Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
This is great Presentation with 3D effects which is all about production of ammonia from natural gas.
I am damn sure you will be getting everything here searching for.
its better to download it and then run in powerpoint 2013.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
This is great Presentation with 3D effects which is all about production of ammonia from natural gas.
I am damn sure you will be getting everything here searching for.
its better to download it and then run in powerpoint 2013.
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
Steam Reformer Surveys - Techniques for Optimization of Primary Reformer Oper...Gerard B. Hawkins
Introduction
Background Radiation and Temperature Measurement
Reformer Survey Inputs
Other Troubleshooting Tools
Safety
Preparation
Onsite Data Collection
TWT Survey
Observation/Troubleshooting
Modelling and Analysis
Results/Outputs
Case Studies
Conclusions
Case Study 1
Case Study 2
Case Study 3
Conclusions
High Temperature Shift Catalyst Reduction ProcedureGerard B. Hawkins
High Temperature Shift Catalyst Reduction Procedure
The catalyst, as supplied, is Fe2O3. This reduces to the active form, Fe3O4, in the presence of hydrogen when process gas is admitted to the reactor.
1. The mildly exothermic reactions are:
3 Fe2O3 + H2 ========= 2 Fe3O4 + H2O
3 Fe2O3 + CO ========= 2 Fe3O4 + CO2
(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
Hydrogen Plant Flowsheet - Effects of Low Steam RatioGerard B. Hawkins
Effect of Low Steam Ratio on the Steam Reformer
Effect of Low Steam Ratio on H T Shift & PSA
Effect of Low Steam Ratio on Gross Efficiency
Effect of Low Steam Ratio on Net Efficiency
Alternative schemes for improving heat recovery
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
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
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
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.
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
Steam Reformer Surveys - Techniques for Optimization of Primary Reformer Oper...Gerard B. Hawkins
Introduction
Background Radiation and Temperature Measurement
Reformer Survey Inputs
Other Troubleshooting Tools
Safety
Preparation
Onsite Data Collection
TWT Survey
Observation/Troubleshooting
Modelling and Analysis
Results/Outputs
Case Studies
Conclusions
Case Study 1
Case Study 2
Case Study 3
Conclusions
High Temperature Shift Catalyst Reduction ProcedureGerard B. Hawkins
High Temperature Shift Catalyst Reduction Procedure
The catalyst, as supplied, is Fe2O3. This reduces to the active form, Fe3O4, in the presence of hydrogen when process gas is admitted to the reactor.
1. The mildly exothermic reactions are:
3 Fe2O3 + H2 ========= 2 Fe3O4 + H2O
3 Fe2O3 + CO ========= 2 Fe3O4 + CO2
(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
Hydrogen Plant Flowsheet - Effects of Low Steam RatioGerard B. Hawkins
Effect of Low Steam Ratio on the Steam Reformer
Effect of Low Steam Ratio on H T Shift & PSA
Effect of Low Steam Ratio on Gross Efficiency
Effect of Low Steam Ratio on Net Efficiency
Alternative schemes for improving heat recovery
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
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
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
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.
Done By: Silver Group
School Name: Al Khor Independent School for Girls
Environmental Catalysis Module: Students examines different types of catalytic systems, including heterogeneous and homogeneous catalysis. Depending on the knowledge they gained during activities, the students are then asked to design their projects.
Our Project:
Converting carbon dioxide into oxygen using calcium oxide and metal catalyst
Factory’s smoke contains many harmful and dangerous materials for both human beings and the environment, this project will not only save our ozone layer but it will save many people in the future generation securing a breath full future for humanity.
Description of the Exhaust system along with its components such as Exhaust manifold,catalytic converter ,muffler ,exhaust tubing and oxygen sensor.The working of some of these components is also explained.
Emission Control by Catalytic Converter, Jeevan B MJeevan B M
A catalytic converter is an emissions control device that converts toxic gases and pollutants in exhaust gas to less toxic pollutants. The catalytic converter was invented by Eugene Houdry, a French mechanical engineer and expert in catalytic oil refining. In the catalytic converter, there are two different types of catalyst at work, a reduction catalyst and an oxidation catalyst.
