Electric Process Heaters
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 ADVANTAGES OF ELECTRIC HEATERS
4.1 Safety
4.2 Environment
4.3 Location of Equipment
4.4 Low Temperature Applications
4.5 Cross Contamination
4.6 Control
5 DISADVANTAGES OF ELECTRIC HEATERS
6 POTENTIAL APPLICATIONS FOR ELECTRIC
PROCESS HEATERS
7 GENERAL DESIGN AND OPERATING CONSIDERATIONS
8 TYPES OF PROCESS ELECTRIC HEATERS
8.1 Pipeline Immersion Heaters
8.2 Tank Heaters and Boilers
8.3 Indirect (Fluid Bath) Heaters
8.4 Radiant Furnaces
8.5 Induction Heaters
8.6 Hot Block Heaters
9 CONTROL
10 REFERENCES
FIGURES
1 ELECTRIC HEAT EXCHANGER CONSTRUCTION
2 SHEATHED HEATING ELEMENTS
Thermal Design Margins for Heat Exchangers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 TERMINOLOGY
5 REASONS FOR SPECIFYING A DESIGN MARGIN
5.1 Instantaneous Rates
5.2 Future Uprating
5.3 Plant Upsets
5.4 Process Control
5.5 Uncertainties in Properties
5.6 Uncertainties in Design Methods
5.7 Fouling
6 COMBINATION OF DESIGN MARGINS
7 CRITICAL AND NON-CRITICAL DUTIES
7.1 General
7.2 Penalties of Over-design
8 OPTIMIZATION OF EXCHANGER DUTY
9 WAYS OF PROVIDING DESIGN MARGINS
9.1 The Provision of Excess Surface
9.2 Decreasing the Design Temperature Difference
9.3 Increasing the Design Process Throughput
9.4 Increasing the Design Fouling Resistance
9.5 Reducing the Design Process Outlet Temperature Approach
9.6 Adjusting the Physical Properties
10 ACCURACY OF THE DESIGN METHODS FOR SHELL AND TUBE EXCHANGERS
10.1 Pressure Drop
10.2 Heat Transfer
11 SUGGESTED DESIGN MARGINS
11.1 No Phase Change Duties
11.2 Condensers
11.3 Boilers
12 EFFECT OF UNDER- OR OVER-SURFACE ON PERFORMANCE
FIGURES
1 EFFECT OF LENGTH ON EXCHANGER DUTY COUNTERCURRENT FLOW, C* = 1.0
2 EFFECT OF NUMBER OF TUBES ON EXCHANGER PERFORMANCE COUNTERCURRENT FLOW, C* = 1.0, ALL RESISTANCE IN TUBES
3 EFFECT OF TUBE LENGTH ON NUMBER OF TUBES, AREA AND PRESSURE DROP
Heating and Cooling of Batch Processes
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 units
4 STATEMENT OF THE PROBLEM
5 DEVELOPMENT OF THE METHOD
5.1 Assumptions
5.2 Basic Equations
6 APPLICATION OF THE METHOD
6.1 Determining the Behavior of an Existing System
6.2 Specifying the Heat Transfer Duty for a New System
APPENDICES
A DERIVATION OF THE EQUATIONS
B WORKED EXAMPLES
FIGURES
1 CASES CONSIDERED
Selection of Heat Exchanger Types
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 FACTORS INFLUENCING SELECTION
5.1 Type of Duty
5.2 Temperatures and Pressures
5.3 Materials of Construction 5.4 Fouling
5.5 Safety and Reliability
5.6 Repairs
5.7 Design Methods
5.8 Dimensions and Weight
5.9 Cost
5.10 GBHE Experience
6 TYPES OF EXCHANGER
6.1 Shell and Tube Exchangers
6.2 Cylindrical Graphite Block Heat Exchangers
6.3 Cubic Graphite Block Heat Exchangers
6.4 Air Cooled Heat Exchangers
6.5 Gasketed Plate and Frame
6.6 Spiral Plate
6.7 Tube in Duct
6.8 Plate-fin
6.9 Printed Circuit Heat Exchanger (PCHE)
6.10 Scraped Surface/Wiped Film Exchangers
6.11 Welded or Brazed Plate
6.12 Double Pipe
6.13 Electric Heaters
6.14 Fired Process Heaters
TABLE
(1) ADVANTAGES AND DISADVANTAGES OF DIFFERENT SHELL AND TUBE DESIGNS
FIGURES
1 ESTIMATED MAIN PLANT ITEM COSTS
2 ESTIMATED INSTALLED COSTS
3 TEMA HEAT EXCHANGER NOMENCLATURE
4 F ‘CORRECTION FACTORS' : TEMA E SHELL WITH EVEN NUMBER OF PASSE
5 SHELL AND TUBE HEAT EXCHANGER HEAD TYPES
6 GENERAL ARRANGEMENT OF A CYLINDRICAL GRAPHITE BLOCK HEAT EXCHANGER
7 EXPLODED VIEW OF A CUBIC GRAPHITE BLOCK
HEAT EXCHANGER
8 TYPICAL AIR COOLED HEAT EXCHANGER
9 GENERAL VIEW OF ONE END OF A 3-STREAM
PLATE-FIN HEAT EXCHANGER
10 TYPICAL PCHE PLATE
11 VICARB ‘COMPABLOC' EXCHANGER
12 ‘BROWN FINTUBE' MULTITUBE HEAT EXCHANGER
13 FIRED HEATER : SCHEMATICS AND NOMENCLATURE
Shell and Tube Heat Exchangers Using Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 HTFS
3.2 TEMA
4 CHECKLIST
5 QUALITY OF COOLING WATER
6 COOLING WATER ON SHELL SIDE OR TUBE SIDE
7 COOLING WATER ON THE SHELL SIDE
7.1 Baffle Spacing
7.2 Impingement Plates
7.3 Horizontal or Vertical Shell Orientation
7.4 Baffle Cut Orientation
7.5 Sludge Blowdown
7.6 Removable Bundles
8 FOULING RESISTANCES AND LIMITING TEMPERATURES
9 PRESSURE DROP
9.1 Pressure Drop Restrictions
9.2 Fouling and Pressure Drop
9.3 Elevation of a Heat Exchanger in the Plant
10 MATERIALS OF CONSTRUCTION
11 WATER VELOCITY
11.1 Low Water Velocity
11.1.1 Tube Side Water Flow
11.1.2 Shell Side Water Flow
11.2 High Water Velocity
12 ECONOMICS
13 DIRECTION OF WATER FLOW
14 VENTS AND DRAINS
15 CONTROL
15.1 Operating Variables
15.2 Heat Load Control
15.2.1 General
15.2.2 Heat load control by varying cooling water flow
15.3 Orifice Plates
16 MAINTENANCE
The Design and Layout of Vertical Thermosyphon ReboilersGerard B. Hawkins
The Design and Layout of Vertical Thermosyphon Reboilers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE DESIGN PROBLEM
5 COMPUTER PROGRAMS
6 GENERAL CONSIDERATIONS
6.1 Heating Medium Temperature
6.2 Fouling Resistance
7 DESIGN PARAMETERS
7.1 Overall Arrangement and Specifications
7.2 Geometry Elements
8 ANALYSIS OF COMMERCIALLY AVAILABLE
PROGRAM RESULTS
8.1 Main Results
8.2 Supplementary Results
8.3 Error Analysis
8.4 Adjustments to Design
9 OPERATING RANGE
10 CONTROL
10.1 Control of Condensing Heating Medium Pressure
10.2 Control of The Condensate Level
10.3 Control of Sensible Fluid Flow Rate
11 LAYOUT
11.1 Factors Influencing Design
11.2 A Standard Layout
12 BIBLIOGRAPHY
101 Things That Can Go Wrong on a Primary Reformer - Best Practices GuideGerard B. Hawkins
This document discusses common problems that can occur in primary reformers and associated equipment. It identifies issues that can lead to plant shutdowns or efficiency losses, grouping them under catalysts, tubes, furnace boxes, burners, flue gas ducts, headers, and refractories. Some examples discussed include carbon formation, tube overheating, flame impingement, leaks in air preheaters, combustion air maldistribution, and damage to coffins. The document provides an overview of these issues to improve plant reliability over its lifespan.
