Distillation is one of the widely used separation method in most of the Chemical Process Industries. Improper design/ operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products, high energy consumption, etc. This presentation is for learning about the troubleshooting of distillation systems. Through conceptual aspects of the overall distillation system, reader can easily identify the various causes of probable troubles and will be able to suggest their remedial measures.
Concepts of Distillation are covered in the presentation. Though it provides the outlines only, but reader can develop more from this presentation. Distillation is one of the majorly used separation technique in the chemical process industries. It is suitable for two or more miscible liquids with different volatility.
Distillation is one of the widely used separation method in most of the Chemical Process Industries. Improper design/ operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products, high energy consumption, etc. This presentation is for learning about the troubleshooting of packed type distillation systems. Through conceptual aspects of the overall distillation system, reader can easily identify the various causes of probable troubles and will be able to suggest their remedial measures.
Process Flow Diagram includes the equipment, major flow stream and control logic of the chemical process plants. This is the very first document prepared to meet specific plant requirements.
Concepts of Distillation are covered in the presentation. Though it provides the outlines only, but reader can develop more from this presentation. Distillation is one of the majorly used separation technique in the chemical process industries. It is suitable for two or more miscible liquids with different volatility.
Distillation is one of the widely used separation method in most of the Chemical Process Industries. Improper design/ operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products, high energy consumption, etc. This presentation is for learning about the troubleshooting of packed type distillation systems. Through conceptual aspects of the overall distillation system, reader can easily identify the various causes of probable troubles and will be able to suggest their remedial measures.
Process Flow Diagram includes the equipment, major flow stream and control logic of the chemical process plants. This is the very first document prepared to meet specific plant requirements.
Concepts of Heat Exchanger from its applications, heat transfer theory, parts of shell & tube heat exchanger, types of heat exchangers are included here
Need for chemical data and properties
Sources for data tables
Use of standard data tables for property estimation
Vapor Liquid Equilibrium for water system
Use of steam tables
Interpolation
PRODUCTION OPTIMIZATION ASSESSMENT USING THAI, AND VAPEX EOR METHODS BY USING...Mahmood Ajabbar
Nowadays the energy sources generation is getting more difficult by using the enhanced and advanced level of technology around the world and as non-renewable energy oil and gas industries have become the largest and most demanded supplements of energy generation.
In brief, this project utilizes two types of EOR methods which use to produce heavy oil. The first method is the TAHI method which use steam to reduce the viscosity. The second method is the VAPEX method which use solvent to produce the heavy oil with economical way and friendly environment. It has bee got the RF for VAPEX IS around 62%, and for THAI is 71%. After comparing the both results in term of ability, now will compared it in terms of economics, the THAI method has profit which is 211.96×10^6 Dollars, and the VAPEX method is around 184.04×10^6$. So, the best method for this reservoir is the THAI method.
Presentation given by Dr Carolina Font Palma from University of Leeds on "Oxyfuel Power Plant with Novel CO2 Separation and Compression Technology" in the Process Engineering Technical Session at the UKCCSRC Biannual Meeting - CCS in the Bigger Picture - held in Cambridge on 2-3 April 2014
Presentation given by Laurence Robinson of E.ON Technologies (Ratcliffe) Limited on "OCTAVIUS - Optimisation of CO2 capture technology allowing verification and implementation at utility scale" at the EC FP7 Projects: Leading the way in CCS implementation event, London, 14-15 April 2014
Air monitoring data for the City of Rhinelander, WI shows SO2 concentrations exceeding the 1-hour standard at the water tower monitoring location (WTM) and, as a result, this area has been designated a SO2 non-attainment area. An analysis of emission sources and air quality modeling indicates that the Expera Rhinelander Mill 63 m tall cyclone boiler stack (S09) appears to be the primary contributor to the ambient air impact at this monitor. One solution being evaluated for showing compliance with the 1-hr SO2 NAAQS is raising the 63 m tall S09 stack to the GEP stack height. Based on the Boiler 7 building dimensions the formula GEP stack height is 75 m.
