C(1202°F)
◦ Review quality of air isolation
most secure philosophy - double block with high pressure
steam between the valves
www.gbhenterprises.com
22. Caused by dehydration - usually due to extended
nitrogen circulation during plant commissioning
Lesson
◦ If you hold fresh HTS under dry nitrogen for an extended
period (days) introduce steam gradually
1st Steam
Introduced
0 20 40 60 80 100
250
300
350
400
450
500
600
700
800
Time, minutes
Temperature(°C)
Temperature(°F)
Inlet
Top
Mid
Bot
www.gbhenterprises.com
23. Lesson
◦ if you have a severe boiler leak dry the catalyst carefully
before going back on line
HTS TEMPERATURE PROFILE BEFORE/AFTER
WETTING
360
380
400
420
440
0.0 20.0 40.0 60.0 80.0 100.0
% BED DEPTH
TEMPERATURE,°C
Dec-02
Jan-03
Pressure drop after = same as before
www.gbhenterprises.com
25. N2 carrier - temperature rise 30°C(54°F) per %
hydrogen
NG carrier - temperature rise 20°C(36°F) per %
hydrogen
NG carrier - additional hazard from catalytic
oxidation of natural gas
Lessons
◦ Closely monitor temperature/hydrogen concentration
◦ With NG carrier keep temperatures below 230°C(450°F)
www.gbhenterprises.com
26. Has the potential to generate temperatures over
900°C(1652°F)
Lesson
◦ Ensure process air cannot reach LTS
www.gbhenterprises.com
27. Some catalysts will break up on contact with water
Water will also wash chlorides down the bed
shortening catalyst lives
Lessons
◦ Ensure quench systems working properly
◦ Ensure secure isolation from process gas during
start-up when LTS is cold
www.gbhenterprises.com
28. Nickel carbonyl (see later)
Overheating
◦ temperature rise 74°C(133°F)/ %CO, 60°C(108°F)/
%CO2
◦ around 4% carbon oxides will raise temperature to vessel
limit
◦ First line of protection is LTS and CO2 removal
LTS failure is probably OK if HTS working
CO2 removal failure can quickly generate temperatures over
700°C(1292°F)
www.gbhenterprises.com
29. ◦ Final protection is the high temperature trip
note thermocouple must be set in relation to exotherm
if thermocouple too near inlet or catalyst deactivated may not
respond
if too far down the bed may respond too late
Lesson
◦ Ensure CO2 removal and methanator trips are working
and the trip thermocouple is in the correct position
www.gbhenterprises.com
30. Hydrogen plant tripped - due to cat in switch-
house
Cause was clearly identified, quickly remedied
Priority is to get the plant back on line
All reactors are still hot so should be able to turn
all back on and recover quickly
OK?
Is this a familiar or unfamiliar task?
What happens next?
www.gbhenterprises.com
31. Methanator temperature goes off-scale
Vessel ruptures, catalyst pouring out of the hole
Cause believed to be delay is establishing liquid
hold-up in CO2 absorber
www.gbhenterprises.com
32. Oxidation can generate temperatures above
1600°C(2900°F) - see later
During shutdowns loop boilers can be at higher
pressures and leak into the loop
◦ Water/oxygen deactivates these catalysts
Lesson
◦ During shutdowns isolate and drain loop equipment
containing water
www.gbhenterprises.com
33. Odorless, colorless, OEL/PEL 0.001ppm
Will form on any Nickel catalyst in the presence of
CO at low temperature
Key rule - never expose nickel catalysts to CO
below 200°C(392°F)
www.gbhenterprises.com
34. A CO plant was shut down, the reformer
depressurized and a CO containing feed isolated
The reformer pressure was seen to rise
◦ passing isolation valve
When the pressure was vented to flare the flame
went black
Fortunately those involved realised that Nickel
Carbonyl was a likely cause
This was confirmed and led to a costly
decontamination process
www.gbhenterprises.com
35. Early days of ammonia manufacture in Europe 6
men were injured by Nickel carbonyl
The plant was forced to shut down due to a severe
leak in the waste heat boiler after the secondary
◦ the HTS stopped reacting (too cold) so the process gas
was blown off and methanator isolated under N2
It then became necessary to fit a slip plate into the
methanator exit line
◦ So the N2 purge was stopped
◦ temperature is now 25°C(77°F)
www.gbhenterprises.com
36. While work was progressing it is believed that process
gas entered the methanator via a passing isolation valve
and formed carbonyl
The 6 men injured were working on the joint or in the
immediate vicinity
One analysis showed a carbonyl concentration of
5800ppm - 5 million times the OEL
Lesson
◦ consider using breathing apparatus when breaking into
lines close to the methanator
www.gbhenterprises.com
37. The stabilization of pre-reduced catalysts is only
retained at low temperatures.
For transport drum sizes are limited
◦ natural heat losses help limit accumulation of heat
◦ drums also limit availability of oxygen
Reactors are very large drums!
◦ heat can accumulate
◦ we should limit the access to oxygen
◦ also moisture can destabilize pre-reduced catalysts
www.gbhenterprises.com
38. Ammonia converter, just loaded and under nitrogen
needed some welding on the exit pipe work
With the exit and the top manway open a chimney
effect allowed fresh air into the vessel
Self heating started - creating temperatures over
700°C(1292°F)
Lesson
◦ keep pre-reduced catalysts under nitrogen when loaded
www.gbhenterprises.com
39. Catalysts can remove oxygen from air -
asphyxiation risk
Contact with water can generate hydrogen
Carbon and sulfides can self ignite
Absorbed gases can be evolved
In-situ oxidation/ passivation can generate very
high local temperatures
www.gbhenterprises.com
40. This requires high gas flow to quench hot spots that
develop
◦ otherwise local hotspots suck oxygen from the
surroundings
Particularly risky if there has been an
upset/mechanical problem damaging the catalyst
and affecting the flow
www.gbhenterprises.com
41. An ammonia converter catalyst was oxidized in-
situ before discharge
There was no indication of high temperatures
during this process
But local areas had got hotter than
1600°C(2912°F)
www.gbhenterprises.com
42. Lesson
◦ must achieve good flow distribution for in-situ oxidation
www.gbhenterprises.com
43. Most of these incidents occurred during a ‘non-
routine’ or ‘unfamiliar’ activity
A short ‘Stop and Think’ can save lives, equipment
and business
I have used an ‘Unfamiliar Tasks Procedure’ with a
one page form to encourage a ‘Stop and Think’
when anyone got into unfamiliar territory
My personal experience plus the fact that this
procedure is still in use today suggests that it is
worthwhile
www.gbhenterprises.com