Thermal Design Margins for Heat Exchangers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 TERMINOLOGY
5 REASONS FOR SPECIFYING A DESIGN MARGIN
5.1 Instantaneous Rates
5.2 Future Uprating
5.3 Plant Upsets
5.4 Process Control
5.5 Uncertainties in Properties
5.6 Uncertainties in Design Methods
5.7 Fouling
6 COMBINATION OF DESIGN MARGINS
7 CRITICAL AND NON-CRITICAL DUTIES
7.1 General
7.2 Penalties of Over-design
8 OPTIMIZATION OF EXCHANGER DUTY
9 WAYS OF PROVIDING DESIGN MARGINS
9.1 The Provision of Excess Surface
9.2 Decreasing the Design Temperature Difference
9.3 Increasing the Design Process Throughput
9.4 Increasing the Design Fouling Resistance
9.5 Reducing the Design Process Outlet Temperature Approach
9.6 Adjusting the Physical Properties
10 ACCURACY OF THE DESIGN METHODS FOR SHELL AND TUBE EXCHANGERS
10.1 Pressure Drop
10.2 Heat Transfer
11 SUGGESTED DESIGN MARGINS
11.1 No Phase Change Duties
11.2 Condensers
11.3 Boilers
12 EFFECT OF UNDER- OR OVER-SURFACE ON PERFORMANCE
FIGURES
1 EFFECT OF LENGTH ON EXCHANGER DUTY COUNTERCURRENT FLOW, C* = 1.0
2 EFFECT OF NUMBER OF TUBES ON EXCHANGER PERFORMANCE COUNTERCURRENT FLOW, C* = 1.0, ALL RESISTANCE IN TUBES
3 EFFECT OF TUBE LENGTH ON NUMBER OF TUBES, AREA AND PRESSURE DROP
Heating and Cooling of Batch Processes
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 units
4 STATEMENT OF THE PROBLEM
5 DEVELOPMENT OF THE METHOD
5.1 Assumptions
5.2 Basic Equations
6 APPLICATION OF THE METHOD
6.1 Determining the Behavior of an Existing System
6.2 Specifying the Heat Transfer Duty for a New System
APPENDICES
A DERIVATION OF THE EQUATIONS
B WORKED EXAMPLES
FIGURES
1 CASES CONSIDERED
Selection of Heat Exchanger Types
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 FACTORS INFLUENCING SELECTION
5.1 Type of Duty
5.2 Temperatures and Pressures
5.3 Materials of Construction 5.4 Fouling
5.5 Safety and Reliability
5.6 Repairs
5.7 Design Methods
5.8 Dimensions and Weight
5.9 Cost
5.10 GBHE Experience
6 TYPES OF EXCHANGER
6.1 Shell and Tube Exchangers
6.2 Cylindrical Graphite Block Heat Exchangers
6.3 Cubic Graphite Block Heat Exchangers
6.4 Air Cooled Heat Exchangers
6.5 Gasketed Plate and Frame
6.6 Spiral Plate
6.7 Tube in Duct
6.8 Plate-fin
6.9 Printed Circuit Heat Exchanger (PCHE)
6.10 Scraped Surface/Wiped Film Exchangers
6.11 Welded or Brazed Plate
6.12 Double Pipe
6.13 Electric Heaters
6.14 Fired Process Heaters
TABLE
(1) ADVANTAGES AND DISADVANTAGES OF DIFFERENT SHELL AND TUBE DESIGNS
FIGURES
1 ESTIMATED MAIN PLANT ITEM COSTS
2 ESTIMATED INSTALLED COSTS
3 TEMA HEAT EXCHANGER NOMENCLATURE
4 F ‘CORRECTION FACTORS' : TEMA E SHELL WITH EVEN NUMBER OF PASSE
5 SHELL AND TUBE HEAT EXCHANGER HEAD TYPES
6 GENERAL ARRANGEMENT OF A CYLINDRICAL GRAPHITE BLOCK HEAT EXCHANGER
7 EXPLODED VIEW OF A CUBIC GRAPHITE BLOCK
HEAT EXCHANGER
8 TYPICAL AIR COOLED HEAT EXCHANGER
9 GENERAL VIEW OF ONE END OF A 3-STREAM
PLATE-FIN HEAT EXCHANGER
10 TYPICAL PCHE PLATE
11 VICARB ‘COMPABLOC' EXCHANGER
12 ‘BROWN FINTUBE' MULTITUBE HEAT EXCHANGER
13 FIRED HEATER : SCHEMATICS AND NOMENCLATURE
Shell and Tube Heat Exchangers Using Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 HTFS
3.2 TEMA
4 CHECKLIST
5 QUALITY OF COOLING WATER
6 COOLING WATER ON SHELL SIDE OR TUBE SIDE
7 COOLING WATER ON THE SHELL SIDE
7.1 Baffle Spacing
7.2 Impingement Plates
7.3 Horizontal or Vertical Shell Orientation
7.4 Baffle Cut Orientation
7.5 Sludge Blowdown
7.6 Removable Bundles
8 FOULING RESISTANCES AND LIMITING TEMPERATURES
9 PRESSURE DROP
9.1 Pressure Drop Restrictions
9.2 Fouling and Pressure Drop
9.3 Elevation of a Heat Exchanger in the Plant
10 MATERIALS OF CONSTRUCTION
11 WATER VELOCITY
11.1 Low Water Velocity
11.1.1 Tube Side Water Flow
11.1.2 Shell Side Water Flow
11.2 High Water Velocity
12 ECONOMICS
13 DIRECTION OF WATER FLOW
14 VENTS AND DRAINS
15 CONTROL
15.1 Operating Variables
15.2 Heat Load Control
15.2.1 General
15.2.2 Heat load control by varying cooling water flow
15.3 Orifice Plates
16 MAINTENANCE
The Design and Layout of Vertical Thermosyphon ReboilersGerard B. Hawkins
The Design and Layout of Vertical Thermosyphon Reboilers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE DESIGN PROBLEM
5 COMPUTER PROGRAMS
6 GENERAL CONSIDERATIONS
6.1 Heating Medium Temperature
6.2 Fouling Resistance
7 DESIGN PARAMETERS
7.1 Overall Arrangement and Specifications
7.2 Geometry Elements
8 ANALYSIS OF COMMERCIALLY AVAILABLE
PROGRAM RESULTS
8.1 Main Results
8.2 Supplementary Results
8.3 Error Analysis
8.4 Adjustments to Design
9 OPERATING RANGE
10 CONTROL
10.1 Control of Condensing Heating Medium Pressure
10.2 Control of The Condensate Level
10.3 Control of Sensible Fluid Flow Rate
11 LAYOUT
11.1 Factors Influencing Design
11.2 A Standard Layout
12 BIBLIOGRAPHY
101 Things That Can Go Wrong on a Primary Reformer - Best Practices GuideGerard B. Hawkins
This document discusses common problems that can occur in primary reformers and associated equipment. It identifies issues that can lead to plant shutdowns or efficiency losses, grouping them under catalysts, tubes, furnace boxes, burners, flue gas ducts, headers, and refractories. Some examples discussed include carbon formation, tube overheating, flame impingement, leaks in air preheaters, combustion air maldistribution, and damage to coffins. The document provides an overview of these issues to improve plant reliability over its lifespan.