A SHORT REVIEW ON ALUMINIUM ANODIZING: AN ECO-FRIENDLY METAL FINISHING PROCESSJournal For Research
Protection of aluminium alloys is most commonly done by forming anodic films. Anodic films can also be formed on metals like titanium, zinc, magnesium, niobium, and tantalum. Aluminium alloy parts are anodized to greatly increase the thickness of the natural oxide layer for corrosion resistance. A thin aluminium oxide film, that seals the aluminium from further oxidation when it is exposed to air. The anodizing process increases the thickness of the oxidized surface. Anodizing is accomplished by immersing the aluminium into an acid electrolyte bath and passing an electric current through the medium. In an anodizing cell, the aluminium work piece is made the anode by connecting it to the positive terminal of a dc power supply and the cathode is connected to the negative terminal of the dc source. Sealing is needed to seal the pores in oxide layer to prevent further corrosion. Oxide layer on the anodized aluminium has a highly ordered, porous structure that allows for secondary processes such as dyeing, printing and sealing. Nanowires and nanotubes can be made by using the pores in the oxide layer as templates.
Protection des métaux contre la corrosionCHTAOU Karim
Cette présentation présentent tout d’abord les principaux types de la corrosion et il présente une description détaillée des trois grandes méthodes, préventives et curatives, utilisées en anticorrosion.
This lecture describes the process of anodic oxidation of aluminium, which is one of the most unique and commonly used surface treatment techniques for aluminium; it illustrates the weathering behaviour of anodized surfaces. Some familiarity with the subject matter covered in TALAT This lectures 5101- 5104 is assumed.
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
Les types de bétons bitumineux pour couche de roulement sont nombreux. Selon leur formulation granulaire, la nature du liant d’enrobage et l’ajout éventuel d’additifs, les caractéristiques des mélanges obtenus présentent des propriétés spécifiques qui élargissent le domaine d’emploi des enrobés classiques.
Report on Low temperature shift converter Catalyst reductionGULFAM KHALID
In 2014 we charged fresh Copper oxide catalyst (vendor: Jonhson Matthey) into Low temperature shift converter (LTS is a reactor in which water gas shift conversion occurs and it is exothermic reaction).During Start-up LTS new catalyst has to be reduced before taking it into service.Hydrogen gas is used as reducing agent and natural gas is used as a carrier gas.Detailed report on our reduction activity is uploaded
Some fact about Ammonia Production by Prem Baboo.pdfPremBaboo4
Operation of the plant is mainly supervised by the operators in the control room, who monitor the various instruments and adjust operating conditions in order to obtain satisfactory operation. They should also react when an alarm is activated. In some cases they can re-establish normal conditions by adjusting the controls in the control room; in other cases they give instructions to a field operator to make the necessary adjustments at various locations in the plant. Field operators work in regular shifts in the plant, especially in the reforming section, in order to supervise the firing of the reformer and the temperature of the tubes in the reformer, to record local instrument readings, and to notice any irregularities such as leaks. Every change of temperature of the reformer a little change can bring big change resulting energy losses, e.g. temperature of the primary reformer and CO slip losses in methanation etc.
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy GasesGerard B. Hawkins
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
This Process Safety Guide has been written with the aim of assisting process engineers, hazard analysts and environmental advisers in carrying out gas dispersion calculations. The Guide aims to provide assistance by:
• Improving awareness of the range of dispersion models available within GBHE, and providing guidance in choosing the most appropriate model for a particular application.
• Providing guidance to ensure that source terms and other model inputs are correctly specified, and the models are used within their range of applicability.
• Providing guidance to deal with particular topics in gas dispersion such as dense gas dispersion, complex terrain, and modeling the chemistry of oxides of nitrogen.
• Providing general background on air quality and dispersion modeling issues such as meteorology and air quality standards.
• Providing example calculations for real practical problems.
SCOPE
The gas dispersion guide contains the following Parts:
1 Fundamentals of meteorology.
2 Overview of air quality standards.
3 Comparison between different air quality models.
4 Designing a stack.
5 Dense gas dispersion.
6 Calculation of source terms.
7 Building wake effects.
8 Overview of the chemistry of the oxides of nitrogen.
9 Overview of the ADMS complex terrain module.
10 Overview of the ADMS deposition module.
11 ADMS examples.
12 Modeling odorous releases.
13 Bibliography of useful gas dispersion books and reports.
14 Glossary of gas dispersion modeling terms.
Appendix A : Modeling Wind Generation of Particulates.
