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
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)Aree Salah
this project submitted in partial fulfilment of the requirements for the degree of bachelor in science in Chemical engineering at Koya University.
The main purpose of our project is to describe and design the production of MTBE, and using it as an additive to gasoline in order to increase its quality.
We work at this plant to produce 112,200tons / year (112,200,000 kg/y) of methyl tertiary butyl ether (MTBE)
Fixed Bed Reactor Scale-up Checklist
The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
• Literature data.
• Lab testing.
• Calculation.
• Modeling.
• Semi-tech testing.
• Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
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
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
PRODUCTION OF METHYL TERTIARY BUTYL ETHER (MTBE)Aree Salah
this project submitted in partial fulfilment of the requirements for the degree of bachelor in science in Chemical engineering at Koya University.
The main purpose of our project is to describe and design the production of MTBE, and using it as an additive to gasoline in order to increase its quality.
We work at this plant to produce 112,200tons / year (112,200,000 kg/y) of methyl tertiary butyl ether (MTBE)
Fixed Bed Reactor Scale-up Checklist
The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
• Literature data.
• Lab testing.
• Calculation.
• Modeling.
• Semi-tech testing.
• Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
Reactor and Catalyst Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 CATALYST DESIGN
4.1 Equivalent Pellet Diameter
4.2 Voidage
4.3 Pellet Density
5 REACTOR DESIGN
6 CATALYST SUPPORT
6.1 Choice of Support
TABLES
1 CATALYST SUPPORT SHAPES
2 SECONDARY REFORMER SPREADSHEET
FIGURES
1 GRAPH OF EFFECTIVENESS v THIELE MODULUS
2 VARIATION OF COSTS WITH CATALYST SIZE
3 VARIATION OF COSTS WITH CATALYST BED VOIDAGE
4 VARIATION OF COSTS WITH VESSEL DIAMETER
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
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
Introduction
Catalyst breakage is a well known phenomena that occurs during operation and transients such as reformer trips, whether this be due to,
• Normal in service breakage,
• Breakage due to carbon formation/removal,
• Breakage due to steam condensation or carry over,
• Breakage during a trip.
The effect of catalyst breakage can be observed in a number of ways,
• Hot bands,
• Speckling and giraffe necking,
• Catalyst breakage and settling.
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDSGerard B. Hawkins
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDS
Case Study: #0953616GB/H
HT SHIFT REACTOR CATALYST SPECIFICATION
Process Specification
This process duty specification refers to a Syngas Conditioning Unit which utilizes HT Shift reaction technology on a slip stream of raw gas to produce a recombined gas stream with a H2:CO ratio of 1.57:1. This is an important consideration as the Shift reactor is not required to minimize CO at outlet, and this specification refers to the expected performance that can be achieved in a single stage reactor scheme.
The Syngas Conditioning Unit is part of a proposed coal-to-liquids complex in which synthesis gas is produced by gasification of coal for downstream processing in a Fischer Tropsch reactor and Hydrocracker unit.
How to use the GBHE Reactor Technology Guides
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 THE DECISION TREE
6 GBHE REACTION ENGINEERING
7 GENERAL ASPECTS OF REACTOR TECHNOLOGY
7.1 Criteria of Reactor Performance
7.2 Factors of Economic Importance
7.3 Physicochemical Mechanisms
8 GENERAL GUIDE TO SELECTION OF REACTOR TYPE AND OPERATION
8.1 Choice of Reactor Type
8.2 Reaction Mechanism and Kinetics
8.3 Thermodynamics
8.4 Other Factors
9 GENERAL REFERENCES AND SOURCES OF
INFORMATION
APPENDICES
A RELATIONSHIP BEWTEEN DEFINED TERMS
FIGURES
1 DECISION TREE
2 RELATIVE YIELDS OF B FOR BATCH (OR PLUG FLOW) AND CST REACTORS
3 REACTOR SURVEY FORM
Shortcut Methods of Distillation Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 ESTIMATIONOF PLATEAGE AND REFLUX
REQUIREMENTS
2.1 Generalized Procedure for Nmin and Rmin
2.2 Equation based Procedure for Nmin and Rmin
3 PREDICTION OF OVERALL PLATE EFFICIENCY
4 SIZING OF MAIN PLANT ITEMS
4.1 Column Diameter
4.2 Surface Area of Condensers and Reboilers
FIGURES
1 NON-IDEAL EQUILIBRIUM CURVE
2 AT A GLANCE CHART BASED ON FENSKE,
UNDERWOOD
3 PLATE EFFICIENCY CORRELATION OF O’CONNEL
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
OVERVIEW - FIXED BED ADSORBER DESIGN GUIDELINES
Fixed-bed adsorber design is based upon the following considerations:
• Adsorbent bed profile and media loading capacity characteristics for the specific application and adsorbent material used.
• Pressure drop characteristics across the adsorbent bed.
• Reaction kinetics.
Typically, adsorber design entails use of the following methodology:
• Adsorbent selection based upon performance and application information.
• Bed sizing based upon adsorbent loading data and service life requirements.
• Bed sizing adjustment based upon pressure drop criteria.
• Bed sizing adjustment based upon reaction kinetics criteria.
A discussion of each design consideration follows.
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
Catalyst poisons & fouling mechanisms the impact on catalyst performance Gerard B. Hawkins
Primary Effects
Secondary Effects
Typical Poisons in hydrocarbon processing
Permanent Poisons
- Arsenic, lead, mercury, cadmium…
- Silica, Iron Oxide….
Temporary Poisons
- Sulfur, Chlorides, Carbon
Boiler Feed water impurities
Heavy Metals
Foulants
THE NATURE OF CARBON DEPOSITS FORMED ON CATALYSTS
- CARBON FORMATION
Type A, B, C
- FEEDSTOCK COMPOSITION EFFECTS
COMMERCIAL’ CARBON DEPOSITS
- CARBON BURNING IN AIR
- CARBON REMOVAL BY STEAMING
- CARBON BURN CONTROL METHODS
- CATALYST – REACTION WITH STEAM
- MAXIMUM OXYGEN CONCENTRATION
- TEMPERATURE OF THE CATALYST SURFACE DURING CARBON BURNS
- CONDITIONS TO BURN OFF CARBON COATED CATALYST
- EFFECT OF CARBON FORMATION
DEACTIVATION OF METHANOL SYNTHESIS CATALYSTS
CONTENTS
1 INTRODUCTION
2 THERMAL SINTERING
3 CATALYST POISONING
4 REACTANT INDUCED DEACTIVATION
5 SUMMARY
TABLES
1 DEACTIVATION PROCESSES ON METHANOL SYNTHESIS CATALYSTS
2 MELTING POINT, HUTTIG AND TAMMANN TEMPERATURES OF COPPER, IRON AND NICKEL
3 SINTERING RATE CONSTANTS CALCULATED INLET AND OUTLET SIDE STREAM UNIT FOR VULCAN VSG-M101
4 COMPARISON BETWEEN CALCULATED S∞ AND DISCHARGED MEASUREMENTS ON VULCAN VSG-M101
5 EFFECT OF POSSIBLE CONTAMINANTS AND POISONS ON CU/ZNO/AL2O3 CATALYSTS FOR METHANOL SYNTHESIS
6 GUARD SCREENING TEST RESULTS ON METHANOL MICRO-REACTOR. EFFECT OF DEPOSITED METALS ON METHANOL ACTIVITY
FIGURES
1 THE HΫTTIG AND TAMMANN TEMPERATURES OF THE COMPONENTS OF A SYNTHESIS CATALYST
2 A SCHEMATIC REPRESENTATION OF TWO CATALYST SINTERING MECHANISMS
3 SIDE STREAM DATA FOR VULCAN VSG-M101. INLET TEMPERATURE 242 OC, PRESSURE 1500 PSI, GAS COMPOSITION 6% CO, 9.2% CO2, 66.9% H2, 2.5% N2 AND 15.4% CH4, SPACE VELOCITY 17,778 HR-1. MEAN OUTLET TEMPERATURE 280 OC
4 TEMPERATURE DEPENDENCE OF THE RATE OF SINTERING
5 MECHANISM OF SULFUR RETENTION
6 CORRELATION OF SULFUR CAPACITY WITH TOTAL SURFACE AREA
7 EFFECT OF DEPOSITED (NI+FE) PPM ON METHANOL SYNTHESIS CATALYST ACTIVITY
8 DISCHARGED (FE + NI) DEPOSITION LEVELS ON METHANOL SYNTHESIS PLANT SAMPLES
9 EPMA ANALYSIS OF DISCHARGED LABORATORY SAMPLE OF POISONED VULCAN VSG-M101
10 THE EFFECT OF CO2 ON SYNTHESIS CATALYST DEACTIVATION
REFERENCES
Flare radiation-mitigation-analysis-of-onshore-oil-gas-production-refining-fa...Anchal Soni
The main objective of this paper is to calculate the sterile area around an existing vertical flare of length 112 meters, located in an onshore facility and evaluate whether the current design is acceptable during a General Power Failure (GPF) scenario. The sterile area will be calculated at an elevation of 2m, which represents the typical head height for personnel.
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
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).
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
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDSGerard B. Hawkins
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDS
Case Study: #0953616GB/H
HT SHIFT REACTOR CATALYST SPECIFICATION
Process Specification
This process duty specification refers to a Syngas Conditioning Unit which utilizes HT Shift reaction technology on a slip stream of raw gas to produce a recombined gas stream with a H2:CO ratio of 1.57:1. This is an important consideration as the Shift reactor is not required to minimize CO at outlet, and this specification refers to the expected performance that can be achieved in a single stage reactor scheme.
The Syngas Conditioning Unit is part of a proposed coal-to-liquids complex in which synthesis gas is produced by gasification of coal for downstream processing in a Fischer Tropsch reactor and Hydrocracker unit.
How to use the GBHE Reactor Technology Guides
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 THE DECISION TREE
6 GBHE REACTION ENGINEERING
7 GENERAL ASPECTS OF REACTOR TECHNOLOGY
7.1 Criteria of Reactor Performance
7.2 Factors of Economic Importance
7.3 Physicochemical Mechanisms
8 GENERAL GUIDE TO SELECTION OF REACTOR TYPE AND OPERATION
8.1 Choice of Reactor Type
8.2 Reaction Mechanism and Kinetics
8.3 Thermodynamics
8.4 Other Factors
9 GENERAL REFERENCES AND SOURCES OF
INFORMATION
APPENDICES
A RELATIONSHIP BEWTEEN DEFINED TERMS
FIGURES
1 DECISION TREE
2 RELATIVE YIELDS OF B FOR BATCH (OR PLUG FLOW) AND CST REACTORS
3 REACTOR SURVEY FORM
Shortcut Methods of Distillation Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 ESTIMATIONOF PLATEAGE AND REFLUX
REQUIREMENTS
2.1 Generalized Procedure for Nmin and Rmin
2.2 Equation based Procedure for Nmin and Rmin
3 PREDICTION OF OVERALL PLATE EFFICIENCY
4 SIZING OF MAIN PLANT ITEMS
4.1 Column Diameter
4.2 Surface Area of Condensers and Reboilers
FIGURES
1 NON-IDEAL EQUILIBRIUM CURVE
2 AT A GLANCE CHART BASED ON FENSKE,
UNDERWOOD
3 PLATE EFFICIENCY CORRELATION OF O’CONNEL
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
OVERVIEW - FIXED BED ADSORBER DESIGN GUIDELINES
Fixed-bed adsorber design is based upon the following considerations:
• Adsorbent bed profile and media loading capacity characteristics for the specific application and adsorbent material used.
• Pressure drop characteristics across the adsorbent bed.
• Reaction kinetics.
Typically, adsorber design entails use of the following methodology:
• Adsorbent selection based upon performance and application information.
• Bed sizing based upon adsorbent loading data and service life requirements.
• Bed sizing adjustment based upon pressure drop criteria.
• Bed sizing adjustment based upon reaction kinetics criteria.
A discussion of each design consideration follows.
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
Catalyst poisons & fouling mechanisms the impact on catalyst performance Gerard B. Hawkins
Primary Effects
Secondary Effects
Typical Poisons in hydrocarbon processing
Permanent Poisons
- Arsenic, lead, mercury, cadmium…
- Silica, Iron Oxide….