Common poisons include
Sulfur
Chlorides and other halides
Metals including arsenic, vanadium, mercury, alkali metals (including potassium)
Phosphates
Organo-metalics
AIChE Smart Stack Damper Design Provides Better Control of Fired HeatersAshutosh Garg
Stack dampers are one of the insignificant yet important component of fired heaters in the refining industry. Over 90% of the heaters in the USA are natural draft and are dependent upon the draft for efficient combustion of fuel gas with air. Stack dampers currently installed are highly oversized and are not able to control draft effectively. Furnace Improvements patent pending design overcomes these limitations and improves the damper control significantly by installing multiple actuators and changing the control characteristics of the dampers.
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).
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
Practical thermal design of air cooled heat exchangersmen jung
The key advantages of air cooling over water cooling are:
1. Location independence as air cooling does not require proximity to water sources.
2. More environmentally friendly as it eliminates thermal and chemical pollution of water sources.
3. Lower maintenance costs as fouling issues like scaling and biofouling on the water side are eliminated.
Low Temperature Shift Catalyst Reduction Procedure
VSG-C111 as supplied contains copper oxide; it is activated for the low temperature shift duty by reducing the copper oxide component to metallic copper with hydrogen. The reaction is highly exothermic. In order to achieve maximum activity, good performance and long life, it is essential that the reduction is conducted under correctly controlled conditions. Great care must be taken to avoid thermal damage during this critical operation.
This presentation was created to provide a quick refresher to single-phase fluid flow line sizing. The content of this presentation was obtained from various literature (handbooks and website).
Please provide your comments
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
GBH Enterprises provides guidance on best practices for measuring tube wall temperatures in steam reformers using optical pyrometers. It is important to measure temperatures accurately to prevent overheating tubes while maximizing plant efficiency. GBH recommends taking multiple temperature and background readings per tube using handheld pyrometers and an emissivity correction factor. Safety precautions like protective equipment are also advised. Detailed procedures are outlined for top-fired, side-fired and terrace wall furnace configurations.
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSGerard B. Hawkins
The document discusses procedures for steaming Vulcan steam reforming catalysts to recover from sulfur poisoning and carbon formation incidents. It describes maintaining steam flow at 30-40% of design levels and an outlet temperature above 780°C. Gas samples should be taken hourly to monitor CO2, CH4, H2S and SO2. Steaming is complete when CO2 levels stabilize over 2-3 samples after increasing the temperature. The process typically takes 12-24 hours to complete and closely monitors pressure drop and tube conditions. After steaming, the catalyst requires reduction before restarting hydrocarbon feed.
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
Boiler Water Circulation Pumps
1 SCOPE
2 CHOICE OF TYPE AND NUMBER OF PUMPS
2.1 Need for Continuous Flow
2.2 Pump Reliability
3 CHOICE OF DRIVER
4 DUTY CALCULATIONS
5 CHOICE OF SEAL
5.1 Mechanical Seals
5.2 Soft-packed Glands
5.3 Construction Features
5.4 Guarding
6 CONSTRUCTION FEATURES
6.1 Vertical Glandless Wet-stator Motor Pumps
7 LAYOUT
7.1 Non-return Valves
7.2 Reducers at Pump Connections
7.3 Glandless Pumps for System Pressures
Exceeding 60 bar abs
7.4 Access round Glandless Pumps
7.5 Cooling Water Supply
8 RECOMMENDED LINE DIAGRAMS
8.1 Horizontal Pumps in Category 1
8.2 Vertical Wet-stator Motor Pumps in Category
APPENDICES
A PROPERTIES OF WATER AT THE SATURATION LINE
B ANNEX TO API 610, 6TH EDITION 1981:
VERTICAL GLANDLESS WET-STATOR MOTOR PUMPS
C ANNEX TO API 610, 6TH EDITION 1981:
HORIZONTAL BACK PULL-OUT PUMPS FOR BOILER
WATER CIRCULATION DUTY
FIGURES
3.1 NPSH CORRECTION FOR WATER
3.2 VELOCITY OF SOUND IN WATER AT 50 BAR
(NO BUBBLES)
3.3 VELOCITY OF SOUND IN WATER AT 50 BAR
(WITH 3% VAPOR CONTENT)
8.1 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - CATEGORY 1
8.2 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - SOFT PACKED GLAND INSTALLATION
8.3 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - MECHANICAL SEAL INSTALLATION
8.4 RECOMMENDED LINE DIAGRAM VERTICAL WET STATOR PUMPS - CATEGORY 2
BIBLIOGRAPHY
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
This document discusses the aMDEA process for removing carbon dioxide from process gas. It begins with an introduction and table of contents, then covers the need for CO2 removal, desirable solvent properties, commercially available processes, differences between physical and chemical absorption, selection criteria for processes, and an overview of the aMDEA process including constituents and reactions. It also discusses why the Rectisol process is not suitable, favorable absorption and regeneration parameters, common problems encountered, handling precautions, process interlocks, and problems and mistakes to avoid.
1) GBHE has extensive experience designing and evaluating methane steam reformer tubes and can perform detailed simulations and modeling to optimize reformer performance during retube evaluations.
2) The methodology involves understanding current operations, simulating the existing reformer, selecting improved tube materials and catalysts, and modeling stress levels and temperatures to determine maximum operating conditions.
3) Case studies demonstrate how optimizing tubes and catalyst can increase production by 3-15% while reducing pressure drop, temperatures, and methane slip.
Definition and selection of design temperature and pressure prg.gg.gen.0001Efemena Doroh
This document provides guidelines for determining the design temperature and pressure of equipment and piping for oil and chemical plants. It defines key terms like operating temperature, design temperature, minimum metal temperature, and design pressure. It outlines general criteria for setting design temperature, such as adding 30°C to the maximum operating temperature below 343°C. It also provides special considerations and guidelines for various equipment types. Minimum design metal temperature should be set to avoid material brittleness at low temperatures and pressures.
This document provides an overview of oil refinery processes, beginning with a brief history and description of petroleum. It then summarizes key unit operations including crude distillation, vacuum distillation, fluid/delayed coking, fluid catalytic cracking, hydrofluoroalkylation, hydrotreating, hydrocracking, and catalytic reforming. Process diagrams and typical yields are included for each unit operation.
The document discusses naphtha hydrotreating, which involves removing sulfur, nitrogen, metals, and olefins from naphtha. It presents information on the process overview, reactor configuration, catalyst preparation and characterization. Details are provided on the catalyst composition and properties, as well as pilot plant trials conducted in Saudi Arabia in the 1990s. Challenges mentioned include providing optimal reaction conditions and adapting to variations in feedstock quality.
Common poisons include
Sulfur
Chlorides and other halides
Metals including arsenic, vanadium, mercury, alkali metals (including potassium)
Phosphates
Organo-metalics
AIChE Smart Stack Damper Design Provides Better Control of Fired HeatersAshutosh Garg
Stack dampers are one of the insignificant yet important component of fired heaters in the refining industry. Over 90% of the heaters in the USA are natural draft and are dependent upon the draft for efficient combustion of fuel gas with air. Stack dampers currently installed are highly oversized and are not able to control draft effectively. Furnace Improvements patent pending design overcomes these limitations and improves the damper control significantly by installing multiple actuators and changing the control characteristics of the dampers.
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).
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
Practical thermal design of air cooled heat exchangersmen jung
The key advantages of air cooling over water cooling are:
1. Location independence as air cooling does not require proximity to water sources.
2. More environmentally friendly as it eliminates thermal and chemical pollution of water sources.
3. Lower maintenance costs as fouling issues like scaling and biofouling on the water side are eliminated.
Low Temperature Shift Catalyst Reduction Procedure
VSG-C111 as supplied contains copper oxide; it is activated for the low temperature shift duty by reducing the copper oxide component to metallic copper with hydrogen. The reaction is highly exothermic. In order to achieve maximum activity, good performance and long life, it is essential that the reduction is conducted under correctly controlled conditions. Great care must be taken to avoid thermal damage during this critical operation.
This presentation was created to provide a quick refresher to single-phase fluid flow line sizing. The content of this presentation was obtained from various literature (handbooks and website).