APPENDIX B TABLE OF PROPERTY VALUES FOR SPECIFIC CHEMICALS
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
Ammonia Plant Technology
Pre-Commissioning Best Practices
GBHE-APT-0102
PICKLING & PASSIVATION
CONTENTS
1 PURPOSE OF THE WORK
2 CHEMICAL CONCEPT
3 TECHNICAL CONCEPT
4 WASTES & SAFETY CONCEPT
5 TARGET RESULTS
6 THE GENERAL CLEANING SEQUENCE MANAGEMENT
6.6.1 Pre-cleaning or “Physical Cleaning
6.6.2 Pre-rinsing
6.6.3 Chemical Cleaning
6.6.4 Critical Factors in Cleaning Success
6.6.5 Rinsing
6.6.6 Inspection and Re-Cleaning, if Necessary
7 Systems to be treated by Pickling/Passivation
Ammonia Plant Technology
Pre-Commissioning Best Practices
Piping and Vessels Flushing and Cleaning Procedure
CONTENTS
1 Scope
2 Aim/purpose
3 Responsibilities
4 Procedure
4.1 Main cleaning methods
4.1.1 Mechanical cleaning
4.1.2 Cleaning with air
4.1.3 Cleaning with steam (for steam networks only)
4.1.4 Cleaning with water
4.2 Choice of the cleaning method
4.3 Cleaning preparation
4.4 Protection of the devices included in the network
4.5 Protection of devices in the vicinity of the network
4.6 Water flushing procedure
4.6.1 Specific problems of water flushing
4.6.2 Preparation for water flushing
4.6.3 Performing a water flush
4.6.4 Cleanliness criteria
4.7 Air blowing procedure
4.7.1 Specific problems of air blowing
4.7.2 Preparation for air blowing
4.7.3 Performing air blowing
4.7.4 Cleanliness checks
4.8 Steam blowing procedure
4.8.1 Specific problems of steam blowing
4.8.2 Preparation for steam blowing
4.8.3 Performing steam blowing
4.8.4 Cleanliness checks
4.9 Chemical cleaning procedure
4.9.1 Specific problems of cleaning with a chemical solution
4.9.2 Preparation for chemical cleaning
4.9.3 Performing a chemical cleaning
4.9.4 Cleanliness criteria
4.10 Re-assembly - general guideline
4.11 Preservation of flushed piping
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF AQUEOUS ORGANIC EFFLUENT STREAMS
CONTENTS
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 IPU
3.2 AOS
3.3 BODs
3.4 COD
3.5 TOC
3.6 Toxicity
3.7 Refractory Organics/Hard COD
3.8 Heavy Metals
3.9 EA
3.10 Biological Treatment Terms
3.11 BATNEEC
3.12 BPEO
3.13 EQS/LV
3.14 IPC
3.15 VOC
3.16 F/M Ratio
3.17 MLSS
3.18 MLVSS
4 DESIGN/ECONOMIC GUIDELINES
5 EUROPEAN LEGISLATION
5.1 General
5.2 Integrated Pollution Control (IPC)
5.3 Best Available Techniques Not Entailing Excessive Costs (BATNEEC)
5.4 Best Practicable Environmental Option (BPEO)
5.5 Environmental Quality Standards(EQS)
6 IPU EXIT CONCENTRATION
7 SITE/LOCAL REQUIREMENTS
8 PROCESS SELECTION PROCEDURE
8.1 Waste Minimization Techniques (WMT)
8.2 AOS Stream Definition
8.3 Technical Check List
8.4 Preliminary Selection of Suitable Technologies
8.5 Process Sequences
8.6 Economic Evaluation
8.7 Process Selection
APPENDICES
A DIRECTIVE 76/464/EEC - LIST 1
B DIRECTIVE 76/464/EEC - LIST 2
C THE EUROPEAN COMMISSION PRIORITY CANDIDATE LIST
D THE UK RED LIST
E CURRENT VALUES FOR EUROPEAN COMMUNITY ENVIRONMENTAL QUALITY STANDARDS AND CORRESPONDING LIMIT VALUES
F ESTABLISHED TECHNOLOGIES
G EMERGING TECHNOLOGY
H PROPRIETARY/LESS COMMON TECHNOLOGIES
J COMPARATIVE COST DATA
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...Gerard B. Hawkins
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs)
FOREWORD
CONTENTS
1 INTRODUCTION
2 THE NEED FOR VOC CONTROL
3 CONTROL AT SOURCE
3.1 Choice or Solvent
3.2 Venting Arrangements
3.3 Nitrogen Blanketing
3.4 Pump Versus Pneumatic Transfer
3.5 Batch Charging
3.6 Reduction of Volumetric Flow
3.7 Stock Tank Design
4 DISCHARGE MEASUREMENT
4.1 By Inference or Calculation
4.2 Flow Monitoring Equipment
4.3 Analytical Instruments
4.4 Vent Emissions Database
5 ABATEMENT TECHNOLOGY
5.1 Available Options