Temporary Poisons
- Sulfur, Chlorides, Carbon
Boiler Feed water impurities
Heavy Metals
Foulants
THE NATURE OF CARBON DEPOSITS FORMED ON CATALYSTS
- CARBON FORMATION
Type A, B, C
- FEEDSTOCK COMPOSITION EFFECTS
COMMERCIAL’ CARBON DEPOSITS
- CARBON BURNING IN AIR
- CARBON REMOVAL BY STEAMING
- CARBON BURN CONTROL METHODS
- CATALYST – REACTION WITH STEAM
- MAXIMUM OXYGEN CONCENTRATION
- TEMPERATURE OF THE CATALYST SURFACE DURING CARBON BURNS
- CONDITIONS TO BURN OFF CARBON COATED CATALYST
- EFFECT OF CARBON FORMATION
DEACTIVATION OF METHANOL SYNTHESIS CATALYSTS
CONTENTS
1 INTRODUCTION
2 THERMAL SINTERING
3 CATALYST POISONING
4 REACTANT INDUCED DEACTIVATION
5 SUMMARY
TABLES
1 DEACTIVATION PROCESSES ON METHANOL SYNTHESIS CATALYSTS
2 MELTING POINT, HUTTIG AND TAMMANN TEMPERATURES OF COPPER, IRON AND NICKEL
3 SINTERING RATE CONSTANTS CALCULATED INLET AND OUTLET SIDE STREAM UNIT FOR VULCAN VSG-M101
4 COMPARISON BETWEEN CALCULATED S∞ AND DISCHARGED MEASUREMENTS ON VULCAN VSG-M101
5 EFFECT OF POSSIBLE CONTAMINANTS AND POISONS ON CU/ZNO/AL2O3 CATALYSTS FOR METHANOL SYNTHESIS
6 GUARD SCREENING TEST RESULTS ON METHANOL MICRO-REACTOR. EFFECT OF DEPOSITED METALS ON METHANOL ACTIVITY
FIGURES
1 THE HΫTTIG AND TAMMANN TEMPERATURES OF THE COMPONENTS OF A SYNTHESIS CATALYST
2 A SCHEMATIC REPRESENTATION OF TWO CATALYST SINTERING MECHANISMS
3 SIDE STREAM DATA FOR VULCAN VSG-M101. INLET TEMPERATURE 242 OC, PRESSURE 1500 PSI, GAS COMPOSITION 6% CO, 9.2% CO2, 66.9% H2, 2.5% N2 AND 15.4% CH4, SPACE VELOCITY 17,778 HR-1. MEAN OUTLET TEMPERATURE 280 OC
4 TEMPERATURE DEPENDENCE OF THE RATE OF SINTERING
5 MECHANISM OF SULFUR RETENTION
6 CORRELATION OF SULFUR CAPACITY WITH TOTAL SURFACE AREA
7 EFFECT OF DEPOSITED (NI+FE) PPM ON METHANOL SYNTHESIS CATALYST ACTIVITY
8 DISCHARGED (FE + NI) DEPOSITION LEVELS ON METHANOL SYNTHESIS PLANT SAMPLES
9 EPMA ANALYSIS OF DISCHARGED LABORATORY SAMPLE OF POISONED VULCAN VSG-M101
10 THE EFFECT OF CO2 ON SYNTHESIS CATALYST DEACTIVATION
REFERENCES
Flare radiation-mitigation-analysis-of-onshore-oil-gas-production-refining-fa...Anchal Soni
The main objective of this paper is to calculate the sterile area around an existing vertical flare of length 112 meters, located in an onshore facility and evaluate whether the current design is acceptable during a General Power Failure (GPF) scenario. The sterile area will be calculated at an elevation of 2m, which represents the typical head height for personnel.
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
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).
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
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 Selection of Flocculants and other Solid-Liquid Separation AidsGerard B. Hawkins
The use of chemical additives, such as flocculants, is a common step in solid-liquid separation operations. The correct selection of agent is an essential part of the design of such processes. Many excellent reviews and guides deal with this topic, and the interested reader is referred to works such as [l-4]. In particular the Harwell-Warren Spring Report “The Use and Selection of Flocculants" provides a good overview on the application of coagulants and flocculants. This section does not attempt to reproduce a detailed treatment of that kind; instead it is our intention to state a few general rules and principles concerning methods of choosing an additive, and to illustrate briefly their application in practice.
The types of agents employed in solid-liquid separation fall into three principal classes:
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
Tube Wall Temperature Measurement On Steam Reformers - Best Practices
Temperature Measurement Techniques
Top – Fired Reformer
- Tube Temperature Measurement
- Background Temperature Measurement
Side – Fired and Terrace Wall Reformer
- Tube Temperature Measurement
- Background Temperature Measurement
Safety Considerations
Reactor Modeling Tools - An Overview
CONTENTS
1 SCOPE
2 OPTIONS IN REACTOR MODELING
2.1 General
2.2 Level of Complexity of Model
2.3 Mode of Operation of Model
2.4 Deterministic versus Empirical Modeling
2.5 Platforms for Model
2.6 Steady State versus Dynamic Model
2.7 Dimensions Modeled in Reactor
2.8 Scale of Modeling for Multiphase Reactors
2.9 Writing and Using the Model
APPENDICES
A CHARACTERISTICS OF DIFFERENT REACTOR MODELS
B NEEDS FOR MODELING AT DIFFERENT SCALES IN
HETEROGENEOUS CATALYTIC REACTORS
C REACTOR MODELS EMPLOYED WITHIN GBHE
DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE
PROJECT MANAGEMENT: A Handbook for Small Projects
INTRODUCTION
This Information for Engineers document comprises two sections.
Section 1 contains the components of the GBHE Project Process, the capabilities and competencies required by a Project Manager and, finally, specific project management good practices including value improving practices.
Section 2 contains information that supports the practices contained within Section 1. This includes helpful checklists, references and information about deliverables and other examples, all of which will provide practical help to Project Managers and their project teams.
The document assists client sites in meeting the necessary engineering requirements related to safety, health and environmental matters on their sites, and supports the GBHE Safety, Security, Health and Environmental Policy.
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
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
Study 3: Detailed Design Hazards
CONTENTS
3.0 PURPOSE
3.0.1 Team
3.0.2 Timing
3.0.3 Preparation
3.0.4 Documentation
HAZARD STUDY 3: APPLICATION
3.1 Continuous Processes
3.2 Batch Processes
3.3 Mechanical Handling Operations
3.4 Maintenance and Operating Procedures
3.5 Programmable Electronic Systems
3.6 Failure Modes and Effects Analysis (FMEA) for Programmable Electronic Systems
3.7 Electrical Systems
3.8 Buildings
3.9 Other Studies
3.10 Other Related Tools
3.11 Human Factors
3.12 Review of Hazard Study 3
APPENDICES
A Continuous Processes
B Batch Processes
C Mechanical Handling Operations Guide Diagram
D Maintenance / Operating Procedure
E Programmable Electronic Systems
F DCS FMEA Method
G Electrical Systems Guide Diagram
H Building Design and Operability
Study 2: Front-End Engineering Design and Project DefinitionGerard B. Hawkins
Study 2: Front-End Engineering Design and Project Definition
CONTENTS
2.0 PURPOSE
2.0.1 Team
2.0.2 Timing
2.0.3 Documentation
HAZARD STUDY 2: APPLICATION
2.1 Study of Process and Non-Process Activities
2.2 Study of Programmable Electronic Systems (PES)
2.3 Risk Assessment
2.4 Defining the Basis for Safe Operation
2.5 Review of Hazard Study 2
APPENDICES
Appendix A Hazard Study 2 Method
A.1 Significant Hazards Flowsheet
A.2 Event Guide Diagram
A.3 Consequence Guide Diagram
A.4 Typical Measures to Reduce Consequences
Appendix B Programmable Electronic Systems (PES) Guide Diagram
Appendix C Risk Assessment
C.1 Risk Assessment Procedure
C.2 Risk Matrix
C.3 Risk Matrix Guidance for Consequence Categories – Safety and Health Incidents
C.4 Risk Matrix Guidance for Consequence Categories – Environmental Incidents
Appendix D Key Hazards and Control Measures
Appendix E Content of Hazard Study 2 Report Package.
Centrifugal Compressors
SECTION ONE - ANTI-SURGE PROTECTION AND THROUGHPUT REGULATION
0 INTRODUCTION
1 SCOPE
2 MACHINE CHARACTERISTICS
2.1 Characteristics of a Single Compressor Stage
2.2 Characteristic of a Multiple Stage Having More
Than One Impeller
2.3 Use of Compressor Characteristics in Throughput
Regulation Schemes
3 MECHANISM AND EFFECTS OF SURGE
3.1 Basic Flow Instabilities
3.2 Occurrence of Surge
3.3 Intensity of Surge
3.4 Effects of Surge
3.5 Avoidance of Surge
3.6 Recovery from Surge
4 CONTROL SCHEMES INCLUDING SURGE PROTECTION
4.1 Output Control
4.2 Surge Protection
4.3 Surge Detection and Recovery
5 DYNAMIC CONSIDERATIONS
5.1 Interaction
5.2 Speed of Response of Antisurge Control System
6 SYSTEM EQUIPMENT SPECIFICATIONS
6.1 The Antisurge Control Valve
6.2 Non-return Valve
6.3 Pressure and flow measurement
6.4 Signal transmission
6.5 Controllers
7 TESTING
7.1 Determination of the Surge Line
7.2 Records
8 INLET GUIDE VANE UNITS
8.1 Application
8.2 Effect on Power Consumption of the Compressor
8.3 Effect of Gas Conditions, Properties and Contaminants
8.4 Aerodynamic Considerations
8.5 Control System Linearity
8.6 Actuator Specification
8.7 Avoidance of Surge
8.8 Features of Link Mechanisms
8.9 Limit Stops and Shear Links
APPENDICES
A LIST OF SYMBOLS AND PREFERRED UNITS
B WORKED EXAMPLE 1 COMPRESSOR WITH VARIABLE INLET PRESSURE AND VARIABLE GAS COMPOSITION
C WORKED EXAMPLE 2 A CONSTANT SPEED ~ STAGE COMPRESSOR WITH INTER-COOLING
D WORKED EXAMPLE 3 DYNAMIC RESPONSE OF THE ANTISURGE PROTECTION SYSTEM FOR A SERVICE AIR COMPRESSOR RUNNING AT CONSTANT SPEED