Please provide your comments
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
GBH Enterprises provides guidance on best practices for measuring tube wall temperatures in steam reformers using optical pyrometers. It is important to measure temperatures accurately to prevent overheating tubes while maximizing plant efficiency. GBH recommends taking multiple temperature and background readings per tube using handheld pyrometers and an emissivity correction factor. Safety precautions like protective equipment are also advised. Detailed procedures are outlined for top-fired, side-fired and terrace wall furnace configurations.
STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTSGerard B. Hawkins
The document discusses procedures for steaming Vulcan steam reforming catalysts to recover from sulfur poisoning and carbon formation incidents. It describes maintaining steam flow at 30-40% of design levels and an outlet temperature above 780°C. Gas samples should be taken hourly to monitor CO2, CH4, H2S and SO2. Steaming is complete when CO2 levels stabilize over 2-3 samples after increasing the temperature. The process typically takes 12-24 hours to complete and closely monitors pressure drop and tube conditions. After steaming, the catalyst requires reduction before restarting hydrocarbon feed.
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
Boiler Water Circulation Pumps
1 SCOPE
2 CHOICE OF TYPE AND NUMBER OF PUMPS
2.1 Need for Continuous Flow
2.2 Pump Reliability
3 CHOICE OF DRIVER
4 DUTY CALCULATIONS
5 CHOICE OF SEAL
5.1 Mechanical Seals
5.2 Soft-packed Glands
5.3 Construction Features
5.4 Guarding
6 CONSTRUCTION FEATURES
6.1 Vertical Glandless Wet-stator Motor Pumps
7 LAYOUT
7.1 Non-return Valves
7.2 Reducers at Pump Connections
7.3 Glandless Pumps for System Pressures
Exceeding 60 bar abs
7.4 Access round Glandless Pumps
7.5 Cooling Water Supply
8 RECOMMENDED LINE DIAGRAMS
8.1 Horizontal Pumps in Category 1
8.2 Vertical Wet-stator Motor Pumps in Category
APPENDICES
A PROPERTIES OF WATER AT THE SATURATION LINE
B ANNEX TO API 610, 6TH EDITION 1981:
VERTICAL GLANDLESS WET-STATOR MOTOR PUMPS
C ANNEX TO API 610, 6TH EDITION 1981:
HORIZONTAL BACK PULL-OUT PUMPS FOR BOILER
WATER CIRCULATION DUTY
FIGURES
3.1 NPSH CORRECTION FOR WATER
3.2 VELOCITY OF SOUND IN WATER AT 50 BAR
(NO BUBBLES)
3.3 VELOCITY OF SOUND IN WATER AT 50 BAR
(WITH 3% VAPOR CONTENT)
8.1 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - CATEGORY 1
8.2 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - SOFT PACKED GLAND INSTALLATION
8.3 RECOMMENDED LINE DIAGRAM HORIZONTAL PUMPS - MECHANICAL SEAL INSTALLATION
8.4 RECOMMENDED LINE DIAGRAM VERTICAL WET STATOR PUMPS - CATEGORY 2
BIBLIOGRAPHY
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
This document discusses the aMDEA process for removing carbon dioxide from process gas. It begins with an introduction and table of contents, then covers the need for CO2 removal, desirable solvent properties, commercially available processes, differences between physical and chemical absorption, selection criteria for processes, and an overview of the aMDEA process including constituents and reactions. It also discusses why the Rectisol process is not suitable, favorable absorption and regeneration parameters, common problems encountered, handling precautions, process interlocks, and problems and mistakes to avoid.
1) GBHE has extensive experience designing and evaluating methane steam reformer tubes and can perform detailed simulations and modeling to optimize reformer performance during retube evaluations.
2) The methodology involves understanding current operations, simulating the existing reformer, selecting improved tube materials and catalysts, and modeling stress levels and temperatures to determine maximum operating conditions.
3) Case studies demonstrate how optimizing tubes and catalyst can increase production by 3-15% while reducing pressure drop, temperatures, and methane slip.
Definition and selection of design temperature and pressure prg.gg.gen.0001Efemena Doroh
This document provides guidelines for determining the design temperature and pressure of equipment and piping for oil and chemical plants. It defines key terms like operating temperature, design temperature, minimum metal temperature, and design pressure. It outlines general criteria for setting design temperature, such as adding 30°C to the maximum operating temperature below 343°C. It also provides special considerations and guidelines for various equipment types. Minimum design metal temperature should be set to avoid material brittleness at low temperatures and pressures.
This document provides an overview of oil refinery processes, beginning with a brief history and description of petroleum. It then summarizes key unit operations including crude distillation, vacuum distillation, fluid/delayed coking, fluid catalytic cracking, hydrofluoroalkylation, hydrotreating, hydrocracking, and catalytic reforming. Process diagrams and typical yields are included for each unit operation.
The document discusses naphtha hydrotreating, which involves removing sulfur, nitrogen, metals, and olefins from naphtha. It presents information on the process overview, reactor configuration, catalyst preparation and characterization. Details are provided on the catalyst composition and properties, as well as pilot plant trials conducted in Saudi Arabia in the 1990s. Challenges mentioned include providing optimal reaction conditions and adapting to variations in feedstock quality.
Catalysis in hydtotreating and hydrocrackingKaneti Pramod
The document summarizes information about hydrocracking and hydrotreating processes. It discusses how hydrocracking uses hydrogen and catalysts to break down larger hydrocarbon molecules into smaller ones like diesel and jet fuel. Hydrotreating also uses hydrogen and catalysts to remove impurities like sulfur, nitrogen and metals from hydrocarbon feeds. Common catalysts used for these processes include zeolites, alumina and metals like nickel and molybdenum. The document provides details on the objectives, reactions and catalysts involved in hydrocracking and hydrotreating.
This document summarizes the process of hydrotreating. Hydrotreating involves removing sulfur, nitrogen, and metal impurities from feedstocks using hydrogen over a catalyst. The main objectives are removing impurities to meet product specifications and preparing feed for downstream units like reformers. Key reactions in hydrotreating include desulfurization, denitrogenation, and hydrogenation of olefins, aromatics, and organometallic compounds. Main hydrotreating processes are naphtha hydrotreating, middle distillate hydrotreating, and atmospheric residue desulfurization.
This document provides recipes from the "Best of Diabetic Connect Low-Carb Recipes" cookbook. It includes an index listing different sections for poultry, fish, beef, pork/lamb, soups/salads/misc, and breakfast recipes. The poultry section provides 10 recipes for items like lemon baked chicken, savory Italian grilled chicken, and black pepper citrus chicken. Each recipe includes nutritional information and user comments praising the recipes.
Hydrotreating and hydrocracking are refinery processes that use hydrogen and catalysts. Hydrotreating primarily removes sulfur, nitrogen, and other impurities from petroleum feeds using catalysts like nickel and molybdenum. Its purpose is to improve final product quality. Hydrocracking breaks longer hydrocarbon chains into shorter molecules using platinum or palladium catalysts. It has a higher conversion rate of over 50% compared to 10-20% for hydrotreating. Both processes operate at high temperatures and pressures but hydrocracking conditions are more severe.
Chapter 6c -_ht_design_consideration_-_latestHelena Francis
The document discusses design considerations for a hydrotreating facility to produce very low sulphur diesel fuel. Key factors include feed characteristics like sulphur content, selecting an appropriate catalyst, and optimizing process variables like temperature, hydrogen pressure, and space velocity. The goal is to effectively remove difficult aromatic sulphur compounds while addressing issues like equipment limitations and product quality requirements.
This document discusses refinery processes for upgrading heavy oils into clean transportation fuels. As petroleum supplies become heavier and more sour, refineries need improved processes like hydrodesulfurization (HDS) to remove sulfur. The document outlines several HDS approaches, including conventional HDS using sulfided CoMo/Al2O3 and NiMo/Al2O3 catalysts. It also discusses new generation HDS catalysts needed to meet stringent low-sulfur fuel standards. Modifying catalyst supports and developing advanced structured catalysts may improve HDS efficiency to allow deep desulfurization of refinery streams.