5.2 Selection of Preferred Option
5.3 Condensation
5.4 Adsorption
5.5 Absorption
5.6 Thermal Incineration
5.7 Catalytic Oxidation
5.8 Biological Filtration
5.9 Combinations of Process technologies
5.10 Processes Under Development
6 GLOSSARY OF TERMS
7 REFERENCES
Appendix 1. Photochemical Ozone Creation Potentials
Appendix 2. Examples of Adsorption Preliminary Calculations
Appendix 3. Example of Thermal Incineration Heat and Mass Balance
Appendix 4. Cost Correlations
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
EMERGENCY ISOLATION OF CHEMICAL PLANTS
CONTENTS
1 Introduction
2 When should Emergency Isolation Valves be Installed
3 Emergency Isolation Valves and Associated Equipment
3.1 Installations on existing plant
3.2 Actuators
3.3 Power to close or power to open
3.4 The need for testing
3.5 Hand operated Emergency Valves
3.6 The need to stop pumps in an emergency
3.7 Location of Operating Buttons
3.8 Use of control valves for Isolation
4 Detection of Leaks and Fires
5 Precautions during Maintenance
6 Training Operators to use Emergency Isolation Valves
7 Emergency Isolation when no remotely operated valve is available
References
Glossary
Appendix I Some Fires or Serious Escapes of Flammable Gases or Liquids that could have been controlled by Emergency Isolation Valves
Appendix II Some typical Installations
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
The Art of the Pitch: WordPress Relationships and SalesLaura Byrne
Clients don’t know what they don’t know. What web solutions are right for them? How does WordPress come into the picture? How do you make sure you understand scope and timeline? What do you do if sometime changes?
All these questions and more will be explored as we talk about matching clients’ needs with what your agency offers without pulling teeth or pulling your hair out. Practical tips, and strategies for successful relationship building that leads to closing the deal.
Elevating Tactical DDD Patterns Through Object CalisthenicsDorra BARTAGUIZ
After immersing yourself in the blue book and its red counterpart, attending DDD-focused conferences, and applying tactical patterns, you're left with a crucial question: How do I ensure my design is effective? Tactical patterns within Domain-Driven Design (DDD) serve as guiding principles for creating clear and manageable domain models. However, achieving success with these patterns requires additional guidance. Interestingly, we've observed that a set of constraints initially designed for training purposes remarkably aligns with effective pattern implementation, offering a more ‘mechanical’ approach. Let's explore together how Object Calisthenics can elevate the design of your tactical DDD patterns, offering concrete help for those venturing into DDD for the first time!
DevOps and Testing slides at DASA ConnectKari Kakkonen
My and Rik Marselis slides at 30.5.2024 DASA Connect conference. We discuss about what is testing, then what is agile testing and finally what is Testing in DevOps. Finally we had lovely workshop with the participants trying to find out different ways to think about quality and testing in different parts of the DevOps infinity loop.
JMeter webinar - integration with InfluxDB and GrafanaRTTS
Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overview
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
To view the webinar recording, go to:
https://www.rttsweb.com/jmeter-integration-webinar
Essentials of Automations: Optimizing FME Workflows with ParametersSafe Software
Are you looking to streamline your workflows and boost your projects’ efficiency? Do you find yourself searching for ways to add flexibility and control over your FME workflows? If so, you’re in the right place.