E EXAMPLE OF INLET GUIDE VANE REGULATION
FIGURES
2.1 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT DISCHARGE CONDITIONS
2.2 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT INLET CONDITIONS
2.3 PERFORMANCE CHARACTERISTICS OF A COMPRESSOR STAGE AT VARYING SPEEDS
2.4 SYSTEM WORKING POINT DEFINED BY INTERSECTION OF PROCESS AND COMPRESSOR CHARACTERISTICS
2.5 DISCHARGE THROTTLE REGULATION
2.6 BYPASS REGULATION
2.7 INLET THROTTLE REGULATION
2.8 INLET GUIDE VANE REGULATION
2.9 VARIABLE SPEED REGULATION
3.1 GAS PULSATION LEVELS FOR A CENTRIFUGAL COMPRESSOR
3.2 REPRESENTATION OF CYCLIC FLOW DURING SURGE OF LONG PERIOD
3.3 TYPICAL WAVEFORM OF DISCHARGE PRESSURE DURING SURGE
3.4 MULTIPLE SURGE LINE FOR A MULTISTAGE CENTRIFUGAL COMPRESSOR
3.5 TYPICAL MULTIPLE SURGE LINES FOR SINGLE STAGE AXIAL-FLOW COMPRESSOR
4.1 GENERAL SCHEMATIC FOR COMPRESSORS OPERATING IN PARALLEL TO FEED MULTIPLE USER PLANTS
4.2 ILLUSTRATION OF SAFETY MARGIN BETWEEN SURGE POINT AND SURGE PROTECTION POINT AT WHICH ANTISURGE SYSTEM IS ACTIVATED
4.3 ANTISURGE SYSTEM FOR COMPRESSOR WITH FLAT PERFO ..........
(HTS) High Temperature Shift Catalyst (VSG-F101) - Comprehensiev OverviewGerard B. Hawkins
The high temperature shift duty introduction and theory
HTS catalyst characteristics
developments over time
Typical HTS operational problems
Improved catalysts
VULCAN Series VSG-F101 Series
Summary
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
Integration of Special Purpose Centrifugal Fans into a ProcessGerard B. Hawkins
Integration of Special Purpose Centrifugal Fans into a Process
0 INTRODUCTION
1 SCOPE
2 NOTATION
3 PRELIMINARY CHOICE OF NUMBER OF FANS
3.1 Volume Flow Q o
3.2 Definitions
3.3 Estimate of Equivalent Pressure Rise Δ P e
3.4 Choice of Fan Type
3.5 Choice of Control Method
4 GAS DENSITY CONSIDERATIONS
4.1 Calculation of Inlet Pressure
4.2 Calculation of Gas Density
4.3 Atmospheric Air Conditions
5 CAPACITY AND PRESSURE RISE RATING
5.1 Calculation of Fan Capacity
5.2 Calculation of Fan Pressure Rise
5.3 Multiple Duty Points
5.4 Stability
5.5 Parallel Operation
6 GUIDE TO FAN SELECTION
6.1 Effect of Gas Contaminants
6.2 Selection of Blade Type
6.3 Selection of Rotational Speed
6.4 Wind milling and Slowroll
6.5 Estimate of Fan External Dimensions
7 POWER RATING
7.1 Estimate of Fan Efficiency
7.2 Calculation of Absorbed Power
7.3 Calculation of Driver Power Rating
7.4 Motor Power Ratings
7.5 Starting Conditions for Electric Motors
8 CASING PRESSURE RATING
8.1 Calculation of Maximum Inlet Pressure ΔP i max
8.2 Calculation of Maximum Pressure Rise Δ P s max
8.3 Calculation of Casing Test Pressure
8.4 Rating for Explosion
9 NOISE RATING
9.1 Estimate of Fan Sound Power Rating LR
9.2 Acceptable Sound Power Level LW
9.3 Acceptable Sound Pressure Level L p
9.4 Assessment of Silencing Requirements
APPENDICES
A RELIABILITY CLASSIFICATION
B FAN LAWS
FIGURES
3.4 GUIDE TO FAN TYPE
4.5 VARIATION OF AIR DENSITY WITH TEMPERATURE AND ALTITUDE
6.3.1 DUTY BOUNDARY FOR SINGLE - INLET IMPELLERS
6.3.3 RELATIONSHIP BETWEEN HEAD COEFFICIENT AND SPECIFIC SIZE
6.3.6 ROTATIONAL SPEEDS FOR FAN IMPELLERS WITH BACK SWEPT VANES
6.3.7 ROTATIONAL SPEED FOR FAN IMPELLERS WITH RADIAL VANES
6.3.8 RELATIONSHIP OF IMPELLER TIP SPEED TO SHAPE
6.3.9 BOUNDARY DEFINING ARDUOUS DUTY
7.1 NOMOGRAPH FOR ESTIMATING THE EFFICIENCY OF A SINGLE STAGE FAN
7.2 GRAPH: COEFFICIENT OF COMPRESSIBILITY vs PRESSURE RATIO
7.5 GRAPH: MOMENT OF INERTIA OF FAN AND MOTOR (wR2) vs kW
Filtration
0 INTRODUCTION
1 The Theory Underlying Filtration Processes
1.1 The Mechanism of Simple Filtration Systems
1.1.2 Cake Filtration
1.1.3 Complete Blocking
1.1.4 Standard Blocking
1.1.5 Intermediate Blocking
1.2 Cake Filtration – Models and Mechanisms
1.2.1 Classical Theory for the Permeability of Porous Cakes and Beds
1.2.2 The Rate of Filtration through a Compressible Cake – The Standard Filtration Equation
1.2.3 The Compression or Consolidation of Filter Cakes – Ultimate degree of dewatering
1.2.4 The Rate of Consolidation
1.2.5 Useful Semi-Empirical Relations for Constant Pressure and Constant Rate Cake Filtration
1.2.6 Constant Pressure Filtration
1.2.7 Constant Rate Filtration
1.2.8 Multiphase Theory of Filtration
1.3 Crossflow Filtration
2 The Range and Selection of Filtration Equipment Technology
2.1 Scale
2.2 Solids Recovery, Liquids Clarification or Feed stream Concentration
2.3 Rate of Sedimentation
2.4 Rate of Cake Formation and Drainage
2.5 Batch vs Continuous Operation
2.6 Solids Loading
2.7 Further Processing
2.8 Aseptic or “Hygienic” Operation
2.9 Miscellaneous
2.10 Shear versus Compressional Deformation
2.11 Pressure versus Vacuum
3 Suspension Conditioning Prior to Filtration
3.1 Simple Filtration Aids
3.2 Mechanical Treatments
4 Post-Filtration Treatments and Further Downstream Processing
4.1 Washing
4.1.1 Air-Blowing
4.1.2 Drying
5 Testing and Characterization of Suspensions
5.1 Introduction – Suspension
5.2 Properties relevant to Filtration Performance
5.2.1 Pre-Filtration Properties of Suspension
5.2.2 Properties of Filter Cake
5.2.3 Laboratory Scale Filtration Rigs
5.3 Means of Monitoring Flocculant Dosage
5.4 Filter Cake Testing
5.4.1 Strength Testing (See also piston press described earlier)
5.4.2 Cake Permeability or Resistance
5.4.3 Rate of Cake Formation
6 Examples of the Application of the Forgoing Principles
6.1 Dewatering of Calcium Carbonate Slurries
6.2 Dewatering of Organic Products – Procion Dyestuffs
6.3 Filtration of Biological Systems – Harvesting a Filamentous Organism
References
Tables
Figures
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
SYNOPSIS
The principles underlying centrifugal separation of particulate species are briefly considered, and the main types of separator available are noted. The procedures available for scale-up from laboratory or semi-technical data are then discussed in detail with particular reference to perhaps the most important class of machine for fine particle processing: the disc-nozzle centrifuge.
Starting with the basic concepts behind their design, discussion follows to explain the factors which may limit centrifuge performance. It is shown how a few simple; laboratory scale tests can give a valuable insight into the design and operation of full-scale industrial machines.
Hydrogen Compressors
Engineering Design Guide
1 SCOPE
2 PHYSICAL ROPERTIES
2.1 Data for Pure Hydrogen
2.2 Influence of Impurities
3 MATERIALS OF CONSTRUCTION
3.1 Hydrogen from Electrolytic Cells
3.2 Pure Hydrogen
4 DESIGN
4.1 Pulsation
4.2 Bypass
5 TESTING OR COMMISSIONING RECIPROCATING COMPRESSORS
6 LUBRICATION
7 LAYOUT
8 REFERENCES
FIGURES
1 MOLLIER CHART - HYDROGEN
2 COMPRESSIBILITY CHART
3 NELSON DIAGRAM
4 WATER CONTENT IN HYDROGEN FOR OIL-LUBRICATED COMPRESSORS AS GRAMM/M2 SWEPT CYLINDER AREA
CONTENTS
1 SCOPE
2 PROPERTIES OF FLUID
2.1 General Properties of Sodium Hydroxide
2.2 Physical Properties of Sodium Hydroxide and its Solutions
2.3 Chemical Properties and uses of Sodium Hydroxide
2.4 Physiological effects of Sodium Hydroxide
2.5 Specifications of Commercial Caustic Soda Grades
3 CHOICE OF PUMP TYPE
3.1 Pump Duty
3.2 Pump Type
4 RECOMMENDED LINE DIAGRAMS
5 RECOMMENDED LAYOUT
6 CONSTRUCTION FEATURES
7 MATERIALS OF CONSTRUCTION
7.1 Nickel and Nickel Alloys
7.2 Austenitic Stainless Steel
7.3 Aluminium, Aluminium Alloys, etc.
7.4 Non-Metallic Materials
TABLES
1 PHYSICAL PROPERTIES (Solid Form)
2 PHYSICAL PROPERTIES (Solution Form)
3 CAUSTIC SODA GRADES
FIGURES
1.1 LINE DIAGRAM - HORIZONTAL GLANDED, GLANDLESS AND VERTICAL IN-LINE PUMPS
1.2 LINE DIAGRAM - VERTICAL SPINDLE CANTILEVER PUMPS
1.3 LINE DIAGRAM - SELF PRIMING PUMPS
1.4 LINE DIAGRAM - RECIPROCATING PLUNGER METERING PUMPS
1.5 LINE DIAGRAM - POSITIVE DISPLACEMENT DIAPHRAGM METERING PUMPS
1.6 WATER FLUSHING ARRANGEMENT FOR DOUBLE MECHANICAL SEAL
1.7 WATER FLUSH (QUENCH) ARRANGEMENT FOR SINGLE HARD FACED (CARBIDE) SEAL AND BACK-UP LIP SEAL
2 PHASE DIAGRAM OF NaOH-H2O
3 VISCOSITY OF AQUEOUS CAUSTIC SODA SOLUTIONS
4 VAPOR PRESSURE OF AQUEOUS CAUSTIC SODA SOLUTIONS
5 ENTHALPY CONCENTRATION FOR AQUEOUS CAUSTIC SODA SOLUTIONS
6 SPECIFIC GRAVITY FOR AQUEOUS CAUSTIC SODA SOLUTIONS
7 DILUTION OF CAUSTIC SODA LIQUOR
8 THERMAL CONDUCTIVITY OF AQUEOUS CAUSTIC SODA SOLUTIONS
9 SPECIFIC HEAT OF CAUSTIC SODA SOLUTIONS
10 BOILING POINTS OF STRONG CAUSTIC SODA SOLUTIONS AT REDUCED PRESSURE
11 COMMENCEMENT OF FREEZING OF CAUSTIC SODA SOLUTIONS (0 - 52% W/W)
12 TEMPERATURES ATTAINED ON DISSOLUTION OF ANHYDROUS CAUSTIC SODA
13 HEAT OF SOLUTION FOR ANHYDROUS CAUSTIC SODA
14 SOLUBILITY OF SODIUM CHLORIDE IN CAUSTIC SODA SOLUTIONS
15 DENSITY - CONCENTRATION TABLES FOR CAUSTIC SODA SOLUTIONS AT 600 F (15.5 0 C)
16 MATERIAL SELECTION CHART FOR CAUSTIC SODA HANDLING
How to Use the GBHE Mixing Guides
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE MIXING GUIDES
4.1 Mixing Guides
4.2 GBHE Mixing and Agitation Manual
5 DEVICE SELECTION
6 MIXING QUESTIONNAIRE
6.1 What is being mixed?
6.2 Why is it being mixed?
6.3 How is it to be mixed?
6.4 Is Heat Transfer Important?
6.5 Is Mixing Time Important?
6.6 Is Inventory Important?
6.7 Is Subsequent Phase Separation Important?
6.8 What Quantities?
6.9 What are the Selection Criteria?
6.10 What Data are required?
7 BASICS
7.1 Bulk Movement
7.2 Shear and Elongation
7.3 Turbulent Diffusion
7.4 Molecular Diffusion
7.5 Mixing Mechanisms
APPENDICES
A ROTATING MIXING DEVICES
B MIXING DEVICES WITHOUT MOVING PARTS
The Preliminary Choice of Fan or Compressor
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 METHOD FOR PRELIMINARY SELECTION
OF COMPRESSOR
5 PROCESS DATA SHEET
5.1 Essential Data for the Completion of a
Process Data Sheet
5.2 Gas Properties
5.3 Discharge Requirements
6 PRELIMINARY CHOICE OF FAN AND
COMPRESSOR TYPE
6.1 Essential Data for Preliminary Selection
7 FAN AND COMPRESSOR APPLICATIONS
7.1 Fans
7.2 Centrifugal Compressors
7.3 Axial Compressors
7.4 Reciprocating Compressors
7.5 Screw Compressors
7.6 Positive Displacement Blowers
7.7 Sliding Vane Compressors
7.8 Liquid Ring Compressors
8 PROVISION OF INSTALLED SPARES
9 PRELIMINARY ESTIMATE OF COSTS
Integration of Special Purpose Reciprocating Compressors into a ProcessGerard B. Hawkins
1 SCOPE
2 CHOICE OF COMPRESSOR TYPE
2.1 Parameters
2.2 Preliminary Choice of Machine Type
2.3 Review of Other Types of Compressor
3 CHOICE OF NUMBER OF COMPRESSORS
3.1 Influence of Reliability Classification
3.2 Driver Considerations
3.3 Deterioration of Standby Machines
4 EFFECTS OF PROCESS GAS COMPOSITION
4.1 Particulate Contamination
4.2 Droplets in Suspension
4.3 Polymer Deposit
4.4 Molecular Weight Variation
4.5 Compressibility Variation
4.6 Gas Dryness
4.7 Gas Solution in Lubricating Oil for Cylinder and Gland
5 THROUGHPUT REGULATION
5.1 Inlet Line Throttle Valve
5.2 Inlet Line Cut-off Valve
5.3 Compressor Inlet Valve Lifter
5.4 Clearance Volume Variation
5.5 Speed Variation
5.6 Bypass
5.7 Hybrid Regulation Systems
6 PRINCIPAL FEATURES
6.1 Calculate Discharge Gas Temperature
6.2 Choice of Number of Stages
6.3 Configuration
6.4 Valve Operation Limit on Piston Speed
6.5 Limits for Mean Piston Speed
6.6 Estimation of Volumetric Efficiency
6.7 Estimation of Crankshaft Rotational Speed
6.8 Calculation of Piston Diameter
6.9 Choice of Number of Cylinders
7 DRIVER TYPE
7.1 Electric Motors
7.2 Steam Turbines
7.3 Special Drivers
8 VESSELS
APPENDICES
A RELIABILITY CLASSIFICATION