Air Cooled Heat Exchanger Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 SUITABILITY FOR AIR COOLING
4.1 Options Available For Cooling
4.2 Choice of Cooling System
5 SPECIFICATION OF AN AIR COOLED HEAT
EXCHANGER
5.1 Description and Terminology
5.2 General
5.3 Thermal Duty and Design Margins
5.4 Process Pressure Drop
5.5 Design Ambient Conditions
5.6 Process Physical Properties
5.7 Mechanical Design Constraints
5.8 Arrangement
5.9 Air Side Fouling
5.10 Economic Factors in Design
6 CONTROL
7 PRESSURE RELIEF
8 ASSESSMENT OF OFFERS
8.1 General
8.2 Manual Checking Of Designs
8.3 Computer Assessment
8.4 Bid Comparison
9 FOULING AND CORROSION
9.1 Fouling
9.2 Corrosion
10 OPERATION AND MAINTENANCE
10.1 Performance Testing
10.2 Air-Side Cleaning
10.3 Mechanical Maintenance
10.4 Tube side Access
11 REFERENCES
Selection and Design of Condensers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CHOICE OF COOLANT
5 LAYOUT CONSIDERATIONS
5.1 Distillation Column Condensers
5.2 Other Process Condensers
6 CONTROL
6.1 Distillation Columns
6.2 Water Cooled Condensers
6.3 Refrigerant Condensers
7 GENERAL DESIGN CONSIDERATIONS
7.1 Heat Transfer Resistances
7.2 Pressure Drop
7.3 Handling of Inerts
7.4 Vapor Inlet Design
7.5 Drainage of Condensate
8 SUMMARY OF TYPES AVAILABLE
8.1 Direct Contact Condensers
8.2 Shell and Tube Exchangers
8.3 Air Cooled Heat Exchangers
8.4 Spiral Plate Heat Exchangers
8.5 Internal Condensers
8.6 Plate Heat Exchangers
8.7 Plate-Fin Heat Exchangers
8.8 Other Compact Designs
9 BIBLIOGRAPHY
FIGURES
1 DIRECT CONTACT CONDENSER WITH INDIRECT COOLER FOR RECYCLED CONDENSATE
2 SPRAY CONDENSER
3 TRAY TYPE CONDENSER
4 THREE PASS TUBE SIDE CONDENSER WITH INTERPASS LUTING FOR CONDENSATE DRAINAGE
5 CROSS FLOW CONDENSER WITH SINGLE PASS COOLANT
Physical Properties for Heat Exchanger Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 COMPONENT PROPERTIES
4.1 General
4.2 Use of Component Properties for Mixtures
5 INPUT OF MIXTURE CURVES
5.1 General
5.2 Generation of the Mixture Curves
5.3 Selection of Temperature Points
5.4 Extrapolation
6 IMMISCIBLE CONDENSATES
FIGURES
1 TEMPERATURE POINTS SELECTED FOR EQUAL ENTHALPY CHANGE
2 TEMPERATURE POINTS SELECTED FOR GOOD
FIT TO CURVE
Mechanical Constraints on Thermal Design of Shell and Tube ExchangersGerard B. Hawkins
Mechanical Constraints on Thermal Design of Shell and Tube Exchangers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 STANDARD DIMENSIONS
4.1 Shell Diameters
4.2 Tube Lengths
4.3 Tube Diameters
4.4 Tube Wall Thicknesses
5 CLEARANCES
5.1 Tube Pitch
5.2 Pass Partition Lane Widths
5.3 Minimum 'U' Bend Clearance
5.4 Tube-to-Baffle Clearance
5.5 Baffle-to-Shell Clearance
5.6 Bundle-to-Shell Clearance
6 TUBESHEET THICKNESS
7 END ZONE LENGTHS
8 TUBE COUNTS
8.1 Program Correlations
8.2 Use of Tube count Tables
8.3 Graphical Layout
8.4 Use of Computer Programs
8.5 Tie Rods
TABLES
1 HEAT EXCHANGER SHELLS - GEOMETRICAL DATA
FOR INLET & OUTLET BRANCHES: PIPE WITH ANSI
150 FLANGE
2 HEAT EXCHANGER SHELLS - GEOMETRICAL DATA
FOR INLET & OUTLET BRANCHES: PIPE WITH ANSI
300 FLANGE
3 TEMA TIE ROD STANDARDS
FIGURES
1 DEFINITION OF TUBE PITCH, LIGAMENT THICKNESS & PASS PARTITION LANE WIDTH
2 DEFINITION OF PASS PARTITION LANE WIDTH FOR U-TUBES
3 BUNDLE TO SHELL CLEARANCES FOR DIFFERENT BUNDLE TYPES
4 ESTIMATED TUBESHEET THICKNESS FOR FIXED TUBE CONSTRUCTION
5 ESTIMATED TUBESHEET THICKNESS FOR U-TUBE CONSTRUCTION
6 END ZONE
7 EXAMPLE OF OPTU3 GRAPHICAL OUTPUT
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
Fouling Resistances for Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL
5 COOLING WATER FOULING
6 CHROMATE SYSTEMS
6.1 General
6.2 Constraints
6.3 Requirements
6.4 Fouling resistances
7 NON-CHROMATE SYSTEMS
7.1 General
7.2 Requirements and Constraints
7.3 Fouling resistances
8 UNTREATED COOLING WATER
9 MATERIALS OTHER THAN MILD STEEL
APPENDICES
A FOULING RESISTANCES FOR COOLING WATER
B FOULING FILM THICKNESS
Data Sources For Calculating Chemical Reaction EquilibriaGerard B. Hawkins
Data Sources For Calculating Chemical Reaction Equilibria
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THEORY
5 BIBLIOGRAPHY
Solid Catalyzed Gas Phase Reactor Selection
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 ADIABATIC REACTORS
4.1 Single Bed Reactors
4.2 Divided Bed Reactors
4.3 Moving Bed Reactors
4.4 Radial Flow Reactors
5 NON ADIABATIC REACTORS
5.1 Tubular Reactor with External Heating/Cooling
5.2 Tube Cooled Reactors
5.3 Autothermal Reactors
5.4 Hot/Cold Shot Reactors
5.5 Divided Bed Reactors with Intercooling
5.6 Radial Flow Reactors with Intercooling
5.7 Fluid Bed Reactors
6 NOTES ON USING REACTOR SELECTION
GUIDE (TABLE 1)
TABLE
1 REACTOR SELECTION GUIDE
FIGURES
1 TUBULAR REACTOR: EXAMPLE OF CATALYST IN ANNULAR TUBES COOLED BY STEAM RAISING
2 AUTOTHERMAL REACTOR: CATALYST BED COOLED BY INFLOWING GAS IN TUBES
3 COLD SHOT CONVERTER: FIXED ADIABATIC BEDS WITH INTERBED QUENCH GAS MIXING
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
General Water Treatment For Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CHOICE OF COOLING SYSTEM
4.1 ‘Once through' Cooling Systems
4.2 Open Evaporative Recirculating Systems
4.3 Closed Recirculating Systems
4.4 Comparison of Cooling Systems
5 MAKE-UP WATER QUALITY
6 FOULING PROCESSES
6.1 Deposition
6.2 Scaling
6.3 Corrosion
6.4 Biological Growth
7 CONTROL OF THE COOLING SYSTEM
7.1 ‘Once through' Cooling Systems
7.2 Closed Recirculating Systems
7.3 Open Evaporative Cooling Systems
TABLES
1 RELATIVE IMPORTANCE OF FOULING PROCESSES AND INSTALLED COSTS
2 WATER QUALITY PARAMETERS
FIGURES
1 PREDICTION OF CALCIUM CARBONATE SCALING
2 CALCIUM SULFATE SOLUBILITY
3 CALCIUM PHOSPHATE SCALING INDEX
Selection and Use of Printed Circuit Heat ExchangersGerard B. Hawkins
Selection and Use of Printed Circuit Heat Exchangers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CONSTRUCTION
5 HEAT TRANSFER AND PRESSURE DROP
6 FOULING
7 MECHANICAL AND MATERIALS ASPECTS
8 COMPACTNESS
9 FLEXIBILITY
10 COST
11 GBHE EXPERIENCE 5
12 BIBLIOGRAPHY
APPENDICES
A HEAT TRANSFER AND PRESSURE DROP IN
WAVY PASSAGES
Temperature excursions in hydrogenation reactors may have several causes, the most common ones being:-
i) Loss of recycle quench system. This could be either the liquid or gas stream. The condition is made worse if the make-up gas keeps flowing.
ii) Excessive temperatures. The loss of cooling medium ........