After investigating the Expera Rhinelander Mill building geometry, it was noticed that the Boiler 7 building corner is directly upwind of the stack when the wind blows directly toward the WTM. When the wind blows along a building corner, building corner vortices are generated that enhance building downwash by as much as a factor of two over that observed for wind directions normal to a building face. Past wind tunnel results suggest that the actual GEP stack height could be up to 95 m for this corner vortex situation. Hence, the purpose of this study was to determine the actual GEP stack height for the Expera Rhinelander Mill cyclone boiler stack (S09) using wind tunnel modeling.
This paper provides detailed information on determining GEP stack height, outlines the wind tunnel modeling method required to demonstrate a GEP stack height taller than the EPA formula height and provides detailed results documenting that a 90 m stack height is creditable as GEP which is well above the 75 m EPA formula height. As part of the GEP stack height demonstration, results are provided that document that the wind tunnel simulation provides similar turbulence and dispersion characteristics as the atmosphere.
Fired heaters and its auxiliaries are an essential component in the Chemical Process Industries (CPI). Fired heaters are primarily used to heat hydrocarbons. They are one of the major consumers of energy and hence, it is indispensable for such systems to have efficient operation.
Furnace Improvements Services has a specialist CFD team for modelling fired heater systems. We have developed best practices for each of the above cases and have successfully implemented various recommendations from CFD simulations.
Computational Fluid Dynamics (CFD) Modelling for Designing & Troubleshooting ...AmarvirChilka
Fired heaters and its auxiliaries are an essential component in the Chemical Process Industries (CPI). Fired heaters are primarily used to heat hydrocarbons. They are one of the major consumers of energy and hence, it is indispensable for such systems to have efficient operation.
Furnace Improvements Services has a specialist CFD team for modelling fired heater systems. We have developed best practices for each of the above cases and have successfully implemented various recommendations from CFD simulations.
A Silicon-to-System Thermo-Mechanical Review of ElectronicsKamal Karimanal
A Silicon-to-System Review of Thermo-Mechanical Considerations in Electronics
Author: Kamal Karimanal, Cielution LLC
Thermal and Mechanical challenges to IC package reliability has been addressed with a sufficiently working system of information exchange across a supply chain that spans the foundries to system level assembly plants.The never ending market demand for miniaturization, performance, functionality and cost reduction invariably translates to manufacturing, design, assembly, and reliability challenges to the engineer. Within the Thermal and Mechanical realm these challenges manifest to the engineer in the form of seemingly disconnected problems areas such as BEOL yield, flipchip interconnect reliability, warpage mitigation, heat sink retention design, interface choice, thermally aware board and chassis layout, fan sizing and system level optimization. Evolving technology also introduces newer puzzles such as heterogeneous packaging using 3D ICs. The talk will focus on the tools, methodologies and information exchange protocols used by the thermal management and mechanical reliability professionals across the supply chain to address the various challenges.
Flex Process undertook a detail dynamic modelling study of a refinery distillation column which had undergone some unexpected process disruptions. Using Dynsim, we were able to identify the cause of previously unexplained events, and provide recommendations to ensure safe operation in the future.
Concepts of Heat Exchanger from its applications, heat transfer theory, parts of shell & tube heat exchanger, types of heat exchangers are included here
Need for chemical data and properties
Sources for data tables
Use of standard data tables for property estimation
Vapor Liquid Equilibrium for water system
Use of steam tables
Interpolation
PRODUCTION OPTIMIZATION ASSESSMENT USING THAI, AND VAPEX EOR METHODS BY USING...Mahmood Ajabbar
Nowadays the energy sources generation is getting more difficult by using the enhanced and advanced level of technology around the world and as non-renewable energy oil and gas industries have become the largest and most demanded supplements of energy generation.
In brief, this project utilizes two types of EOR methods which use to produce heavy oil. The first method is the TAHI method which use steam to reduce the viscosity. The second method is the VAPEX method which use solvent to produce the heavy oil with economical way and friendly environment. It has bee got the RF for VAPEX IS around 62%, and for THAI is 71%. After comparing the both results in term of ability, now will compared it in terms of economics, the THAI method has profit which is 211.96×10^6 Dollars, and the VAPEX method is around 184.04×10^6$. So, the best method for this reservoir is the THAI method.