B CONDITIONS FOR LUBRICATED CYLINDERS AND GLANDS
C ESTIMATE OF LUBE OIL CONTAMINATION OF PROCESS GAS
D INFLUENCE OF GAS COMPOSITION AND MACHINE CONSTRUCTION
ON FILLED PTFE PISTON RING SEALS
E LIMITS ON GAS TEMPERATURES
FIGURES
1 SELECTION CHART
2 DESIGN SEQUENCE 1 - ESTIMATE NUMBER OF STAGES
3 DESIGN SEQUENCE 2 - ESTIMATE CYLINDER SIZES
Gas Mixing
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 RECOMMENDATIONS FOR GAS MIXING:
PLUG FLOW
5 RECOMMENDATIONS FOR GAS MIXING:
BACKMIXED INITIAL ZONE
6 BIBLIOGRAPHY
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
VLE Data - Selection and Use
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 DIAGRAMMATIC REPRESENTATION OF IDEAL
AND NON-IDEAL SYSTEMS
4.1 Ideal Mixtures
4.2 Non-Ideal Mixtures
5 REVIEW OF VLE MODELS
5.1 Ideal Behavior in Both Phases
5.2 Liquid Phase Non-Idealities
5.3 High Pressure Systems
5.4 Special Models
6 SETTING UP A VLE MODEL
6.1 Define Problem
6.2 Select Data
6.3 Select Correlation(s)
6.4 Produce Model
7 AVOIDING PITFALLS
7.1 Experimental Data is Better than Estimates
7.2 Check Validity of Fitted Model
7.3 Check Limitations of Estimation Methods
7.4 Know Your System
7.5 Appreciate Errors and Effects
7.6 If in Doubt – Ask
8 A CASE STUDY
8.1 The Problem
8.2 The System
8.3 Data Available
8.4 Selected Correlation
8.5 Simulation
8.6 Selection of Model
9 RECOMMENDED READING
10 VLE EXPERTS IN GBHE
APPENDICES
A USE OF EXTENDED ANTOINE EQUATION
B USE OF WILSON EQUATION
C USEFUL METHODS OF ESTIMATING
D EQUATIONS OF STATE FOR VLE CALCULATIONS
TABLES
1 SUMMARY OF VLE METHODS
2 LIST OF USEFUL REFERENCES
FIGURES
1 VAPOR-LIQUID EQUILIBRIUM - IDEAL SOLUTION
BEHAVIOR
2 VAPOR-LIQUID EQUILIBRIUM - A GENERALISED
Y-X DIAGRAM
3 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE
4 VAPOR-LIQUID EQUILIBRIUM - MAXIMUM BOILING
AZEOTROPE
5 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE -TWO LIQUID PHASES
6 SENSITIVITY TO ERROR IN VLE DATA (BASED ON FENSKE EQUATION)
7(a) FITTING WILSON 'A' VALUES TO VLE DATA - CASE A
7(b) FITTING WILSON 'A' VALUES TO VLE DATA - CASE B
7(c) FITTING WILSON 'A' VALUES TO VLE DATA - CASE C
Large Water Pumps
CONTENTS
1 SCOPE
SECTION ONE: INTEGRATION OF PUMPS INTO THE PROCESS
2 PROPERTIES OF FLUID
2.1 Cooling Water
2.2 Brine
2.3 Estuary Water
2.4 Harbor Water
2.5 Oil-field water
3 CALCULATION OF DUTY
4 CHOICE OF TYPE AND NUMBER OF PUMPS
4.1 Type of Pump
4.2 Points to Consider
4.3 Number of Pumps
5 RECOMMENDED LINE DIAGRAM
5.1 Check List for Each Pump
6 RECOMMENDED LAYOUT
SECTION TWO: CONSTRUCTION FEATURES
7 HORIZONTAL, AXIALLY SPLIT CASING PUMPS
7.1 Pressure Casing
7.2 Bolting
7.3 Flanges and Connections
7.4 Rotating Elements
7.5 Wear Rings
7.6 Running Clearances
7.7 Mechanical Seals
7.8 Packed Glands
7.9 Bearings and Bearing Housings
7.10 Lubrication
7.11 Couplings
7.12 Guards
7.13 Baseplates
7.14 Flywheels
8 VERTICAL PUMPS
8.1 General
8.2 Pressure Casing
8.3 Bolting
8.4 Flanges and Connections
8.5 Rotating Element
8.6 Packed Glands
8.7 Bearings and Bearing Housings
8.8 Pump Head
8.9 Column Pipes
8.10 Line Shaft and Couplings
8.11 Reverse Rotation
8.12 Gearboxes
9 MATERIALS
9.1 Castings
9.2 Casings
9.3 Impellers
9.4 Shafts
9.5 Shaft Sleeves
9.6 Bolts and Nuts
10 DRIVERS
10.1 Electric Motor Drives
11 BIBLIOGRAPHY
APPENDICES:
A COOLING WATER - EUROPEAN SITE
B TIDAL RIVER ESTUARY
C FLYWHEEL INERTIA FOR PRESSURE SURGE ABATEMENT
D RESIN COATING OF CASINGS FOR WATER PUMPS
E AREA RATIO METHOD
F NOTES ON PUMP IMPELLERS CASTINGS
G LIMIT ON SHAFT DIAMETER FOR HORIZONTAL PUMPS HAVING
ONE DOUBLE-ENTRY IMPELLER SUPPORTED BETWEEN BEARINGS
H FORCES AND BENDING MOMENTS ON RISING MAIN ASSEMBLY
I POWER COSTS
J PUTATIVE COST COMPARISON SHEET
K TECHNICAL COMPARISON SHEETS
FIGURES
2.1 VAPOR TEMPERATURE CURVES
2.2 DENSITY TEMPERATURE CURVES
3.1 TYPICAL HEAD OF PUMPS
3.2 TOTAL HEAD OF VERTICAL IMMERSED PUMP
3.3 TYPICAL TIDAL RIVER ESTUARY LEVELS
3.5 SUBMERGENCE LIMITS
4.1 TYPES OF PUMP
4.2 GUIDE TO PUMP TYPE AND SPEED
5.1 TYPICAL LINE DIAGRAM
6 GUIDE TO SUCTION PIPEWORK DESIGN
7 CASING AND IMPELLER DETAILS
8.1 DRY WELL AND WET WELL PUMP INSTALLATIONS
8.2 BELLMOUTH DIMENSIONS FOR VERTICAL INTAKES
8.3 MAXIMUM SPACING BETWEEN SHAFT GUIDE BUSHING
8.4 LINE SHAFT COUPLING
9 TYPICAL VOLUTE CASING
10 TYPICAL CASE WEAR RINGS
11 SEAL AREA
TABLES
1 LIQUID PROPERTIES SODIUM CHLORIDE (25% W/W)
2 LIQUID PROPERTIES SODIUM CHLORIDE (20% W/W)
3 LIQUID PROPERTIES SODIUM CHLORIDE (16.25% W/W)
4 LIQUID PROPERTIES SODIUM CHLORIDE (15% W/W)
5 LIQUID PROPERTIES SODIUM CHLORIDE (10% W/W)
6 LIQUID PROPERTIES SODIUM CHLORIDE (5% W/W)
7 GUIDE TO PUMP TYPE AND SPEED
8 RECOMMENDED CAST MATERIALS FOR USE IN THE PUMP INDUSTRY
GRAPHS
1 GUIDE TO ROTOR INERTIA
2 LIMITS BETWEEN BEARINGS
DOCUMENTS REFERRED TO IN THIS ENGINEERING DEPARTMENT DESIGN GUIDE
Pressure Systems
CONTENTS
0 INTRODUCTION
1 SCOPE
2 DEFINITIONS ADDITIONAL TO THOSE IN THE EP GLOSSARY
2.1 PRESSURE VESSEL
2.2 ATMOSPHERIC PRESSURE STORAGE TANK
2.3 VESSEL
2.4 PIPING SYSTEM
2.5 NON-PRESSURE PROTECTIVE DEVICE
2.6 ASSOCIATED RELIEF EQUIPMENT
3 APPLICATION OF PRINCIPLES
3.1 IMPLEMENTATION OF PEG 4
3.2 DESIGN, MANUFACTURE, REPAIR AND MODIFICATION
3.3 VERIFICATION OF DESIGN
3.4 GBHE REGISTRATION AND RECORDS
3.5 PERIODIC EXAMINATION
4 AUDITING
4.1 General
4.2 Scope of Audit
APPENDICES
A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION
C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT
D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT
E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES
F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS
G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION
TABLES
1 REGISTERED VESSELS AND PIPING SYSTEMS: MAXIMUM EXAMINATION INTERVALS
2 EQUIPMENT TO BE CONSIDERED FOR CATEGORY LLT
FIGURES
1 SIMPLE PRESSURE RELIEF ARRANGEMENT
2 COMPLEX PRESSURE RELIEF ARRANGEMENT
DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS DOCUMENT
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainl...Gerard B. Hawkins
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainless Steels in Chloride and Caustic Environments
SYNOPSIS
This Maintenance Best Practice Guide is concerned with the performance of carbon and low alloy steels, and austenitic stainless steels, in chloride and caustic containing fluids. Those factors which are known to promote stress corrosion cracking are outlined, and service charts defining environmental boundaries for stress corrosion cracking in caustic and chloride containing fluids are presented.
General guidance on the avoidance of stress corrosion cracking is provided.
Similar to GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases (20)
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
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
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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
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Brief History
Reformer Burner Types/Design
Types of Reformers
Combustion Characteristics
Excess Air/Heater Efficiency
Maintenance, Good Practice
Low Nox Equipment
Summary
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...Gerard B. Hawkins
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates
1 Executive Summary
2 Claus Process
2.1 Partial Combustion Claus
2.2 Split Flow Claus
2.3 Sulfur Recycle Claus
3 Zinc Titanates
4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10%
4.1 Process
4.2 ASPEN Modeling Results
4.3 Cost of Zinc Titanate Bed Installation
4.3.1 Basis of Costing
4.3.2 Zinc Titanate Beds
4.3.3 Regen Cooler
4.3.4 Blowers
4.3.5 Results
4.4 Alternative Debottlenecking Technology for Partial Combustion Claus
4.5 Cost of 10% Debottlenecking Using COPE Process
5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates
6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate
7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems
7.1 Selectox
7.2 SuperClaus99
7.3 Superclaus 99.5
7.4 SCOT Process
7.5 Zinc Titanate as a Claus Tail Gas Treatment
7.6 H2S Removal Efficiency With Zinc Titanate
8 Effects on COS and CS2 Formation
9 Questions for further Investigation
FIGURES
Figure 1 Claus Unit and TGCU
Figure 2 Claus Process
Figure 3 Typical Claus Sulfur Recovery Unit
Figure 4 Two-Stage Claus SRU
Figure 5 The Super Claus Process
Figure 6 SCOT
Figure 7 SCOT/BSR-MDEA (or clone) TGCU
REFERENCES: PATENTS
US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT
US4394297_ZINC_TITANATE_CATALYST
US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS
Catalyst Catastrophes in Syngas Production - II
Contents
Review of incidents by reactor
Primary reforming
Secondary reforming
HTS
LTS
Methanator
Reactor loading
Support media
Some general comments on alternative actions when a plant gets into abnormal operation
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
Integration of Special Purpose Centrifugal Pumps into a ProcessGerard B. Hawkins
Integration of Special Purpose Centrifugal Pumps into a Process
CONTENTS
1 SCOPE
2 PRELIMINARY CHOICE OF PUMP
SECTION A - INLET CONDITIONS
Al Calculation of Basic Nett Positive Suction Head (NPSH)
A2 Correction to Basic NPSH for Temperature Rise at Pump Inlet
A3 Correction to Basic NPSH for Acceleration Head
A4 Calculation of Available NPSH
A5 Correction to NPSH for Fluid Properties
A6 Calculation of Suction Specific Speed
A7 Priming
A8 Submergence
SECTION B – FLOW / HEAD RATING SEQUENCE
B1 Calculation of Static Head
B2 Calculation of Margins for Control
B3 Calculation of Q-H Duty
B4 Stability and Parallel Operation
B5 Corrections to Q-H Duty for Fluid Properties
B6 Guide to Pump Type and Speed
SECTION C – DRIVER POWER RATING
C1 Estimation of Pump Efficiency
C2 Calculation of Absorbed Power
C3 Calculation of Driver Power Rating
C4 Preliminary Power Ratings of Electric Motors
C5 Starting Conditions for Electric Motors
C6 Reverse Flow and Reverse Rotation
SECTION D - CASING PRESSURE RATING
D1 Calculation of Maximum Inlet Pressure
D2 Calculation of Differential Pressure
D3 Pressure Waves
D4 Pressure due to Liquid Thermal Expansion
D5 Casing Hydrostatic Test Pressure
SECTION E – SEALING CONSIDERATIONS
E1 Preliminary Choice of Seal
E2 Fluid Attributes
E3 Definition of Flushing Arrangements
APPENDICES
A RELIABILITY CLASSIFICATION
B SYMBOLS AND PREFERRED UNITS
DOCUMENTS REFERRED TO IN THIS ENGINEERING DESIGN GUIDE
Amines
Stereochemistry, Reaction Mechanisms, Catalysis, Production Processes and Applications
Contents
Historical perspective
Background
(MMA, DMA and TMA)
Stereochemistry and Structure
Reaction Mechanisms and Thermodynamics
CATALYSTS FOR AMINATION
Non-Zeolitic Catalysts for Amination
Mordinite (MOR) Catalysts for Amination
Zeolite Catalysts for Amination
Amines Production
Amines: Markets and Applications
Gas Separation
Conventional Amines Treating System
Amine System for Gas Sweetening
APPENDIX
Structures
Ethyleneamines Production
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SAP heatmap example with demo
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Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
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GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBH Enterprises, Ltd.
Process Safety Guide:
GBHE-PGP-020
GAS DISPERSION
A Definitive Guide to Accidental Releases
of Heavy Gases
Process Information Disclaimer
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.