Physical properties and thermochemistry for reactor technologyGerard B. Hawkins
Physical Properties and Thermochemistry for Reactor Technology
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 PHYSICAL PROPERTIES
4.1 Form of Equations
4.2 The Physical Property System: “The VAULT”
4.3 Physical Property Programs
4.4 Physical Property Estimation
4.5 Sources of Expertise
5 INTERFACING COMPUTER PROGRAMS TO THE
GBHE VAULT PHYSICAL PROPERTIES PACKAGE
5.1 Preparation of the Physical Property Data
6 THERMOCHEMISTRY
6.1 Hess's Law
6.2 Standard States
6.3 Heats of Formation
6.4 Determination of Heats of Reaction
7 CALCULATION OF HEATS OF REACTION
7.1 Analogous Reactions
7.2 Heat of Formation Data Compilations
7.3 Estimation of Standard Heats of Formation
7.4 Heats of Neutralization
7.5 Temperature Effect on Heat of Reaction
8 HEATS OF SOLUTION, DILUTION AND MIXING
8.1 Calculation of Heats of Solution / Dilution from
Literature Data
8.2 Estimation of Heats of Solution and Mixing
8.3 Integral and Differential Heats
9 EXPERIMENTAL DETERMINATION OF
THERMOCHEMICAL PARAMETERS
9.1 Isoperibol Calorimetry for Heats of Reaction and Solution
9.2 Heat Flow Calorimetry
9.3 Adiabatic Calorimeter
9.4 Differential Scanning Calorimetry
10 COMPUTER CALCULATION OF ENTHALPY OR
TEMPERATURE
11 BIBLIOGRAPHY
This document provides guidance on implementing procedures for managing critical pressure systems as outlined in PEG 4. It covers the design, manufacture, repair, modification and periodic examination of pressure vessels, piping systems, and pressure relief streams. Key requirements include using recognized standards, qualified personnel, design verification, registration of equipment, and periodic inspections to ensure safety. The document is intended to support the development of detailed local engineering procedures for managing pressure equipment over its lifecycle.
Turbulent Heat Transfer to Non Newtonian Fluids in Circular TubesGerard B. Hawkins
Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE INTEGRATION OF THE ENERGY EQUATION
5 THE EDDY VISCOSITY FOR NON-NEWTONIAN AND DRAG REDUCING FLUIDS
6 THE CALCULATION OF HEAT TRANSFER
COEFFICIENTS FOR NON-NEWTONIAN AND DRAG
REDUCING FLUIDS IN TURBULENT PIPE FLOW
6.1 General
6.2 Drag Reducing Fibre Suspensions
6.3 Transition Delay
7 NOMENCLATURE
8 BIBLIOGRAPHY
Laminar Heat Transfer to Non Newtonian Fluids in Circular TubesGerard B. Hawkins
Laminar Heat Transfer to Non Newtonian Fluids in Circular Tubes
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 APPLICABILITY AND LIMITATIONS
4.1 Applicability
4.2 Limitations
5 THEORETICAL BACKGROUND
6 PRESENTATION OF RESULTS
7 PRESENTATION OF RESULTS
8 USE OF “The VAULT”
8.1 Limitations of “The VAULT”
9 NOMENCLATURE
10 BIBLIOGRAPHY
H - Acid Caustic Fusion Stage
CONTENTS
0 INTRODUCTION
1 DESIGN INFORMATION
1.1 Reactor Type
1.2 Temperature Range
1.3 Pressure Range
1.4 Chemical System
2 BACKGROUND
3 KINETICS AND MECHANISM
4 MAXIMUM YIELD AND IMPLICATIONS FOR REACTOR DESIGN
5 USE OF DESIGN MODEL FOR START-UP AND MANUFACTURING MONITORING
6 BIBLIOGRAPHY
FIGURES
1 FUSION MODEL OUTLINE MECHANISM AND KINETIC SCHEME
2 TEST RUN OPTIMIZATION OF HEATING TIME 3600 kg/h STEAM
Reactor Modeling Tools – Multiple Regressions
CONTENTS
0 INTRODUCTION
1 SCOPE
2 THEORY
3 EXCEL 2007: MULTIPLE REGRESSIONS
3.1 Overview
3.2 Multiple Regression Using the Data Analysis ADD-IN
3.3 Interpret Regression Statistics Table
3.4 Interpret ANOVA Table
3.5 Interpret Regression Coefficients Table
3.6 Confidence Intervals for Slope Coefficients
3.7 Test Hypothesis of Zero Slope Coefficients ("Test of Statistical Significance")
3.8 Test Hypothesis on a Regression Parameter
3.8.1 Using the p-value approach
3.8.2 Using the critical value approach
3.9 Overall Test of Significance of the Regression Parameters
3.10 Predicted Value of Y Given Regressors
3.11 Excel Limitations
4 SPECIAL FEATURES REQUIRING MORE SOPHISTICATED TECHNIQUES
5 USER INFORMATION SUPPLIED
A SUBROUTINE
B DATA
C RESULTS
6 EXAMPLE
This document provides guidelines for engineering design of pressure relief systems. It discusses key principles such as identifying potential overpressure and underpressure causes, sizing relief systems to prevent hazards, and safely disposing of relieved materials. The guidelines cover statutory requirements, recommended design procedures, and documentation standards. The overall goal is to preserve equipment integrity and prevent failure from over or under pressure during all process phases.
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
El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...Gerard B. Hawkins
El documento describe los procesos de refinería y catalizadores, así como los efectos del envenenamiento y ensuciamiento en el rendimiento de los catalizadores. El envenenamiento reduce la actividad de los catalizadores al bloquear los sitios activos o modificar la química de la superficie, lo que afecta la actividad y selectividad. Los niveles bajos de contaminantes tienen un mayor impacto en catalizadores con menor área de superficie. El envenenamiento también puede causar cambios estructurales en el catalizador y permitir
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
Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...Gerard B. Hawkins
The document discusses adiabatic reactor analysis for methanol synthesis from syngas. It provides the reaction kinetics and calculates conversion, temperature, and reactor volume needed at different conversions. Energy and mass balances are used to derive relationships between conversion, temperature and reaction rate. Data is generated to plot conversion versus volumetric flow rate for reactor sizing. The plot indicates a continuous stirred tank reactor (CSTR) could achieve 85% conversion before switching to a plug flow reactor (PFR) for higher conversion with less volume.
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
Investigation of the Potential Use of (IILs) Immobilized Ionic Liquids in Sha...Gerard B. Hawkins
The document discusses using immobilized ionic liquids (IILs) in shale gas sweetening reactions. It proposes immobilizing a cobalt catalyst in the surface ionic liquid layer of a solid supported ionic liquid catalyst. This would create a "homogeneous catalyst" dissolved within the fixed IIL layer. Competing reactions like oxidation of sulfides to sulfones would need to be considered. Related work on using similar approaches for hydroformylation reactions is referenced. The concept aims to develop a solid IIL catalyst for sweetening reactions involving oxidation using techniques from other areas like hydroformylation.