Presentation given by Dr Carolina Font Palma from University of Leeds on "Oxyfuel Power Plant with Novel CO2 Separation and Compression Technology" in the Process Engineering Technical Session at the UKCCSRC Biannual Meeting - CCS in the Bigger Picture - held in Cambridge on 2-3 April 2014
Presentation given by Laurence Robinson of E.ON Technologies (Ratcliffe) Limited on "OCTAVIUS - Optimisation of CO2 capture technology allowing verification and implementation at utility scale" at the EC FP7 Projects: Leading the way in CCS implementation event, London, 14-15 April 2014
Air monitoring data for the City of Rhinelander, WI shows SO2 concentrations exceeding the 1-hour standard at the water tower monitoring location (WTM) and, as a result, this area has been designated a SO2 non-attainment area. An analysis of emission sources and air quality modeling indicates that the Expera Rhinelander Mill 63 m tall cyclone boiler stack (S09) appears to be the primary contributor to the ambient air impact at this monitor. One solution being evaluated for showing compliance with the 1-hr SO2 NAAQS is raising the 63 m tall S09 stack to the GEP stack height. Based on the Boiler 7 building dimensions the formula GEP stack height is 75 m.
After investigating the Expera Rhinelander Mill building geometry, it was noticed that the Boiler 7 building corner is directly upwind of the stack when the wind blows directly toward the WTM. When the wind blows along a building corner, building corner vortices are generated that enhance building downwash by as much as a factor of two over that observed for wind directions normal to a building face. Past wind tunnel results suggest that the actual GEP stack height could be up to 95 m for this corner vortex situation. Hence, the purpose of this study was to determine the actual GEP stack height for the Expera Rhinelander Mill cyclone boiler stack (S09) using wind tunnel modeling.
This paper provides detailed information on determining GEP stack height, outlines the wind tunnel modeling method required to demonstrate a GEP stack height taller than the EPA formula height and provides detailed results documenting that a 90 m stack height is creditable as GEP which is well above the 75 m EPA formula height. As part of the GEP stack height demonstration, results are provided that document that the wind tunnel simulation provides similar turbulence and dispersion characteristics as the atmosphere.
Fired heaters and its auxiliaries are an essential component in the Chemical Process Industries (CPI). Fired heaters are primarily used to heat hydrocarbons. They are one of the major consumers of energy and hence, it is indispensable for such systems to have efficient operation.
Furnace Improvements Services has a specialist CFD team for modelling fired heater systems. We have developed best practices for each of the above cases and have successfully implemented various recommendations from CFD simulations.
Computational Fluid Dynamics (CFD) Modelling for Designing & Troubleshooting ...AmarvirChilka
Fired heaters and its auxiliaries are an essential component in the Chemical Process Industries (CPI). Fired heaters are primarily used to heat hydrocarbons. They are one of the major consumers of energy and hence, it is indispensable for such systems to have efficient operation.
Furnace Improvements Services has a specialist CFD team for modelling fired heater systems. We have developed best practices for each of the above cases and have successfully implemented various recommendations from CFD simulations.
A Silicon-to-System Thermo-Mechanical Review of ElectronicsKamal Karimanal
A Silicon-to-System Review of Thermo-Mechanical Considerations in Electronics
Author: Kamal Karimanal, Cielution LLC
Thermal and Mechanical challenges to IC package reliability has been addressed with a sufficiently working system of information exchange across a supply chain that spans the foundries to system level assembly plants.The never ending market demand for miniaturization, performance, functionality and cost reduction invariably translates to manufacturing, design, assembly, and reliability challenges to the engineer. Within the Thermal and Mechanical realm these challenges manifest to the engineer in the form of seemingly disconnected problems areas such as BEOL yield, flipchip interconnect reliability, warpage mitigation, heat sink retention design, interface choice, thermally aware board and chassis layout, fan sizing and system level optimization. Evolving technology also introduces newer puzzles such as heterogeneous packaging using 3D ICs. The talk will focus on the tools, methodologies and information exchange protocols used by the thermal management and mechanical reliability professionals across the supply chain to address the various challenges.