2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Process Safety Guide: Gas Dispersion
CONTENTS
0 INTRODUCTION
0.1 AIMS
0.2 SCOPE
0.5 FURTHER INFORMATION
1 METEOROLOGICAL PARAMETERS WHICH AFFECT DISPERSION
1.1 ROUGHNESS LENGTHS (Zo)
1.2 WIND SPEEDS
1.3 ATMOSPHERIC STABILITY
1.3.1 General
1.3.2 Pasquill - Gifford Methods of Characterizing Atmospheric Stability
1.3.3 Monin-Obukhov Length Methods of Representing Atmospheric
Stability
TABLES
1.1 TYPICAL ROUGHNESS LENGTHS
1.2 KEY TO PASQUILL - GIFFORD STABILITY CATEGORIES
1.3 METHOD OF ESTIMATING LEVEL OF INCIDENT RADIATION
1.4 EXAMPLE PASQUILL-GIFFORD STABILITY ANALYSIS
FIGURES
1.1 THE EFFECT OF ATMOSPHERIC STABILITY ON PLUME DISPERSION
1.2 RELATIONSHIP BETWEEN PASQUILL-GIFFORD STABILITY
CATEGORY AND MONIN-OBUKHOV LENGTH
2 AIR QUALITY STANDARDS
2.1 WHAT ARE AIR QUALITY STANDARDS?
2.2 WHAT AIR QUALITY STANDARDS EXIST
2.2.1 General Background
2.2.2 United States
2.2.3 European Union
2.2.4 The Netherlands
2.2.5 Japan
2.2.6 Taiwan
2.2.7 United Kingdom Air Quality Strategy
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2.2.8 Non-Governmental Organizations
2.2.9 Occupational Exposure Limits
2.2.10 General Comparison
2.2.11 Air Quality Standards for Odor Impacts
2.3 WHAT IS THE LAW - AND WHAT ISN’T
2.4 FUTURE DEVELOPMENTS
3 MODEL COMPARISON AND SELECTION
3.1 CLASSIFICATION OF DISPERSION MODELING PROBLEMS
3.2 WHAT MODELS ARE AVAILABLE?
3.3 DESCRIPTION OF AVAILABLE MODELS
3.3.1 General
3.3.2 ADMS (Atmospheric Dispersion Modeling System)
3.3.3 ALOHA (Areal Locations of Hazardous Atmospheres)
3.3.4 DISP2
3.3.5 ISC (Industrial Source Complex)
3.3.6 PHAST (Process Hazard Assessment Tools)
3.3.7 Other Models
3.3.8 Summary of Model Applications
3.4 COMPARISON OF MODEL RESULTS
3.4.1 General
3.4.2 Buoyant gas releases
3.4.3 Dense Gas Dispersion
3.5 RECOMMENDATIONS
TABLES
3.1 COMMONLY USED DISPERSION MODELS
3.2 SUMMARY OF MODEL APPLICATIONS
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FIGURES
3.1 CATEGORIZATION OF DISPERSION MODELING
PROBLEMS
3.2 BUOYANT GAS RELEASE: ADMS RESULTS
3.3 BUOYANT GAS RELEASE : DISP2 RESULTS
3.4 BUOYANT GAS RELEASE: ISC RESULTS
3.5 BUOYANT GAS RELEASE: PHAST RESULTS
3.6 SINGLE PHASE DENSE GAS RELEASE UNDER STABLE
ATMOSPHERIC CONDITIONS
3.7 CATASTROPHIC DENSE GAS RELEASE UNDER
UNSTABLE ATMOSPHERIC CONDITIONS
3.8 SINGLE PHASE DENSE GAS RELEASE: ALOHA
RESULTS
3.9 TWO PHASE DENSE GAS RELEASE: PHAST RESULTS
4 STACK DESIGN
4.1 INTRODUCTION
4.2 STACK DESIGN
4.2.1 Stage A: Preceding Design Work
4.2.2 Stage B: Estimate Mass Emission Rates
4.2.3 Stage C: Identify Acceptable Process Contributions
4.2.4 Stage D: Identify Significant Pollutants
4.2.5 Stage E: Initial Stack Design
4.2.6 Stage F: Model On-site Concentrations
4.2.7 Stage G: Model Off-site Concentrations
4.2.8 Stage H: Assess Results
4.3 FURTHER CASE STUDY
FIGURE
4.1 FLOW CHART FOR STACK DESIGN
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5 DENSE GAS DISPERSION
5.1 INTRODUCTION
5.2 MODELING METHODOLOGIES
5.2.1 Instantaneous Catastrophic Releases
5.2.2 The Dispersion of a Continuous Dense Gas Plume
5.3 POINTS TO NOTE
5.4 VALIDATION WORK
5.5 DISPERSION MODELS AVAILABLE
5.5.1 DISP2
5.5.2 HGSYSTEM5
5.5.3 ALOHA
5.5.4 PHAST
5.5.5 EFFECTS
5.5.6 GASTAR
5.5.7 LORIMAR Model
FIGURES
5.1 CLOUD SHAPE AS A FUNCTION OF TIME
5.2 BEHAVIOR OF A DENSE GAS PLUME WITH VERTICAL MOMENTUM
6 SOURCE TERMS
6.0 INTRODUCTION
6.1 SOURCE CHARACTERISTICS AND HOLE SIZES
6.1.1 Ammonia Storage Tank Example
6.1.2 Estimation of Hole Sizes
6.1.3 Inventories and Time Dependent Behavior
6.2 THE DISCHARGE OF GASES THROUGH HOLES
6.2.1 Compressible Choked Flow
6.2.2 Compressible Unchoked Flow
6.2.3 Incompressible Flow
6.2.4 Discharge Coefficients
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6.3 TWO-PHASE RELEASES
6.3.1 Catastrophic Releases of a Liquefied Gas
6.3.2 Two-Phase Releases Arising from Guillotine Failures of Pipe work
6.4 LIQUID POOL SPREADING AND EVAPORATION
6.5 SOURCE TERMS FOR ENVIRONMENTAL RELEASES
6.5.1 General
6.5.2 A Real Example
6.5.3 A Source Data Checklist for Environmental Applications
6.6 REFERENCES
FIGURES
6.1 POSSIBLE RELEASE SCENARIOS FROM A LIQUEFIED AMMONIA
STORAGE TANK
6.2 COMPARISON OF PLUME CHARACTERISTICS vs. TARGET
DISTANCE
6.3 DIAGRAMMATIC REPRESENTATION OF PSEUDO SOURCE
DIAMETER
6.4 EVAPORATION RATE OF CHLORINE FROM AN INSTANTANEOUS
10 TONNE SPILL
7 BUILDING WAKE EFFECTS
7.1 WHY ARE BUILDING WAKE EFFECTS IMPORTANT?
7.2 HOW DO BUILDINGS INFLUENCE ATMOSPHERIC
DISPERSION?
7.3 SCIENTIFIC UNDERSTANDING OF BUILDING WAKE EFFECTS
7.4 THE BUILDINGS MODULE IN ADMS: PRINCIPLES
7.5 THE BUILDINGS MODULE IN ADMS: APPLICATION
7.5.1 When Should the Buildings Module be Used?
7.5.2 Points to Note About Using the Buildings Module
7.5.3 Interpreting the Results of the Buildings Module
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FIGURES
7.1 THE INFLUENCE OF A BUILDING WAKE ON PLUME
DISPERSION
7.2 SCHEMATIC DIAGRAM OF TURBULENT ZONES USED IN
ADMS BUILDING MODULE
7.3 EFFECT OF BUILDING WIDTH ON WAKE DISPERSION
7.4 AREAS OF CONCERN DUE TO BUILDING EFFECTS
7.5 THE BUILDINGS MODULE OF ADMS (STABLE CONDITIONS)
8 MODELING THE DISPERSION OF OXIDES OF NITROGEN
8.1 GENERAL
8.2 ASSESSING NOx LEVELS
8.2.1 Approach 1
8.2.2 Approach 2
8.2.3 Approach 3
8.2.4 Approach 4
8.2.5 Suggested Method
8.3 EXAMPLE: DISPERSION OF NOx FROM A BOILER HOUSE
FIGURE
8.1 SAMPLE NO2 NOx RATIO CALCULATION
9 THE COMPLEX TERRAIN MODULE IN ADMS
9.1 WHAT IS THE COMPLEX TERRAIN MODULE?
9.2 HOW DOES THE COMPLEX TERRAIN MODULE OF ADMS
WORK?
9.2.1 Wind Flow
9.2.2 Dispersion Calculations
9.3 WHEN AND HOW SHOULD THE COMPLEX TERRAIN MODULE
BE USED?
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9.4 WHAT IS THE EFFECT OF USING THE COMPLEX TERRAIN
MODULE?
9.4.1 Conclusions - Terrain Elevations
9.4.2 Conclusions - Variations in Surface Roughness
9.4.3 Conclusions - Buoyant Releases
TABLES
9.1 COMPARISON OF REPRESENTATIVE CONCENTRATIONS FOR
RELEASES UPWIND OF HILL
9.2 COMPARISON OF REPRESENTATIVE CONCENTRATIONS FOR
RELEASES DOWNWIND OF HILL
FIGURES
9.1 WIND FLOW AROUND A HILL (SIDE VIEW)
9.2 WIND FLOW AROUND A HILL UNDER STABLE ATMOSPHERIC
CONDITIONS (PLAN VIEW)
9.3 TOPOGRAPHY OF THE RUNCORN AREA
9.4 MODELED CONCENTRATIONS DUE TO EMISSIONS FROM 60 m
STACKS UPWIND OF HILL B STABILITY / 2 m/s
9.5 MODELED CONCENTRATIONS DUE TO EMISSIONS FROM 60 m
STACKS DOWNWIND OF HILL B STABILITY / 2 m/s
9.6 MODELED CONCENTRATIONS DUE TO EMISSIONS FROM 60 m
STACKS UPWIND OF HILL D STABILITY / 5 m/s
9.7 MODELED CONCENTRATIONS DUE TO EMISSIONS FROM 60 m
STACKS DOWNWIND OF HILL D STABILITY / 5 m/s
9.8 MODELED CONCENTRATIONS DUE TO EMISSIONS FROM 60 m
STACKS UPWIND OF HILL F STABILITY / 2 m/s
9.9 MODELED CONCENTRATIONS DUE TO EMISSIONS FROM 60 m
STACKS DOWNWIND OF HILL F STABILITY / 2 m/s
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10 THE DEPOSITION MODULE OF ADMS - A BRIEF GUIDE
10.1 INTRODUCTION
10.2 DEPOSITION MODELING METHODOLOGY USED IN ADMS
10.3 DEFAULT AND RECOMMENDED INPUTS USED IN ADMS
10.3.1 Wet Deposition
10.3.2 Dry Deposition
10.4 RECOMMENDATIONS FOR USING DEPOSITION MODULE
10.5 EXAMPLE APPLICATION OF THE DEPOSITION MODULE
TABLES
10.1 WET DEPOSITION COEFFICIENTS
10.2 DRY DEPOSITION VELOCITIES FOR GASEOUS COMPOUNDS
10.3 DISTANCES AT WHICH DEPOSITION PROCESSES HAVE A
SIGNIFICANT EFFECT ON AIR CONCENTRATIONS
FIGURES
10.1 PARTICULATE DRY DEPOSITION VELOCITIES AS A FUNCTION OF
PARTICLE DIAMETER
11 EXAMPLE GAS DISPERSION CALCULATIONS FOR
ENVIRONMENTAL APPLICATIONS USING ADMS
11.1 INTRODUCTION
11.2 SOURCE DATA
11.3 EXAMPLE CALCULATIONS
11.3.1 EXAMPLE ONE - CONTINUOUS EMISSIONS
11.3.2 EXAMPLE TWO - MULTIPLE STACK CALCULATION
11.3.3 EXAMPLE THREE - ODOR DISPERSION CALCULATION
11.3.4 EXAMPLE FOUR - DISPERSION AROUND A BUILDING
11.3.5 EXAMPLE FIVE - ANNUAL AVERAGE STATISTICAL
CALCULATION FOR AN AREA SOURCE
11.3.6 EXAMPLE SIX - DISPERSION OF PARTICULATES FROM
A PRILLING TOWER
11.4 ACCURACY OF ADMS-2
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11.5 CHOICE OF WIND AND WEATHER CONDITIONS FOR DESIGN
11.6 RUN TIMES
11.6.1 GENERAL
11.6.2 RUNNING BATCH FILES
11.7 WIND AND WEATHER DATA
11.8 SUMMARY OF ROUGHNESS LENGTHS (Z O)
11.9 CALCULATION TRENDS
FIGURES
11.1 OUTPUT FROM X-Y PLOTTING OPTION
11.2 THE DISPERSION OF SULFUR DIOXIDE FROM A 40 M STACK
11.3 SAMPLE ADMS LINE PLOT : PLUME HEIGHT (M)
11.4 SAMPLE ADMS LINE PLOT : MAXIMUM CONCENTRATION IN
PLUME
11.5 THE DISPERSION OF THE OXIDES OF NITROGEN FROM A
PLASTICS WORKS
11.6 THE DISPERSION OF THE OXIDES OF NITROGEN FROM A
PLASTICS WORKS
11.7 THE DISPERSION OF THE OXIDES OF NITROGEN FROM A
PLASTICS WORKS
11.8 THE DISPERSION OF THE OXIDES OF NITROGEN FROM A
PLASTICS WORKS
11.9 ANNUAL AVERAGE CONCENTRATION OF THE OXIDES OF
NITROGEN - BOTH STACKS AT 40 m
11.10 MEAN GROUND-LEVEL CONCENTRATION - EXAMPLE THREE
11.11 THE DISPERSION OF ETHYL ACRYLATE FROM A 15 m HIGH
STACK - 98th PERCENTILE OF CONCENTRATION
FLUCTUATIONS - 5 m/s NEUTRAL ATMOSPHERIC STABILITY
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11.12 THE DISPERSION OF ETHYL ACRYLATE FROM A 15 m HIGH
STACK - 2 m/s UNSTABLE ATMOSPHERIC CONDITIONS -
98th
PERCENTILE OF SHORT TERM CONCENTRATIONS
11.13 THE DISPERSION OF ETHYL ACRYLATE FROM A 50 m HIGH
STACK - 2 m/s UNSTABLE ATMOSPHERIC CONDITIONS -
98th
PERCENTILE OF CONCENTRATION FLUCTUATIONS
11.14 EFFECT OF WIND DIRECTION ON CONCENTRATION -
EXAMPLE FOUR
11.15 DISPERSION OF SO2 FROM A SULFURIC ACID RECOVERY
PLANT - EXAMPLE FOUR
11.16 DISPERSION OF SO2 FROM A SULFURIC ACID RECOVERY
PLANT - 30 m STACK - EXAMPLE FOUR
11.17 ANNUAL AVERAGE BENZENE CONCENTRATIONS FROM A
SMALL LAGOON
11.18 THE DISPERSION OF PARTICULATES FROM A PRILLING
TOWER - EXAMPLE SIX
11.19 TOTAL ANNUAL DEPOSITION RATE FROM THE PRILLING
TOWER (µg/m2
s)
11.20 MAXIMUM 24 HOUR MEAN PARTICULATE CONCENTRATION
FROM A PRILLING TOWER
12 DISPERSION MODELING OF ODOROUS RELEASES
12.1 ODOR EMISSIONS - CHARACTERIZATION AND
MEASUREMENT
12.2 AVERAGING TIMES
12.2.1 Concentration Fluctuations
12.2.2 Change in Mean Wind Direction
12.2.3 Accounting for Dependence on Averaging Time
12.3 ODOR THRESHOLDS
12.4 ODOR DISPERSION MODELING
12.5 EXAMPLE ODOR DISPERSION MODELING STUDY
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FIGURES
12.1 INSTANTANEOUS AND AVERAGED PLUME DISPERSION
12.2 ACTUAL CONCENTRATIONS OF RELEASED MATERIAL
12.3 ACTUAL AND MEASURED CONCENTRATIONS OF RELEASED
MATERIAL
12.4 STATISTICAL DESCRIPTIONS OF MEASURED
CONCENTRATIONS
12.5 WIND DIRECTION ENVELOPES FOR SHORT AND LONG-TERM
MEANS
12.6 EXAMPLE STUDY : SITE DIAGRAM
TABLES
12.1 APPROPRIATE AVERAGING TIMES
12.2 EXAMPLE STUDY: PLANT ODOROUS RELEASES
12.3 EXAMPLE STUDY: MODELED CONCENTRATIONS
13 BIBLIOGRAPHY
14 GLOSSARY
APPENDICES
APPENDIX A WIND GENERATION OF PARTICULATES
APPENDIX B TABLE OF PROPERTY VALUES FOR SPECIFIC
CHEMICALS
DOCUMENTS REFERRED TO IN THIS PROCESS SAFETY GUIDE
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0 INTRODUCTION
0.1 AIMS
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.