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Webinar: Designing a schema for a Data WarehouseFederico Razzoli
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Have you ever been confused by the myriad of choices offered by AWS for hosting a website or an API?
Lambda, Elastic Beanstalk, Lightsail, Amplify, S3 (and more!) can each host websites + APIs. But which one should we choose?
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Electric Process Heaters
1. GBH Enterprises, Ltd.
Process Engineering Guide:
GBHE-PEG-HEA-509
Electric Process Heaters
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.
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
2. Process Engineering Guide:
Electric Process Heaters
CONTENTS
SECTION
0
INTRODUCTION/PURPOSE
2
1
SCOPE
2
2
FIELD OF APPLICATION
2
3
DEFINITIONS
2
4
ADVANTAGES OF ELECTRIC HEATERS
2
4.1
4.2
4.3
4.4
4.5
4.6
Safety
Environment
Location of Equipment
Low Temperature Applications
Cross Contamination
Control
2
2
3
3
3
3
5
DISADVANTAGES OF ELECTRIC HEATERS
3
6
POTENTIAL APPLICATIONS FOR ELECTRIC
PROCESS HEATERS
3
7
GENERAL DESIGN AND OPERATING CONSIDERATIONS 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
3. 8
TYPES OF PROCESS ELECTRIC HEATERS
5
8.1
8.2
8.3
8.4
8.5
8.6
Pipeline Immersion Heaters
Tank Heaters and Boilers
Indirect (Fluid Bath) Heaters
Radiant Furnaces
Induction Heaters
Hot Block Heaters
5
6
7
7
7
7
9
CONTROL
8
10
REFERENCES
8
FIGURES
1
ELECTRIC HEAT EXCHANGER CONSTRUCTION
2
5
SHEATHED HEATING ELEMENTS
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
4. 0
INTRODUCTION/PURPOSE
This Guide is one of a series on Heat Transfer prepared for GBH Enterprises.
Electric heaters are used in the process industries for some duties as alternatives
to fluid heated or fired process exchangers. When specified and used properly,
electric heaters will last for many years without problems. However, there are
special features to consider in specifying and operating electric heaters, which, if
not understood, can result in damage to the equipment leading to early burn-out
of the elements or potentially hazardous equipment failure.
1
SCOPE
This Guide is intended to assist engineers in the selection and trouble free
operation of electric heaters.
This Guide describes the major types of electric process fluid heater and the
sorts of duties for which they are applicable. It gives guidelines on key points to
observe when specifying and operating electric heaters, in order to avoid
problems. It does not give detailed information on design methods; electric
heaters are generally designed by the suppliers.
Further information on electric heaters may be found in [Refs1 and 2].
2
FIELD OF APPLICATION
This Guide applies to process engineers in GBH Enterprises worldwide, who
may be involved in the specification or operation of electric heat exchangers.
3
DEFINITIONS
For the purposes of this Guide, the following definition applies:
HTFS
Heat Transfer and Fluid Flow Service. A cooperative
research organization, in the U.K., involved in research into
the fundamentals of heat transfer and two phase flow and
the production of design guides and computer programs for
the design of industrial heat exchange equipment.
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
5. With the exception of terms used as proper nouns or titles, those terms with initial
capital letters which appear in this document and are not defined above are
defined in the Glossary of Engineering Terms.
4
ADVANTAGES OF ELECTRIC HEATERS
4.1
Safety
Very high temperatures (over 1000°C, and up to 1400°C with certain designs)
can be achieved, without the potential fire and explosion hazards associated with
fired heaters. All potential fire hazards may be contained in explosion proof
terminal boxes. No fuel storage tanks or gas let-down stations, which may affect
the plant area electrical classification, are required.
4.2
Environment
There are no local pollution problems (e.g. NOx and SOx production) with electric
heaters.
4.3
Location of Equipment
An electric heater will generally be considerably lighter and more compact than a
fired heater for the same duty. There will usually be fewer restrictions on the
location of an electric heater than a fired heater, enabling it to be placed locally
within the main process structure rather than at some peripheral point; thus
saving on process pipework. No long service feed and return lines are
necessary. It can be used on locations where other forms of heating are not
available. Cost advantages are particularly great in the smaller sizes (up to 1
MW).
4.4
Low Temperature Applications
Electric heaters do not suffer from the problems associated with fluid heaters at
very low temperatures, such as freezing of condensate or viscous behavior.
4.5
Cross Contamination
There is no service fluid which could leak into the process.
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
6. 4.6
Control
Very good control of power input to the process fluid can be achieved, across a
wide range, typically down to 5% of the rated maximum power. The control
response is usually quicker than with fluid heaters.
5
DISADVANTAGES OF ELECTRIC HEATERS
Electric heaters require careful selection, design, construction and operation,
otherwise premature burn-out of the heating elements may occur.
Electricity is generally a relatively expensive form of energy. However, for high
temperature applications, a fired heater often has a relatively low thermal
efficiency because of losses with the flue gases, especially if there is no suitable
low temperature duty, such as preheating or boiler feed water heating, to cool the
stack gases. Electric heaters, in conjunction with properly designed heat
insulation, can achieve local efficiencies approaching 100%.
6
POTENTIAL APPLICATIONS FOR ELECTRIC PROCESS HEATERS
(a)
Fluid heating to temperatures above 400°C up to over 1000°C for
reactors, catalyst regeneration etc.
(b)
Heating in remote locations where piping costs would be prohibitive if
heated elsewhere, or where no other heating medium is available.
(c)
Heating on offshore rigs, where the reduced size and weight of electric
heaters compared with fired heaters can substantially reduce the cost of
the platform, and the fire danger is largely removed.
(d)
In place of fired heaters for small to medium applications or for
temperatures above 400°C in batch mode, or where extremely careful
temperature control is required.
(e)
For cryogenic duties, or where the ambient conditions could cause
condensate return lines to freeze.
(f)
Where electric power is cheap.
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
7. 7
GENERAL DESIGN AND OPERATING CONSIDERATIONS
Electric process heaters are not only pieces of electrical equipment; they are also
heat exchangers. Their specification and selection should involve not only an
electrical engineer but also a process engineer with an understanding of process
heat transfer. Some of the past problems experienced with electric heaters, can
be attributed in part to a lack of process engineering input at the selection stage.
Many electrical heaters are of a very lightweight construction for domestic and
light commercial duty. Moreover, the manufacturers of such units may have only
a limited understanding of heat transfer. This type of unit is unsuitable for heavy
process duty. Use only equipment that has been specifically designed and built
for refinery or process plant duty by a competent manufacturer with a proper
understanding of process heat transfer.
The heat transferred between two fluids in a conventional heat exchanger is
limited by the surface area, the temperature difference and the overall heat
transfer coefficient. In contrast, the heat transferred in most types of electrical
heater is limited only by the power input to the heating elements. Many of the
problems associated with electric heaters arise from a failure to appreciate the
implications of this.
The power generation in an electric heater is governed by the design of the
resistance heating elements and, except for minor variations in electrical
resistance with temperature, will depend only on the applied voltage. The system
will seek to dissipate this power to the fluid regardless of either the area for heat
transfer or the heat transfer coefficient, by adjustment of the temperature of the
heating elements. Moreover, the power output is usually uniform along the
elements. Thus, if the local coefficient is low, either because of low local fluid
velocities or fouling, the local element temperature will rise to compensate. If the
process fluid is temperature sensitive it may degrade in these regions, leading to
a progressive build-up of fouling deposits. This in turn will lead to an increasing
element temperature, until the maximum safe working temperature is exceeded,
and element burn-out occurs.
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8. The key points to remember when seeking to avoid this are:
(a)
Do not use designs which have dead zones in the heated region. For
example, segmental baffles should not be used on immersion type heaters
[see (1) below].
(b)
Heaters should not be run at below the design minimum flow rate; trip
systems to prevent this are recommended.