Join us for an insightful dive into the world of FME parameters, a critical element in optimizing workflow efficiency. This webinar marks the beginning of our three-part “Essentials of Automation” series. This first webinar is designed to equip you with the knowledge and skills to utilize parameters effectively: enhancing the flexibility, maintainability, and user control of your FME projects.
Here’s what you’ll gain:
- Essentials of FME Parameters: Understand the pivotal role of parameters, including Reader/Writer, Transformer, User, and FME Flow categories. Discover how they are the key to unlocking automation and optimization within your workflows.
- Practical Applications in FME Form: Delve into key user parameter types including choice, connections, and file URLs. Allow users to control how a workflow runs, making your workflows more reusable. Learn to import values and deliver the best user experience for your workflows while enhancing accuracy.
- Optimization Strategies in FME Flow: Explore the creation and strategic deployment of parameters in FME Flow, including the use of deployment and geometry parameters, to maximize workflow efficiency.
- Pro Tips for Success: Gain insights on parameterizing connections and leveraging new features like Conditional Visibility for clarity and simplicity.
We’ll wrap up with a glimpse into future webinars, followed by a Q&A session to address your specific questions surrounding this topic.
Don’t miss this opportunity to elevate your FME expertise and drive your projects to new heights of efficiency.
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
2. The reduction is highly exothermic and
temperatures must be controlled carefully during
this period to avoid damaging the catalyst.
Reduction is carried out using hydrogen or
hydrogen/carbon monoxide mixtures in an inert
carrier gas such as nitrogen or natural gas.
The inert gas must be free of catalyst poisons.
The hydrogen plus carbon monoxide in the
circulating gas should be adjusted to control the
reactor temperatures, but will typically be in the
range of 1.5-2.5% at the inlet to the converter.
3. During the reduction, approx' 15Nm3 of CO2 is evolved
from 1 ton of methanol synthesis catalyst. This must be
purged from the loop to keep the pressure constant.
Water is also released from the hydrated salts in the
catalyst as well as from the reduction of the copper oxide
by hydrogen. The total quantity of water produced amounts
to approx' 15% of the weight of catalyst installed.
Less water is produced if the reduction gas contains CO.
Once the catalyst has been reduced it can be brought on
line immediately.
Alternatively, it can be put on standby and commissioned
at a later date.
4. An on line hydrogen analyzer
A flow meter that shows the rate of hydrogen or synthesis
gas addition.
Provision to analyse for CO2 content every hour, if possible
by an on-line analyzer.
Converter temperatures, cold shot flows, heater
temperatures etc., should be within the control room.
A start up heater specified to be able to handle the
maximum load under reduction conditions as well as any
duties in normal operation.
Circulator - this must be specified, or at least checked out
with the machine vendor, for reduction gas flow,
temperature, pressure and composition in addition to the
normal circulating gas.
5. Hydrogen for reduction is normally obtained
from synthesis gas by starting up the reformer.
The theoretical quantity of hydrogen required
for the reduction of VSG-M101is 145 - 160
Nm3/ton (4900 - 5400 SCF/ton) of catalyst
installed.
If synthesis containing CO and/or CO2 is used
as a source of hydrogen, this will increase the
need to purge from the loop and there may be
an increased loss of hydrogen due to this extra
purging.
6. If cracked ammonia is used as the source of
hydrogen, the quantity required for reduction is
unchanged. The extra N2 accumulating in the
loop will have to be purged out and will carry CO2
with it. This will reduce the amount of N2 required
from other sources. The maximum concentration
of NH3 in the circulating gas must not exceed 10
ppm and so ammonia cracking conditions must
be selected to achieve this. An NH3 content of
200 ppm in the cracked gas is normally sufficient
and can be easily achieved.
7. Reduction is carried out in an inert gas such as nitrogen
or natural gas. The inert gas must not contain
excessively high levels of catalyst poisons, and a
specification for inert gas is:
Oxygen <1000 ppm v/v
CO < 1.0% v/v
H2 < 1.0% v/v
S < 1.0 ppm v/v
NH3 < 10 ppm v/v
Unsaturated Hydrocarbons traces only
Other poisons e.g. chlorides absent
8. Purge the synthesis loop with inert gas to less than 1% v/v
oxygen and then increase the pressure to the appropriate
level. For plants designed to operate at 1450 psig, the
reduction pressure should be approx' 100 - 115 psig.