• Identifying personnel within GBHE's Alliance Network with expertise and
experience of dispersion modeling.
• Providing example calculations for real practical problems.
0.2 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.
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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
The two models referred to by name are the currently preferred models for dense
gas dispersion (PHAST) and neutral/buoyant gas dispersion (ADMS).
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1 METEOROLOGICAL PARAMETERS WHICH AFFECT DISPERSION
1.1 ROUGHNESS LENGTHS (Zo)
The roughness length is a parameter which quantifies the effect ground
roughness has on the turbulent flow properties of the wind - the higher the
roughness length, the more turbulent the wind flow.
For an elevated stack, the higher the roughness length, the more rapidly the
plume centerline concentration decreases with distance. However, the higher
the roughness length, the more rapidly the plume spreads in the vertical
direction, counteracting the effect of roughness on plume centerline
concentrations. Hence it is not possible to generalize the effect surface
roughness has on ground level concentrations.
For a ground level release of a heavier-than-air gas cloud, the higher the surface
roughness, the more rapid is the dispersal rate of the cloud Estimating roughness
lengths can be difficult - rarely is the terrain uniform around a source - in general,
consider the roughness of the ground upwind of the source. Typical values are
as given in Table 1.1 below:-
TABLE 1.1 TYPICAL ROUGHNESS LENGTHS
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GBHE suggests that if in doubt one should choose a roughness length of
h/30 where h is the average height of the obstacles e.g. if the typical size of the
roughness elements is 9-10 m, use Zo = 0.3 m. This is only a simple rule of
thumb.
Commercial programs, can only accept roughness length inputs of 0.01, 0.1 and
1 m - use a roughness length of 0.1 m for an industrial site.
1.2 WIND SPEEDS
Wind speed varies as a function of height and ground roughness. In general,
whenever a wind speed is quoted, it refers to the speed at a height of 10 m,
although sometimes data from the US or from a small local weather station may
be measured at a height of 2 m.
The velocity profile as a function of height is dependent on atmospheric stability.
Models such as the US-EPA models, commercial programs assume a power law
velocity profile:-
where n is a function of roughness and atmospheric stability; z is the height
above the ground (m), and uz is the velocity at height z m.
More widely used is a log-law relationship based originally upon Prandtl mixing
length theory for the turbulent boundary layer over a flat surface:-
where L mo is the Monin-Obukhov length. Y is a function that takes into account
the effect of atmospheric stability - usually found empirically. u* is a term known
as the friction velocity defined as √(τ/ρa), where τ is the surface shear stress
and ρa is the air density. k is the von Karman constant, which has a value close
to 0.4.
The effect of the variation in wind speed as a function of height does have a
significant effect on gas dispersion modeling. For example, the advection
velocity of a dense gas box-type model is usually taken to be the wind speed at
half the height of the gas cloud. As more air is entrained into the cloud, its height
increases and hence the bulk velocity of the cloud increases.
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1.3 ATMOSPHERIC STABILITY
1.3.1 General
The term atmospheric stability describes the degree of stratification of the
atmosphere, which plays a vital part in the dispersion of atmospheric pollutants.
On hot sunny days with cloudless skies, the ground absorbs radiation from the
sun at a faster rate than the air above it. The ground then re-radiates and
convects heat back into the atmospheric boundary layer setting up large scale
convective motions. These cause rapid plume spreading in the vertical direction
and large scale plume meandering. This rapid spreading brings elevated plumes
down to ground level. For elevated stacks, the highest ground level
concentrations occur in low wind speed, unstable atmospheric conditions.
During cold winter evenings and nights with little or no cloud cover, the ground is
at a lower temperature than the air above it and heat is transferred from the air to
the ground. This sets up a stratified layer of colder air close to the ground which
dampens out atmospheric turbulence. Gaseous effluent from elevated stacks
form narrow pencil-shaped plumes which rarely strike the ground. Hence, stable
conditions, in general, give low ground level concentrations from elevated stacks.
However, stable conditions would give the worst case conditions if the plume
directly impacted an adjacent plant structure or hill nearby. Low wind speed,
stable atmospheric conditions always give the worst case scenario for
catastrophic releases of a heavier than air gas cloud and for any ground level
release.
In practice, for at least 60% of the time in the USA, there is neutral atmospheric
stability where the effect of heat transfer from the ground into the plume is
negligible. In this case, mechanical turbulence generated by the wind flow in
addition to turbulence generated by the initial momentum of the plume, control
the dispersion rate. Neutral conditions usually prevail when the wind speed
exceeds 5 m/s. The effect of atmospheric stability on plume dispersion is
illustrated in Figure 1.1.
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There are two commonly applied ways of characterizing atmospheric stability:-
Pasquill -Gifford stability scheme and Monin-Obukhov length scaling. The
former methodology is used by many models, including DISP2 and PHAST but
there is increasing tendency for the latest dispersion models such as UK-ADMS,
to adopt the latter approach.
1.3.2 Pasquill - Gifford Methods of Characterizing Atmospheric Stability
Pasquill - Gifford stability analyses assign a letter in the range A to G in order to
characterize atmospheric stability. The most unstable atmospheric conditions,
characteristic in the USA of a few really hot summer afternoons, are represented
by the letter A; neutral conditions by the letter D and stable conditions by F. A
few modelers in Northern Latitudes use G conditions to represent really stable
conditions (e.g. winter evenings in Norway).
The actual choice of stability category is governed by wind speed and cloud
cover and is defined in Tables 1.2 and 1.3.
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A typical wind speed/direction/Pasquill-Gifford atmospheric stability analysis is
shown in Table 1.4.
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TABLE 1.4 EXAMPLE PASQUILL-GIFFORD STABILITY ANALYSIS
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Typically, the atmospheric stability categories in the USA occur with the following
probabilities:
A-stability < 1%
B-stability 1-2%
C-stability around 10%
D-stability 50-70%
E-stability 10-20 %
F-stability 5-15%
G-stability <2%
In general the further the meteorological station is from the sea, the higher is the
frequency of stable and unstable conditions. Also, note that in the categorization
of atmospheric stability category in Table 1.2, there is no link between
temperature and stability category. In the USA we automatically associate F-
stability conditions with cold weather - in fact, the definition of atmospheric
stability is linked with cloud cover and incident radiation levels.
In the Far East, cloudless skies at night often occur far more frequently than in
the USA. This can lead to F-stability frequencies of 30%, even though
temperatures do not fall below freezing.
1.3.3 Monin-Obukhov Length Methods of Representing Atmospheric
Stability
Many gas dispersion models developed since 1990 have adopted Monin-
Obukhov length scaling methods. The Monin-Obukhov length (Lmo) is defined
by:-
where ρa is the air density (kg/m3); Ta is the air temperature (K); u* is the friction
velocity as defined above; k is the von Karman constant (0.4); H is the surface
heat flux (W/m2) - the heat flow from the ground into the atmosphere rather than
the incident radiative heat flow.
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The Monin-Obukhov length is a parameter for the ratio of the mechanical
turbulent energy to that produced by buoyancy. It is an extremely awkward
parameter to use since in neutral atmospheric conditions (Pasquill - Gifford
stability category D), the surface heat flux is zero and hence L mo is infinite.
Consequently many models use as an input the reciprocal of the Monin-Obukhov
length. Note that the L mo is negative in unstable conditions and positive in stable
conditions.
For the gas dispersion practitioner, the Monin-Obukhov length is very difficult to
measure. To estimate u*, it is necessary to take measurements in order to
quantify the velocity profile of the wind flow with height above the ground.
Additionally the surface heat flux would have to be measured. In practice,
standard values for the Monin-Obukhov length are used. Also, because the
friction velocity is dependent on the ground roughness, the Monin-Obukhov
length is both a function of roughness length and atmospheric stability
category.
The following Figure 1.2, derived from Golder (1972) enables a direct
comparison to be made between Pasquill Gifford stability category and Monin-
Obukhov lengths.
Typical values of the reciprocal of the Monin-Obukhov length for a roughness
length of 0.1 m are:-
1 m/s A-stability - 0.5 m-1
2 m/s B-stability - 0.075 m-1 (or possibly as high as -0.1 m-1)
5 m/s C-stability - 0.01 m-1
5 m/s D-stability 0.00 m-1
3 m/s E-stability 0.01 m-1
2 m/s F-stability 0.05 m-1
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2 AIR QUALITY STANDARDS
2.1 WHAT ARE AIR QUALITY STANDARDS?
Air quality standards are limits on concentrations of pollutants in the air.
The limits are usually set on the basis of the health effects of the particular
pollutants. In some cases, there are also limits designed to protect
vegetation (for example, World Health Organization guidelines for ozone).
In other cases, where pollutants interact, standards have been set for two
pollutants in combination: for example, European Union limits on smoke
and sulfur dioxide. The limits are designed to ensure that there would be
no significant adverse effects to the most vulnerable in society arising from
exposure to the pollutant at levels below the air quality standard.
Air quality standards are set by international or national governments.
Recommendations are also made by interested bodies, notably the World
Health Organization. The standards are used by licensing agencies such
as the United States Environmental Protection Agency, or the
Environment Agency/Scottish Environmental Protection Agency
in the UK. These bodies would use the standards to determine whether
pollution levels in their areas are acceptable. This will feed into their
readiness or otherwise to license new or existing processes, and may also
be used to limit the contribution that each individual process can make to
off-site levels of air pollution. Air quality standards apply to environmental
levels of pollutants from all sources in combination, rather than to
emissions from a single source, or works.
Air quality standards need the following components:
• Identification of the pollutant (for example, sulfur dioxide, or "particulate
matter which passes through a size selective inlet with a 50%
collection efficiency cut-off at 10 microns ( PM10)").
• A numerical concentration (for example, 100 parts per billion by
volume (ppb), or 50 micrograms per cubic meter (μgm-3
)).
• An averaging time for the numerical concentration (for example, 15-
minute mean, or running 24-hour mean).
• An acceptable level of compliance (for example, 99th
percentile, or
complete compliance) - see Box 1.
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Additionally, air quality standards may have other relevant information,
such as an indication of their status (for example, legislative limit, or
government objective), details of their applicability (for example,
appropriate for use in sensitive areas, or particular designated planning
zones), and specification of the conditions to which the standards refer to
enable conversion between units (for example, 20°C, 760 mmHg
pressure)
Once all this information is known, it is possible to investigate measured
pollution levels to determine whether compliance with a quality standard
has been achieved. An example is given in Box 2. When compliance or
non-compliance has been established, it is also necessary to consider the
status of the standard to determine how significant this result is. For
example, could non-compliance result in prosecution for the company, or
significant expenditure in the period leading up to the implementation of an
objective?
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As well as looking at measured pollution levels, it is also possible to
consider the results of dispersion models in the light of air quality
standards. This would enable a similar assessment to be carried out at
locations where measurements have not yet been carried out, for future
years at existing plants, or for new plants and developments. This kind of
assessment is very useful in obtaining licenses to operate new plant, and
in planning the extent of investment that will be necessary to meet
forthcoming air quality standards.
In the next sections, we will consider the various types of standards that
exist; what the standards actually are, and how they should be applied in
various situations.
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2.2 WHAT AIR QUALITY STANDARDS EXIST?
2.2.1 General Background
There are two complementary approaches to regulating air pollution
emissions. You can either place limits on emissions (that is, what goes
up), or place limits on ambient concentrations (that is, what comes down) -
or both. Placing limits on emissions is an attractive approach, because it
enables the regulator to ensure that emissions from each source are
appropriately limited, and measurement is relatively straightforward. In
principle, this approach avoids the need to work backwards from high
ambient levels of air pollution to establish which sources should be
controlled.