(c)
Tank heaters should not be operated below a minimum safe liquid level
which ensures that the elements are covered at all times. Trips may be
required to guarantee this.
(d)
Heaters should not be operated in a badly fouled condition.
Failure to understand the operating characteristics of electric heaters has lead to
several failures in plants. Two examples are given below:
(1)
An electric heater of the pipeline immersion type (see 8.1) was installed on
a European plant, to heat a heat transfer oil used to raise the temperature
of the reactor. The process operators were experiencing difficulty in
obtaining the desired reactor temperature. They incorrectly deduced that
this was simply due to the low temperature of the heat transfer oil, and to
raise this they reduced the flow rate. The heater had segmental baffles,
which are undesirable in this type of heater (see 8.1.2). Breakdown of the
oil in the dead zones behind the baffles occurred, leading to severe
coking.
(2)
An electric heater was installed on an Aromatics plant in Europe to provide
hydrogen at 200°C for start-up. In 1989, the shell of this unit failed, leading
to a fire. The Dangerous Incident Investigation [Ref 3] concluded that the
cause of failure short term overheating at pressure. The heater was
allowed to operate in this condition because the low flow protection had
been defeated, and the temperature trips were set too high.
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9. 8
TYPES OF PROCESS ELECTRIC HEATERS
8.1
Pipeline Immersion Heaters
8.1.1 General
This type of heater resembles a shell and tube heat exchanger, with the
tubes replaced by electric resistance heating elements encased inside
metal tubes. See Figure 1. The tubes may be sealed at one end and pass
through a tubesheet at the other, or be of a U-tube construction with both
ends passing through the tubesheet. The tube material depends on the
process fluid. The space between the element and the tube is packed with
an inert material, usually magnesia, at a sufficient density to provide good
thermal conductance whilst retaining electrical resistance. The tubes
containing the elements protrude beyond the tubesheet and are fastened
to a terminal box, where all the electrical connections are made. This can
be designed to be explosion proof if necessary. Figure 2 shows the main
components of a typical heating element.
Pipeline immersion heaters are available for duties up to 5 MW, for
heating liquids to about 350°C or gases to about 600°C. Typical design
heat fluxes are 40-100 kW/m2. They are available in most metals, in
working pressures up to 700bar.
FIGURE 1
ELECTRIC HEAT EXCHANGER CONSTRUCTION
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10. FIGURE 2
SHEATHED HEATING ELEMENTS
8.1.2 Design Points
The heating elements should be welded to the tubesheet. Designs which
use compression fittings to seal the element to the tubesheet develop
leaks over a period of time due to temperature cycling.
The terminal box should be provided with an adequate stand-off from the
tubesheet. This ensures no fluid leakage into the terminal box, and also
keeps the box cool. The electrical wiring in this part of the tube is designed
with a low electrical resistance to avoid heating.
Avoid dead spots and zones of low flow. Do not use segmentally cut
baffles. Baffling to provide element support and improve heat transfer
should be by means of rod baffles or similar. The inlet zone by the
tubesheet will inevitably have dead spots; the elements should be
designed to be unheated in the entrance zone.
The shell of an immersion heater runs hotter than the fluid, particularly if a
gas is being heated, because of radiation from the elements. Remember
that these may have been designed to operate at temperatures
considerably above normal fluid temperatures. The shell should be
designed for a temperature calculated allowing for radiation from the
bundle. Shell skin temperature alarms or even trips may be desirable. It is
possible that the shell may become hot enough to be a source of ignition
for gases in the atmosphere even when the process temperatures are
below the ignition temperature.
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11. Low flow trips are essential. It is common practice to provide high
temperature alarms/trips, usually in the form of thermocouples attached to
the outside of selected tubes. Remember that these will not give warning
of local problems, and rely on the assumption that conditions are
uniform throughout the bundle.
The magnesium oxide insulation round the elements has to be sealed
from the atmosphere to prevent moisture ingress. This is usually done with
a seal of cured silicone rubber. Although this should give a good seal, it is
possible that during periods of prolonged shut-down, moisture can get into
the magnesia. If the heater is subsequently turned on at full power, a short
may occur which could result in element burn-out. A check on the
electrical resistance should always be made before bringing a heater on
line after a prolonged shut-down, or if there is any reason to suspect
moisture ingress. Generally, the elements can be restored to their proper
condition by operating for several hours at a low voltage, until the
resistance is restored to its correct value.
8.2
Tank Heaters and Boilers
Tank heaters use similar heating elements to the pipeline heaters, but the
bundles of elements are positioned in the lower part of storage vessels to
maintain fluid temperature. The tubes may be either bare or finned on the
outside. Some designs allow for removal of the heating elements from an outer
sheath which is in contact with the process fluid. This enables replacement of the
elements without the need to drain the tank.
Bundles of heating elements in tubes may also be used for boiling liquids,
producing a design which is superficially like a fluid heated kettle boiler.
Unlike fluid heated systems, for an electrically heated reboiler or tank heater, it is
essential to provide controls to cut off the electricity in the event of the liquid level
falling sufficiently to uncover any of the tubes.
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12. 8.3
Indirect (Fluid Bath) Heaters
These consist of a pressurized shell containing a suitable heat transfer fluid with
an electric heating coil in the lower part and a fluid heating coil, usually a U-tube
bundle, in the upper part. The heat transfer fluid may heat the process coil either
by convection in the liquid phase, or may boil on the electric elements and
condense on the process coil. The heat transfer fluid is chosen to have the right
combination of properties over the operating conditions. Typical fluids are water,
ammonia, methanol or heat transfer oils such as "Thermex", "Dowtherm",
"Santotherm" etc.
Fluid bath heaters can be economic for heating corrosive fluids, since only the
process fluid coil need be fabricated from corrosion resistant alloys. They may
also be less costly than pipeline immersion heaters for high pressure operation.
8.4
Radiant Furnaces
These consist of a heating coil to contain the fluid being heated, surrounded by
radiant electric heating elements. The elements are backed by an insulated steel
shell, ceramic fibre generally being used for insulation. The radiant elements may
be divided into zones, to give a controlled pattern of heating. Temperatures up to
1300°C can be achieved.
Electric radiant heaters are an alternative to fired heaters. They have a high
thermal efficiency as there is no stack loss. For batch processes, the operating
cost of electricity may be less than that of fuel for a fired heater.
Radiant heaters require proper design of the heating elements and fluid coil,
ensuring good view factors etc.
8.5
Induction Heaters
In these, the process fluid flows in a helical coil which acts as the secondary
winding to a transformer. Very high currents at low voltage are induced in the
coil, generating heat by resistance. These are used for special applications and
are designed on a one-off basis.
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13. 8.6
Hot Block Heaters
One potential problem with the pipeline immersion heater is burn-out of the
heater elements, resulting from a failure in the process flow. This is avoided in
the hot block heater. This uses a cast block, generally of aluminium, in which
both electric heating elements and coils carrying the process fluids are cast. The
temperature of the block is monitored by thermocouples in tubes in the block,
which are used to control the power input to the heating elements. The elements
are generally removable cartridge heaters.
9
CONTROL
Very precise and programmable heating control, with full proportional control, can
be achieved with electric heaters. Electronic controls are usually employed. The
preferred form uses Silicon Controlled Rectifiers (SCRs) operating with zero
voltage switching. These operate by energizing the heater for some of the cycles
in the supply voltage, and cutting off the power for others, the switching taking
place at the zero voltage points. The heater can be energized for as little as one
cycle per second up to the full 50 cycles.
Other forms of power control, such as phase angle control, where the current is
cut off for part of each cycle, but not at the zero voltage condition, can result in
radio frequency interference, which may affect other electronic equipment in the
area.
The SCRs generate some parasitic heat, which requires the control panel to be
cooled to keep the temperature below 50°C.
For further information on the control problems, consult a Control/Electrical
Engineer.
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