Flex Process undertook a detail dynamic modelling study of a refinery distillation column which had undergone some unexpected process disruptions. Using Dynsim, we were able to identify the cause of previously unexplained events, and provide recommendations to ensure safe operation in the future.
Distillation is one of the widely used separation method in most of the chemical process industries. Improper design
/operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products,
high energy (utility) consumption, etc.
Electric motors and the systems they drive consume electrical energy more than twice as much as lighting, while lighting is typically considered a major low-lying fruit for energy reduction in a factory. It is estimated that motors account for between 43% and 46% of all global electricity consumption particularly from the manufacturing sector. The presentation will cover topics like the effort to ensure the motor efficiency in manufacturing sector; the application of variable speed drives and other factors which affect the motor efficiency such as power quality; and good maintenance regimes for energy reduction
TSV Mining: Variation Analysis in Mining Part 1 - Precision and AccuracyTotius Mining
Variation is one of the largest value destroyers in the mining industry. This presentation shows how to reduce and manage variation using the definitions of Precision and Accuracy.
The ability to remove floating bottlenecks in an operation is linked to the precision of processes, and to the demand placed on them. Often in mining, the cost associated with removing processes from being an occasional bottleneck is higher than the gain in throughput.
Process capacity and inventory requirements are heavily linked to precision, which is rarely reviewed by any mining operations.
This is a slideshow / resource / support material of the course.
Get full access (videlectures)
https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
x-x-x
Requirements
Basic understanding of Plant Design & Operation
Strong Chemical Engineering Fundamentals
Aspen Plus V10 (at least 7.0)
Aspen Plus – Basic Process Modeling (Very Recommended)
Aspen Plus – Intermediate Process Modeling (Somewhat Recommended)
Description
This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes.
It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning.
You will learn about:
Better Flowsheet manipulation and techniques
Understand Property Method Selection and its effects on simulation results
More than 15 Unit Operations that can be used in any Industry
Model Analysis Tools required for process design
Reporting Relevant Results Plot relevant data
Analysis & Optimization of Chemical Plants
Economic Analysis
Dynamic Simulations
At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.
Centrifugal Pumps - Concept E-Learning Program - Study MaterialPankaj Khandelwal
Study Material of Koncept Learning Center's Concept E-Learning Program on Distillation .
The course is directed by Mr. Pankaj Khandelwal
Centrifugal pump is one of the widely used liquid transportation rotary equipment in most of the industries either for the chemical transfer or utilities circulation.
Like any pumps, it also increases fluid energy due to which liquid is transferred from its low energy source to high energy destination. Impeller plays a major role for this purpose. Impeller is driven by the suitable drive either by the electric motor or diesel engine set.
Centrifugal pump supplier’s have their own pump designs while users have vary much varied applications from low flow & high differential pressure to high flow & low differential pressure. Thus the selection of centrifugal pumps is critical. This is done by matching duty point determined by the user and the characteristics curves supplied by the suppliers.
Contents:
1) Why Pump is required?
2) Pumping System
3) Industrial applications
4) Parts of Pumps
5) MWC Concepts
6) Fluid Energy Concepts
7) Cavitation Concepts
8) Characteristics Curves
9) Hydraulic Calculations
10) Pump Selection
For course details - klcenter@gmail.com / www.konceptlearningcenter.com
Call / Whatsapp - 8237829150 or 9371121220
Prithviraj Khandelwal
Distillation - Concept E-Learning Program - Study MaterialPankaj Khandelwal
Study Material of Koncept Learning Center's Concept E-Learning Program on Distillation .
The course is directed by Mr. Pankaj Khandelwal
For course details - klcenter@gmail.com / www.konceptlearningcenter.com
Call / Whatsapp - 8237829150 or 9371121220
Prithviraj Khandelwal
Life Concept Program - "Ownership - Doing Things Own Way" by Pankaj Khandelwal & Prithviraj Khandelwal (Koncept Learning Center)
In-house corporate training program for Leadership Development.