The disadvantage is that careful specification and enforcement of
emissions controls is required to restrict levels of pollutants in air to
acceptable levels. The lack of overall controls of air pollution impacts in
the UK culminated in the smogs of the 1950s and 1960s, when as many
as 4,000 additional deaths were caused by air pollution within a few days.
Nowadays, emissions from individual sources of pollutants (including road
vehicles) are regulated. However, the lack of overall controls on emissions
of oxides of nitrogen and volatile organic compounds (VOCs)
particularly from road traffic results in high levels of ozone and
photochemical smog in many parts of the world.
2.2.2 United States
The United States has specified air quality standards since the
introduction of the Clean Air Act in 1970. Recently, revisions have been
made to the air quality standards for ozone and fine particulate matter
(July 1997). The current standards are given in Box 3. Many other
countries adopt the USEPA standards for use where there are no local
standards.
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2.2.3 European Union
The European Union has specified ambient air quality standards for pollutants in
a series of directives in the 1980s. These are now implemented into
environmental legislation throughout Europe. The European Union standards are
given in Box 4.
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For some pollutants, the existing standards comprise mandatory "limit
values" and discretionary "guide values". The limit values are mandatory
standards for application throughout member states, whereas the guide
values are intended to contribute to the long-term protection of the
environment, particularly in setting up specific environmental improvement
projects. These would not generally be directly relevant to all businesses
in Europe, although they may influence the policy of regulatory bodies.
In some European countries, additional standards have been specified.
These include The Netherlands, where standards have additionally been
specified for carbon monoxide and benzene. The Dutch standard for
benzene is an annual mean concentration of 10 µgm-3.
The European Union has recently implemented a directive known as the
"Air Quality Framework Directive". This directive lays down a mechanism
of establishing a sliding scale of air quality standards. Two levels can be
specified for a pollutant, the first for immediate application and the second
for application at a specified future date. In the intervening period, the
standard is progressively tightened towards the second more stringent
level. At the time of writing, proposed standards for sulfur dioxide, nitrogen
dioxide, PM10 and lead have been published (see Box 5). The link
between levels of sulfur dioxide and particulates (see Box 4) has not been
carried through into this new generation of air quality standards.
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2.2.4 The Netherlands
Ambient air quality standards have been specified in the Netherlands which
exceed the current requirements deriving from the EU directives. The relevant
standards are given in Box 6.
2.2.5 Japan
Air quality standards are specified in the Basic Law for Environmental
Control. The standards were set between 1969 and 1978. The standards
of relevance to select chemical companies are summarized in Box 7.
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2.2.6 Taiwan
Air quality standards are based on the Release of Air Quality Standard in
Taiwan. The standards of relevance to select chemical companies are
summarized in Box 8.
2.2.7 United Kingdom Air Quality Strategy
Recent developments in air quality policy in the UK are highly significant in
the development of air quality standards. A government advisory panel
known as the Expert Panel on Air Quality Standards (EPAQS) has made
recommendations for standards for 8 pollutants, with several more due to
be produced by the end of 1998. These recommendations do not have
any legal basis, but they have formed the basis of the UK air quality
strategy objectives.
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The Environment Act 1995 provided for the preparation of a national air quality
strategy and guidance on its implementation. In 1996, the Government consulted
on the air quality strategy for the UK. In March 1997, this air quality strategy was
published in its final version. The EPAQS recommendations were used in this
document as objectives to be achieved by 2005 - see Box 9. The UK air quality
strategy and the air quality objectives contained in it will be very influential in
guiding Environment Agency and Local Authority thinking on air quality.
Regulations implementing the air quality objectives have been made under the
Environment Act, and commenced in December 1997, specifying that
compliance is to be achieved by 2005.
The Environment Act also introduced a program of "Local Air Quality
Management" in which local authorities are required to assess their air quality. If
it appears that the statutory air quality objectives will not be met by 2005, then a
local air quality management plan should be devised and implemented to ensure
that the objectives will be met. This may include additional controls on industrial
emissions and traffic pollution, although the plan should ensure that the burdens
on various sectors are "proportionate".
2.2.8 Non-Governmental Organizations
The World Health Organization published an influential set of air quality
guidelines in 1987 ("Air Quality Guidelines for Europe", WHO European Office,
Copenhagen). These were, in general, relatively stringent guideline values for
levels of air pollutants, and included guidelines for pollutants not covered in
legislation. Guidelines were specified to protect not only human health, but also
components of the natural environment. These guidelines have been used by
select chemical companies as objectives for ambient air quality for pollutants
which do not have air quality standards (for example, vinyl chloride and toluene).
The guidelines are also used by some countries in place of specific local air
quality standards (for example, Pakistan). The guidelines are due to be updated
during 1998, but the process has currently stalled due to financial difficulties
within the WHO. The draft guidelines are given in Box 10.
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The World Bank has also specified air quality standards for use in
assessing projects which it funds - see Box 11. These have been adopted
for use in some countries including Pakistan
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2.2.9 Occupational Exposure Limits
Occupational exposure limits exist for a very wide range of pollutants.
These are specified to protect the health of employees in the workplace.
Ambient air quality guideline values are frequently derived from these
occupational exposure limits for pollutants which do not have any specific
air quality standards or WHO guidelines. These occupational limits
themselves should not be used directly for ambient air, as they are
appropriate to fit and healthy adults (making no allowance for sensitive
members of the population such as children and those suffering from
respiratory disease), and they are specified on the basis that exposure
takes place during working hours only.
With suitable adjustments to allow for these constraints, however, ambient
air quality guideline values can be derived from the occupational exposure
limits. This is achieved by dividing the occupational exposure limit by a
specified factor to give the ambient air quality standard. A range of factors
have been used for this purpose in the past, ranging from one twenty-fifth
to one hundredth.
In the UK, the Environment Agency has issued guidance on how this
conversion should be addressed in a recent publication (Technical
Guidance Note (Environmental) E1, "Best Practicable Environmental
Option Assessments for Integrated Pollution Control", 1996). It indicates
that "environmental assessment levels" for pollutants can be
determined as follows:
• Hourly mean concentration:
2% of the 15-minute maximum exposure limit (MEL: these are
occupational exposure limits for carcinogens) or 10% of the 15-
minute occupational exposure standard for materials where no
MEL has been specified (i.e., non-carcinogens).
• Annual mean concentration:
0.2% of the 8-hour maximum exposure limit or
1% of the 8-hour occupational exposure standard.
The guidance note indicates that individual processes should be a "priority
for control" if they contribute more than 2% of the environmental
assessment level for a given pollutant.
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This is a highly restrictive constraint, and in practice, a process that
contributes less than 10% of the environmental assessment level will
generally be considered acceptable.
Further guidance on acceptable off-site concentrations is given in Box 3 of
Part 4.
2.2.10 General Comparison
In general, newer air quality standards tend to be more stringent than
older standards, and guidelines tend to be more stringent than regulatory
limits. The least stringent standards are standards specified during the
1970s and 1980s such as the US National Ambient Air Quality Standards,
and the existing set of EU standards. Standards based on occupational
health guidelines also tend to be relatively lax. For example, the hourly
average environmental assessment level for use in the UK based upon
10% of the occupational health standard for nitrogen dioxide would be 500
ppb. In contrast, the UK Air Quality Strategy objective for hourly mean
nitrogen dioxide concentrations is 150 ppb.
Newer standards such as the UK Air Quality Strategy objectives, the EU
daughter directive proposals and the US standards for ozone and PM2.5
are more stringent than the existing legislative standards, and cover a
wider range of pollutants. The UK Air Quality Strategy objectives are
similar to the WHO guidelines of 1987 in most respects, although
for particulate matter, new information has led to a significantly tighter
objective. The WHO guidelines also cover a wider range of pollutants. It
may be expected that the revised WHO guidelines to be issued during
1998 will be more stringent than the 1987 document.
2.2.11 Air Quality Standards for Odor Impacts
Odor impacts are likely to become an increasingly important driver of limits
on air pollution emissions. In many countries, process operators are
required to ensure that there is no off-site odor.
Odor impacts can be forecast, or estimated from process emissions data,
but the procedure is very uncertain, and because a large number of
safeguards must be built in, the assessments are of necessity very
stringent in terms of acceptable release conditions.
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A reasonable standard for off-site Odor would be that hourly average
concentrations of an odorous chemical should not exceed 2.5% - 5% of
the Odor threshold. Odor thresholds are discussed in Box 12. This
standard would provide a sufficient safety margin to protect against the
uncertainty in Odor threshold measurements, short-term fluctuations in
concentration that can give rise to transient Odor, and the variability in
human response to different Odors. The Odor standard is likely to be
much more stringent than the corresponding health-based guidelines,
reflecting the fact that Odor is generally significant at lower concentrations
than health effects, and also reflecting the additional safety margin in the
Odor standard. It should be noted that for a few chemicals such as
ethylene dichloride, the health impacts occur at concentrations below the
Odor threshold.
2.3 WHAT IS THE LAW - AND WHAT ISN’T
A clear distinction should be made between air quality standards which
comprise legal limits in particular countries, and other recommendations
and guidelines which are not limits. In practice, air quality standards are
frequently exceeded in many parts of the world - particular problems
surround standards for ozone and fine particulate matter. This does
not translate into legal action against emitters of pollution. Process
operators would be affected by air quality standards under the following
circumstances:
• A new process is highly unlikely to be permitted if emissions will
lead to a contravention of an air quality standard.
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• In some countries (for example, China), different air quality
standards apply in different planning zones. Thus, the locations
where chemical industries may be located could be restricted by
the more stringent standards in some areas.
• Continued operation of a process may be at risk in an area where
air quality standards are frequently exceeded. Under these
circumstances, the process operator may be required to reduce
emissions to enable the air quality standards to be met.
Legislative air quality standards currently applicable in various parts of the
world are as follows:
USA: National Ambient Air Quality Standards (see Box 3)
European Union: Directives 80/779, 82/884, 85/203 as enacted in
individual Member States (see Box 4)
Netherlands: Legal and non-legal air quality standards (see Box 6)
Japan: Basic Law for Environmental Control (see Box 7)
Taiwan: Release of Air Quality Standard in Taiwan (see Box 8)
Air quality standards are progressively tightening. The EU is due to
propose a range of new and progressively tightening standards for air
quality over the coming year. New limits for nitrogen dioxide, smoke,
particulate matter and lead have been specified (see Box 5). These will be
made under the "Framework Directive", and will eventually have legal
force. In the period between the standards being adopted by the EU and
their implementation in individual member states, they should be treated
as if they were legal limits. For design of new plant in the EU at any time,
the new limits should also be treated as if they had legal force to ensure
that plant design is adequate. In the UK, the new standards are unlikely to
lead to a significant additional burden on industry, over and above the
burden imposed by the new UK air quality objectives.
There are now objectives for air quality in the UK, specified as part of the
UK air quality strategy. These objectives are shown in Box 9. The
objectives will be reviewed during 1998, and may be tightened, and/or
brought into line with any new European air quality standards.
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The objectives will have legal force, but the onus will be on local
authorities to implement air quality management plans to achieve
compliance by 2005 rather than on individual process operators. Thus,
local authorities and/or the Environment Agency are likely to require action
to be taken in any areas where it is likely that the objectives will not
be achieved. These objectives may impact select chemical companies as
the regulatory bodies assess their requirements for reductions in the
impact of industrial air pollution to meet the air quality objectives by 2005.
Select chemical companies operating in the UK may need to be prepared
to undertake independent assessments of the impact of their air pollution
emissions in order to ensure that any additional regulatory burden is
appropriate and proportionate (see Box 13 for an example).
Apart from these legislative and proposed air quality standards and
objectives, a number of other guidelines for ambient air quality may be
used. These do not have legal force. They would be used where
businesses are releasing compounds for which there are no other air
quality standards. This covers a wide range of Select chemical companies
process emissions, whereas combustion emissions would generally be
covered by the air quality standards and objectives. The World Health
Organization standards and the application of occupational health
standards in ambient air quality assessments is described in Section 2.2
above.
National Air Quality Standards do not apply in plant areas to which the
public cannot gain unrestricted access. In these areas, Occupational
Exposure Standards (OESs) and Maximum Exposure Limits (MELs) are
appropriate.
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Materials with a Maximum Exposure Limit present serious concerns about
possible health effects in workers. In practice, MELs have most often been
allocated to chemicals for which there is no clearly defined safe
concentration level and for which there is no doubt about the seriousness
of the hazard posed by the substance. Usually MELs are defined for
chemicals which are carcinogenic or can cause occupational asthma.
OESs are set at levels below which it is believed (based on current
scientific knowledge) that the substance would not damage the health of
workers exposed to it day after day.
For listings of OESs and MELs, see either the UK Health and Safety
Executive’s EH 40 document - “Occupational Exposure Limits”, which is
published annually.
The HSE provides the following guidance on how to apply OESs and
MELs:
“Applying OESs:- if exposure to a substance that has an OES is reduced
at least to that level, then adequate control has been achieved. If this level
is exceeded, the reason must be identified and measures to reduce
exposure to the OES put into action as soon as reasonably practicable.
Applying MELs:- Exposure should be reduced as far below the MEL as
reasonably practicable and should never exceed the MEL when averaged
over the appropriate reference period.”
2.4 FUTURE DEVELOPMENTS
In general terms, the most significant future development is the
progressive tightening of air quality standards around the world. One
example is the recent introduction of a tighter ambient air quality standard
for ozone, and a new standard for PM2.5 in the USA.