For the ICI lozenge design, circulate the inert gas through
the converter ensuring that the cold shot valves are closed.
The circulation rate should be sufficient to give a minimum
space velocity of 300-600 Hr-1. The upper limit of the
circulation rate will be fixed by pressure drop through the
system and the characteristics of the circulator. The
advantage of increasing the circulation rate is that a more
rapid and more even reduction is obtained.
9. In tube cooled converters, gas should be sent directly to the
top of the bed, with no flow up the tubes since this would
lead to uneven reduction, as the catalyst close to the tubes
would be below the reduction 'strike' temperature.
Heat the converter to 130°C inlet at a rate not exceeding
50°C/hr
Introduce about 1 % of H2 or (H2 + CO) as a single shot, to
check the calibration of the hydrogen analysers and to
calibrate the reduction gas flow meter.
Increase the inlet converter temperature to 180°C at a rate
of approx' 20°C/hr. Reduction will commence between 150
and 160°C.
10. With an inlet temperature of 180°C, introduce reduction
gas initially to maintain a H2 + CO concentration inlet the
converter between 1.0 and 1.5 %.Once the temperatures
have stabilized, this can be increased to between 1.5 and
2.5 %. If the reduction proceeds too slowly the inlet
temperature may be increased to 200°C. The best inlet
temperature is that which gives peak catalyst temperatures
of about 230°C and a H2 concentration at the outlet <0.1
%.
During the reduction maintain a constant pressure by
purging or making up with extra inert gas as required.
Ensure that water produced during reduction is drained
from the catchpot. It can be useful to measure the quantity
as an aid to determining when complete reduction has
occured.
11. If, despite precautions, peak temperatures exceed 240°C,
stop the hydrogen addition. Do not open the cold shot
valves, as this will merely cause overheating to occur
elsewhere in the converter.
When there is no further sign of reaction (no temperature
point reading higher than the one above it and no
difference in the inlet and exit hydrogen analysis) raise the
inlet temperature to 240°C or as near as possible. If there
is still no sign of reaction, raise the H2 content to 10 - 20 %.
The increase must be stopped immediately if there are
signs of further temperature rise. Holding the catalyst under
high concentrations of H2 and at high temperature is called
'soak'. this period should last for 4 to 6 hours.
12. Reduction is now complete. The whole process,
excluding the time taken to heat the catalyst to
reduction temperatures (say 150°C) will take
about 24 - 36 hours.
13. Reduce the converter inlet temperature to 210 -
220°C and wait for all catalyst bed temperatures
to stabilise at this temperature. All converter
temperatures must be between 210 and 220°C.
Start introducing synthesis gas, which will cause
the pressure to rise. The rate of increase of
pressure should be about 10% of design
operating pressure per hour. This constraint is
imposed by the equipment in the synthesis loop
and not by the catalyst, and is only an estimate.
Different pressurisation rates may be acceptable.
14. The introduction of synthesis gas will cause
the converter temperatures to rise as the
methanol reaction commences. The partial
pressure of methanol vapour will increase,
but at first this vapor will not condense and
an equilibrium concentration of methanol
will be established. Consequently, the
temperature rise will only persist as long as
synthesis gas is being introduced. Aim to
keep the inlet converter temperature at 210
- 215°C.
15. When the pressure reaches 145 - 175 psig, the exact
value will depend on the temperature of the cooling water
and the water content of the first methanol made,
methanol will start to condense. This will allow a larger
continuous rate to be fed in for the same rate of pressure
rise. At this stage a temperature rise will consistently
appear across the catalyst.
When methanol first condenses, commission the cold shot
to the second bed with the control point inlet that bed set
at 210 - 215°C. Commission the cold shot to the
subsequent bed once the temperature at the exit of the
bed is steady. The control point should be 210 - 215°C at
each bed inlet.
16. In tubular converters as methanol starts to form, the
flow up the tubes should be gradually increased as
the peak bed temperature rises. For steam raising
converters the steam pressure should be set to give
a cooling temperature of about 215°C. This will be
approximately 300 psig. As methanol is formed the
steam pressure can be raised to its flowsheet value.