A motivational program to bring about a sense of Ownership in individuals
Program Objective - To bring out Ownership in every individual working in the organizations.
Whether an individual’s way of solving any problem is right or wrong, it can be judged by the ultimate result of success or failure. Surely, they will be fully satisfied with their approach.
Owners do things their own way without worrying much about success or failure. Success brings happiness while failure adds new experience.
Fear of failures often stops an individual to take any risky initiatives. Owners are “Risk Takers” & also believe on “First to Start” approach. Looking at the problem, they deeply involve themselves to find out its solution. They are good at judging and timely evaluating the probable returns of their efforts and are flexible to alter the methodology adapted earlier. They always look for improved versions through their creative minds.
Often owners are impatient to grow, which many times brings imbalance in their lives. They need to learn to “Grow with Happiness”.
This booklet contains mainly the concepts of distillation which are required by the plant designers as well as plant operational teams. This will help readers to get more of insight of distillation column understanding.
This presentation is developed for working managers who want to transform self as mentors...Different roles of managers, teachers are combined to mentor. Why to become mentor, Mentor's desired qualities and how to become mentor, etc. are covered here...
This presentation is for transforming Consumers to Creators. As high degree of consumerism often blocks the person's creative behavior despite born as creator. This also highlights Conceptual Approach for Innovative Solutions which are perfect in nature.
This presentation includes applications of filtration, filtration processing steps, different filtration conditions, affect of fluid characteristics on filtration, classification and scale up of filters.
This presentation outlines about Evaporation and different types of evaporators...Various industrial applications, different types of solutions, material & energy balance, concept of steam economy, system pressure conditions, feeding pattern, etc. are covered.
Conceptual Approach for Trouble Shooting of Chemical Process Industry. Proper design and trained operating manpower ensures trouble free plant operation.
Want to be on the top of your profession, you need to develop Soft Skills along with your professional skills. With time , need of soft skills changes. Thus you need to upgrade your soft skills regularly.
Transforming Lab work to Commercial Scale Chemical Process Industry require through knowledge of chemical engineering. This presentation shows step by step method for the development of process block diagram of a typical chemical manufacturing industry.
Francesca Gottschalk - How can education support child empowerment.pptxEduSkills OECD
Francesca Gottschalk from the OECD’s Centre for Educational Research and Innovation presents at the Ask an Expert Webinar: How can education support child empowerment?
Acetabularia Information For Class 9 .docxvaibhavrinwa19
Acetabularia acetabulum is a single-celled green alga that in its vegetative state is morphologically differentiated into a basal rhizoid and an axially elongated stalk, which bears whorls of branching hairs. The single diploid nucleus resides in the rhizoid.
Embracing GenAI - A Strategic ImperativePeter Windle
Artificial Intelligence (AI) technologies such as Generative AI, Image Generators and Large Language Models have had a dramatic impact on teaching, learning and assessment over the past 18 months. The most immediate threat AI posed was to Academic Integrity with Higher Education Institutes (HEIs) focusing their efforts on combating the use of GenAI in assessment. Guidelines were developed for staff and students, policies put in place too. Innovative educators have forged paths in the use of Generative AI for teaching, learning and assessments leading to pockets of transformation springing up across HEIs, often with little or no top-down guidance, support or direction.
This Gasta posits a strategic approach to integrating AI into HEIs to prepare staff, students and the curriculum for an evolving world and workplace. We will highlight the advantages of working with these technologies beyond the realm of teaching, learning and assessment by considering prompt engineering skills, industry impact, curriculum changes, and the need for staff upskilling. In contrast, not engaging strategically with Generative AI poses risks, including falling behind peers, missed opportunities and failing to ensure our graduates remain employable. The rapid evolution of AI technologies necessitates a proactive and strategic approach if we are to remain relevant.
How to Make a Field invisible in Odoo 17Celine George
It is possible to hide or invisible some fields in odoo. Commonly using “invisible” attribute in the field definition to invisible the fields. This slide will show how to make a field invisible in odoo 17.