New air quality standards have been drafted by the European Commission
(see Box 5). A further standard for ozone is expected to be published by
the end of 1998, with proposals for polycyclic aromatic hydrocarbons and
some heavy metals to follow. These represent a considerable tightening of
standards in comparison to current air quality standards in Europe.
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The planned revisions to the World Health Organization air quality
guidelines are unlikely to have as profound an impact as the original 1987
guidelines. Many of the considerations adopted by the WHO have been
taken on board by bodies such as the US EPA and European Union in
setting air quality standards.
A significant future development in the UK will be the implementation of
the air quality strategy up to 2005. This may well lead to additional
constraints on industrial emissions in some areas where the UK air quality
objectives would not otherwise be met. These constraints may be
implemented through limits on emissions agreed between individual
process operators and the regulator (Environment Agency and/or Local
Authority). The current set of air quality objectives (see Box 9) are under
revision, with revised targets and/or dates to be published during 1998.
Again in the UK, the implementation of Technical Guidance Note E1 may
lead to tighter restrictions on emissions of pollutants not covered by the air
quality strategy. This is because of restrictions on the contribution of
individual processes to ambient levels of air pollutants. The guidance
indicates that those pollutants contributing more than 2% of the
Environmental Assessment Level off-site will become "a priority for
control". It will not be possible to apply this process in practice because of
the large number of industrial processes which will become "priorities for
control". A value of 10% of the EAL is generally considered to be
acceptable. However, the Guidance Note does indicate a significant shift
in Environment Agency policy.
Odor issues are likely to become an increasing driver for restrictions on
emissions. This reflects some success in dealing with emissions of the
health effects of pollutants, and also sustained public awareness and
concern regarding air pollution. There is very little formal guidance on the
assessment of odor emissions, but it is likely that plants which have
known odor problems are likely to come under increasing pressure to
control the emissions. If this cannot be achieved via process
improvements, investment in end-of-pipe control equipment may be
required.
Finally, aesthetic effects may well become more important. Already, local
authorities are often unwilling to allow new tall stacks to be constructed
because of their visual impact. In the next few years it is likely that industry
will be under pressure to reduce the visual impact of large plumes of water
vapor from vents.
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3 MODEL COMPARISON AND SELECTION
3.1 CLASSIFICATION OF DISPERSION MODELING PROBLEMS
Dispersion modeling problems are commonly categorized as “safety” or
“environmental.” - see Figure 3.1. “Safety” issues involve the assessment
of the consequences of unplanned releases which may present a
significant direct hazard to the health of individuals located either on or off-
site. Because the majority of chemicals used by chemical businesses are
heavier than air, these are usually dense gas releases. Storage at low
temperature also tends to result in releases of gases which are denser
than air. These are seen as safety issues because the effects are
potentially serious, and the release will only take place over a short period.
In contrast, “environmental” issues generally arise from continuous or
intermittent releases of material of similar density to air (“neutral”), or
lighter than air (“buoyant”). Occasionally, continuous releases may be
more dense than the air. These are generally planned releases of material
arising from normal process operations. Any effects of these releases tend
to be most significant off-site. As well as short-term toxicity effects, the
assessment of environmental releases also takes into account the effects
of long-term exposure to released materials. In some cases, consideration
is given to effects on the natural environment, as well as on the human
population. For the purposes of dispersion modeling, there is some
overlap between the two categories of problem.
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FIGURE 3.1 CATEGORIZATION OF DISPERSION MODELING PROBLEMS
The range of potential release scenarios means that a large number of
dispersion modeling tools have been designed to assess their
consequences. The aim of this Part of the guide is to provide guidance on
selecting the appropriate tool for a particular problem. The appropriate
model(s) to use for a particular application is dependent on the initial
density, duration and location of the release.
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3.2 WHAT MODELS ARE AVAILABLE?
To deal with the situations for which dispersion modeling is required, a
range of modeling tools have been developed. For the purposes of this
guide, a “model” is defined as a computational code which provides an
airborne concentration of material given a set of release conditions, a set
of meteorological conditions, and a location relative to the source.
These have been developed to varying specifications over and above the
minimum model definition. For example, some models contain algorithms
for calculating loss rates of material, given some assumptions regarding
the quantity of material, the size and location of a leak, etc. Some models
permit highly flexible specification of the locations at which concentrations
are to be calculated, or permit the use of long-term meteorological data to
calculate long-term mean concentrations of material. A number of
commonly-used models are listed in Table 3.1, together with an indication
of the type of situations in which they can be applied, and their
functionality.
TABLE 3.1 COMMONLY USED DISPERSION MODELS
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3.3 DESCRIPTION OF AVAILABLE MODELS
3.3.1 General
As indicated in Table 3.1, the dispersion models listed in the table all have
advantages and disadvantages associated with their use. The aim of this
section is to set out the pros and cons of each model, and to provide some
practical guidance in using each model. Finally, Table 3.2 summarizes the
type of problem for which each model should be used.
The use of dispersion models is regulated to varying extents in different
countries of the world. In some countries, a specific model needs to be
used in a specific way; in other countries, the applicant is free to use any
appropriate model. Some examples are as follows:
• Germany: Dispersion modeling to be carried out as laid down in TA
Luft regulations. These specify the dispersion equations to be used,
and appropriate values for many of the inputs.
• UK: ADMS is preferred by the Environment Agency for regulatory
applications, but no formal guidance exists.
• Netherlands: EFFECTS is the preferred model for dense gas
releases, and PLUIM for buoyant/neutral releases.
• USA: A variety of different models are approved by the US EPA for
various situations, as laid down in Appendix W to the 40th
Congressional Federal Register part 51. For modeling point source
emissions in non-complex terrain, ISC is recommended (section 4.1
of Appendix W; see the USEPA web site for further details:
www.epa.gov). For dense gas dispersion modeling, any appropriate
model is permitted.
Attempts are currently under way to harmonize the approach to dispersion
modeling across national boundaries, but many countries (e.g. Hungary)
insist on the use of a national dispersion model.
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3.3.2 ADMS (Atmospheric Dispersion Modeling System)
This model is produced and developed by Cambridge Environmental
Research Consultants on behalf of the Environment Agency, Health and
Safety Executive, and a consortium of industry and government bodies
including select chemical companies. The model flexibility is enhanced
with a number of additional modules for dealing with specific cases, as
listed in Table 3.1.
The model is designed for neutral density and buoyant releases. ADMS
can also be used for releases of dense gases from elevated sources
providing the plume does not slump to ground level. This can be a matter
of judgment, but some indication can be gained from consideration of the
plume centerline height, and/or by considering near-source results
from a dense gas dispersion model such as PHAST.
The model is straightforward to use, with a series of screens providing
rapid data entry. The model is supplied with a range of example source
and meteorological data files, which can be used as a basis for compiling
inputs for other applications. The file "r91a-g.met" is particularly useful, as
it provides a set of 7 meteorological conditions representative of the range
of conditions encountered in temperate regions.
ADMS has a straightforward x-y plotting program, and can provide contour
plots via a link to the SURFER package. The program can be linked to a
GIS system if required, to facilitate data input and results presentation.
The program uses state-of-the-art understanding of meteorology to
represent the atmospheric boundary layer. Output is provided in a set of
separate ASCII text files, which can be imported into other applications
if required. Percentile concentrations can be obtained provided the
appropriate meteorological data is used: this is useful for obtaining
predictions in terms of air quality standards and objectives. ADMS is the
preferred model for regulatory applications in the UK. In view of its
technical merits and the wide range of problems it can deal with, it is
also recommended for use outside the UK in situations where no other
model is specified by the regulatory authority.
ADMS only permits modeling to be carried out for a limited number of
receptors (maximum grid size: 31 x 31 x 2 receptors). This may be a
restriction for some applications. Model run times can be very long when
long-term meteorological data is being used, particularly where building
effects or complex terrain are incorporated into the model.
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3.3.3 ALOHA (Areal Locations of Hazardous Atmospheres)
This model is a user-friendly version of the US Coastguard/University of
Arkansas model DEGADIS. It is extremely user-friendly, and enables even
a novice user to set up appropriate meteorological and source inputs
rapidly. The tank source options are particularly user-friendly with
graphical images to assist the source specification. It is probably best
used as an emergency response tool, with more complex planning cases
being handled by a more flexible model such as PHAST. It may also be
appropriate for use in Risk Management Planning in the US.
The model can provide indoor concentrations of pollutants, based on
certain assumptions relating to air exchanges in the building. The model
can handle a variety of source types including mixed aerosol/vapor
releases arising due to a tank rupture, and liquid puddles. Because
ALOHA is set up to model releases from a relatively simple set of cases in
an emergency situation, more complex cases cannot easily be modeled.
The major disadvantage of ALOHA for planning purposes is that receptors
must be specified individually, and the model re-run for every receptor.
The model only allows for a one-hour run time, and so concentrations are
not predicted at locations where the maximum concentration from a
release would not have been reached one hour after the release. The
model has also been found to reset parameters without warning (for
example, changing units from mgm-3 to ppm), and frequently clears the
values of modeling parameters which have already been entered. This
can occur for example when attempting to edit the source details if the
wrong type of source is selected in error.
3.3.4 DISP2
DISP2 was developed by a European chemical company, and has two
components. The BURST model gives concentrations arising from a short
emission period, and the PLUME model gives concentrations arising from
a continuous emission. It has been shown to be robust in handling a wide
range of cases for both environmental and safety applications. However,
it cannot handle two phase releases. The model is not used outside of the
European chemical company that developed it, and there may be
problems in justifying its use to regulatory authorities. It should, in general,
not be used for new applications as there are externally validated models
available which can cover most of the situations for which DISP2 was
designed.
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DISP2 is straightforward to operate. Study inputs are entered via a series
of screens in a logical sequence. The "mass fraction" option for burst
releases (i.e., instantaneous catastrophic releases) of mixtures should not
be used, as there is an error in the software associated with this option.
The model is limited to three values for surface roughness (0.01 m, 0.1 m
and 1 m). This can be a restriction in the common situation of a release in
a typical urban/industrial area where a value of around 0.3 - 0.5 m would
be appropriate. Using a surface roughness of 0.1 m could underestimate
the influence of the terrain on dispersing emissions from a ground level
release. Data for each run is saved in a file named
"c:windowstempanalysis.lis": the data in this file is overwritten each time
the model is run, and must be extracted between runs if required. More
information is given in the model problem file (*.prb)
A maximum of 21 receptors downwind of the source is permitted. A single
source, wind direction and downwind line of receptors is considered in
each model run, although the model does provide off-axis concentration
isopleths if required. The meteorological data entry can be unclear: the
available conditions are specified using codes such as "B2." The default
setting is for the number 2 in this context to refer to Force 2 on the
Beaufort scale, rather than 2 ms-1.
Care needs to be taken when considering dense gas releases to ensure
that two-phase effects are not significant.
STACK2 is a multi-source neutral/buoyant release dispersion model. It
should not be used for new applications as both ADMS and ISC can be
used to carry out all the calculations that are possible with STACK2.
3.3.5 ISC (Industrial Source Complex)
ISC is available as ISCST (Short Term) and ISCLT (Long term) and was
developed by the US-EPA. This model is very widely used throughout the
world for environmental modeling applications. It is prescribed for
regulatory use in the USA. The core of the model is now some 20 years
old, and it contains some major shortcomings - for example, the inability to
specify the terrain surface roughness (see below). The model is due to be
replaced by a new version currently known as “Aermod” within the next
12-18 months. The use of ISC is prescribed for regulatory calculations in
the US and some other countries. Where the use of ISC is not prescribed,
it would generally be preferable to use ADMS in view of the more
advanced modeling methods and greater flexibility of ADMS.
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ISC is not straightforward to use. In principal, a logically ordered input
(.dat) file is written, and the model produces an output .lst file. However,
the user interface requires a number of apparently unrelated inputs to
compile an appropriate .dat file, and it can be difficult to provide a
combination of inputs that is acceptable for the model. For example, a
parameter "RUNORNOT" must be set to "RUN" for the model to proceed.
Some processing of the output .lst file is necessary to produce contours
which can be incorporated into a graphical plotting or numerical analysis
package. This can be time consuming and is a potential source of error.
The model is very flexible in terms of the number and type of sources that
can be included. Also, concentrations can be modeled at a very large
number of receptors. The model runs relatively quickly, which is useful for
producing long-term statistics based on measured meteorological data. A
serious disadvantage is that the effects of surface roughness can only be
incorporated by running the model in "urban" or "rural" modes, and it is not
clear what values of Zo these modes correspond to. As a rough guide,
"rural" is likely to correspond to Zo ~ 0.1 m, and "urban" is likely to
correspond to Zo ~ 1.0 m.
Some example meteorological data is provided with the model; however, it
is not straightforward to provide data in the correct format for the model to
use.
User friendly versions of the US-EPA models are produced by various
Consultants in the USA. File driven versions of models, available free of
charge from the US-EPA Bulletin Board, are very difficult to use.
3.3.6 PHAST (Process Hazard Assessment Tools)
This model has been developed by DNV Technica. It is probably the most
sophisticated general purpose hazard assessment software package
currently available - for example, it covers high momentum jet releases at
a range of angles, catastrophic dense gas releases, pool evaporation, two
phase releases, fires and explosions. The model has an extensive
physical properties database. The two main drawbacks are firstly its cost -
with an annual maintenance fee of around; secondly, there are a number
of bugs in the program. Some of these are inconvenient, but others could
give rise to serious errors in executing the model.