2024.06.01 Introducing a competency framework for languag learning materials ...Sandy Millin
http://sandymillin.wordpress.com/iateflwebinar2024
Published classroom materials form the basis of syllabuses, drive teacher professional development, and have a potentially huge influence on learners, teachers and education systems. All teachers also create their own materials, whether a few sentences on a blackboard, a highly-structured fully-realised online course, or anything in between. Despite this, the knowledge and skills needed to create effective language learning materials are rarely part of teacher training, and are mostly learnt by trial and error.
Knowledge and skills frameworks, generally called competency frameworks, for ELT teachers, trainers and managers have existed for a few years now. However, until I created one for my MA dissertation, there wasn’t one drawing together what we need to know and do to be able to effectively produce language learning materials.
This webinar will introduce you to my framework, highlighting the key competencies I identified from my research. It will also show how anybody involved in language teaching (any language, not just English!), teacher training, managing schools or developing language learning materials can benefit from using the framework.
Normal Labour/ Stages of Labour/ Mechanism of LabourWasim Ak
Normal labor is also termed spontaneous labor, defined as the natural physiological process through which the fetus, placenta, and membranes are expelled from the uterus through the birth canal at term (37 to 42 weeks
Model Attribute Check Company Auto PropertyCeline George
In Odoo, the multi-company feature allows you to manage multiple companies within a single Odoo database instance. Each company can have its own configurations while still sharing common resources such as products, customers, and suppliers.
3. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Why the Trouble occur?
First Observation
50%w/w Liquid converts to 70%w/w Vapor
Second Requirement
Heat Liquid by Direct Contact Vapors
Third Provision
Space like Tray/ Packing for Heat & Mass Transfer
Here the Imperfection Starts (Man Made) which leads to Trouble
4. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Existing (Present) Trouble
Financial Losses (Material, Energy, Time)
Other Sides of Trouble
“-” Side : Safety (If trouble is not solved)
“+” Side : Plant Improvement
All are easily possible by Visualization
8. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Major Troubles
a) Low Plant Capacity
b) Poor Quality of Separated Products
c) High Consumption of Utilities
d) Poor Efficiency/ Recovery
e) Frequent Shut Downs
9. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Trouble Identification
By CEO (Source Annual Report)
Production Capacity
Expected : 100 TPA
Actual : 90 TPA
Shortfall : 10 TPA
WHY?
10. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Trouble Identification
By Site Head (Source Plant Section Data)
Section Expected Actual
Reaction 10 TPD 10 TPD
Filtration 10 TPD 10 TPD
Drying 15 TPD 15 TPD
Pulverizing 20 TPD 20 TPD
Distillation 100 TPD 90 TPD
Scrubbing 2 TPD 2 TPD
11. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Trouble Identification
By Unit In-charge (Source Plant Section Data)
Sub-Section Expected Actual
Feed 50 m3/hr 45 m3/hr
Top 50 TR 50 TR
Bottom 35 TPD 35 TPD
12. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Trouble Identification
By Section Engineer (Source Vendor Details)
Pump Specification
Flow Rate : 50 m3/hr
Diff. Head : 20 MWC
Actual Head : 21 MWC
15. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
a.) Fluid Flow Related
•Fluid Flows from “High Energy” to “Low Energy” Naturally
•Otherwise add Energy by Pump
16. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
a.) Fluid Flow Related
•External Flow Streams
•Feed to Pre-heater
•Pre-heater to Column
•Steam to Pre-heater
•Vapors to Condensor
•Reflux to Column
•Top Product to Storage
17. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
a.) Fluid Flow Related
•External Flow Streams
•Typical Troubles
•Insufficient Liquid in Reflux Drum
•Low Elevation of Gravity Feed Tank
•High Pressure Drop in Reflux Line
•Lower Head Pump Selected
18. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
a.) Fluid Flow Related
•Internally, within Distillation Column
•Typical Troubles
•Liquid Distribution/ Redistribution in Packed Column
•Slope in Trays
•Higher Liquid Level in Downcomer
19. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
b.) Heat Transfer Related
•Heat Naturally Flows from “High” to “Low” Temperature
Q = U A ΔT
20. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
b.) Heat Transfer Related
•Units Involved
•Feed Pre-heater
•Reboiler
•Condensor
•Top Product Cooler
•Bottom Product Cooler
21. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
b.) Heat Transfer Related
Q = U A ΔT
•Typical Troubles
Design Considered During Operation
Heat Transfer Coefficient Low Reduced due to scale
Heat Transfer Area Less Tubes Plugged Tubes
Temperature Difference Less steam temperature or
high cooling water temp.
Low steam pressure or
Cooling Tower Performance
22. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
b.) Heat Transfer Related
•Other Troubles
•Trapped Air in Steam (Reboiler)
•Superheated Steam
•Insulation Stripped Off
23. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
c.) Mass Transfer Related
•Difference in Vapor & Liquid Composition as per Equilibrium
24. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
c.) Mass Transfer Related
•Typical Troubles of Packed Column
•Dry Packing – Less Liquid in Column
•Flooded Packing – More Liquid in Column
•Bigger Packing Size – Less available area for contact
25. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
c.) Mass Transfer Related
•Typical Troubles of Tray Column
•Less Liquid Level in Tray – Less vapor liquid contact
•Missing Downcomer – Bypassing vapor to next tray
26. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Basic Issues Affecting Distillation Performance
c.) Mass Transfer Related
•Other Issues
•Flooding
•Entrainment
•Weeping
•Dumping
•Channeling
•Coning
•Priming
27. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Fluid Specific Troubles of Distillation
• Liquid with Suspended Solids
• Liquid with Dissolved Solids
• Liquid with Trapped Gases
• Foaming Liquids
• Corrosive Liquids
• Decomposing Components
• Flammable Liquids
• Hazardous Liquids
28. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Column Internals
Tray Column
Outlet Weir Height : Low / High
Inlet Weir Height : Low / High
Down comer Height : Low / High
Number of Sieves : Less / More
Down comer Area : Less / More
29. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Column Internals
Tray Column
Wrong Location of Feed Nozzle (In down comer)
Wrong Location of Side Stream Draw (in Vapor zone)
Gap between Tray & Shell
Valve tray vibration
Improper slope of trays
30. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Column Internals
Packed Column
Packing Size : Smaller / Bigger
Liquid Distributor : Plugging & Fouling
Support Plate : Choked by Packing
Inlets/ Outlets : Flashing fluids feed
31. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Column Internals
Packed Column
Fouled Packing
Damaged Packing
Improper Feed Introduction
Flooded Gas Riser
Excessive Entrainment
Vapor Mal-distribution
32. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Heat Exchangers
•Feed Pre-heater
•Condensor
•Reboiler
•Coolers
•Heat Transfer Area – Less / More
•Orientation – Horizontal / Vertical
•Location - Elevation
33. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Pumps
•Feed Pump
•Reflux Pump
•Product Draw Pump
•Flow Rate vs. Head
•NPSH (Required) vs. NPSH (Available)
34. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Hardware Specific Troubles of Distillation
Piping
•Reflux Line with Loop
•Thermo-siphon Reboiler Piping
•Utility Piping – Steam, Cooling Water
•Vacuum Line
•Pump Suction Line
35. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Manpower Specific Troubles of Distillation
Process Design
High Design Margin in Capacity
•Oversized Distillation column
•Higher number of sieves
42. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Troubleshooting to De-Bottlenecking
Reflux Ratio
Desired : 4
Actual : 3
Result : Poor Quality Product
or Low Plant Capacity
Reflux Ratio
Operating : 4
Possibility : 3
Conclusion : for same product
quality & quantity, lowering
reflux reduces Energy
Consumption.
43. klcenter@gmail.comKoncept Learning Center
Troubleshooting of Distillation
Enhancing Visualization
Troubleshooter Skills
1. Safety first.
2. Good trouble shooters understand the basics well.
3. Know what to expect before you start.
4. Do not overlook the obvious.
5. The so-called mental model both helps and hurts the troubleshooting process.
6. Think of ways to challenge the mental model.
7. Testing strategy advice varies considerably, and depends on your situation.
8. Believe your instruments, unless you have a good reason not to.
9. Use people as sources of information.