As methanol starts to form in sufficient quantity,
commission the level controllers of the separator and
the letdown vessel.
Commission the purge of flash gas from the letdown
vessel.
17. When the concentrations of nitrogen and
methane reach flowsheet values, commission
the purge from the synthesis loop. It is usual
anyway to have a small purge from the time that
methanol first starts to condense.
Maintain the bed inlet temperature at 210 -
215°C by commissioning the interchanger
bypass and admitting cold gas to the converter
inlet gas stream, or by making suitable
adjustments to the heat recovery system.
When the reaction is autothermal the start up
heater can be shut down.
18. If the start up cannot follow soon after reduction,
sweep out the loop with an inert gas until the H2
concentration is less than 1% and cool down the
converter. When the catalyst is subsequently
started up, the following procedure is used.
19. Pressurise the loop with inert gas to 7 - 8
barg. Establish circulation with a space
velocity of at least 300-600 hr -1.
Heat the reactor inlet temperature to 200°C
with the loop start up heater. Allow all
reactor temperatures to reach a minimum of
180°C.
Introduce Synthesis gas to the loop and
allow the pressure to rise.
20. As reactions start the reactor temperatures
will rise and methanol will begin to condense
in the catchpot, (when the pressure reaches
about 10 - 12 barg).
• As the inlet temperatures of the lower beds begin
to rise commission the shot flows to these beds
controlling the inlet temperatures at around 210 -
215 °C
• When sufficient heat generation is taking place the
loop start up heater can be decommissioned.
21. After shutdowns of a short duration the catalyst
may be hot enough to allow the reactor to be
started without additional heating.
◦ Bring the circulator up to normal speed as
quickly as possible consistent with the vendor's
instructions.
When the reactor temperatures are above 210
°C bring the circulator up to normal speed.
Begin to introduce fresh synthesis gas.
As temperatures begin to rise commission shot
flows as appropriate.
22. In a start up situation reaction heat for heating
of the reactor inlet gas is not available.
• Steam from the reforming section is used via the
loop start up heater
• Gas is redirected through the start up heater via
valve in the HL interchanger inlet and HIC007.
• Minimum stop valve to prevent isolation of HL interchanger
23. As reaction occurs reactor exit gas
temperature rises
◦ Heat will be picked up in HL interchanger
• As exit temperature continues to rise HL
interchanger valve can be adjusted to allow more
gas to flow through HL interchanger
• When temperature exit HL interchanger is high
enough to sustain reaction gas flow through start
up heater can be stopped
24. E1113E1112
E1110
V1107
Shot Gas
Converter Inlet
Gas
180 °C
0
0
0
0
Shot Flows
kNm3/hr
From C1102
210 °C
E1111
Loop start Up
Heater
100 bar
steam
TIC
060
HIC 007
240 °C
ShutOpen
180 °C
210
190
230 100
220
210
240 150
25 %
50 %
25. Stop the synthesis gas
• Continue to circulate the loop gas over the
catalyst to react all the carbon oxides
• When the temperature starts to fall commission
the start up heater and maintain the catalyst
temperature above 200 °C
• Maintain these conditions until synthesis gas is
available again
26. Carry out the short period shutdown
procedure
• Reduce the circulator to minimum speed and
reduce loop pressure. Allow the catalyst to cool
at a rate of around 50°C/hr
• While the circulator is running purge the loop with
N2 until the H2 content is below 1 %.
27. While shutdown the loop should be kept
under an inert atmosphere to prevent the
catalyst contacting oxygen
28. In the event of a trip the loop pressure should
be reduced by 10 %
– This prevents the catalyst overheating due to continuing
reaction of residual carbon oxides
• The purge can then be isolated and loop can be
left to depressurise slowly until ready to start up
again.
– If the trip will last more than 24 hours then the loop
should be shutdown in accordance with the prolonged
shutdown procedure
29. This procedure has been developed due to the development
of the ICI ARC converter. The new ARC converter has
individual catalyst beds which make it very difficult to
discharge the catalyst from the converter.
◦ To compensate for this GBHE has developed an in-situ oxidation process
that will completely oxidize the catalyst while it is still inside the reactor.
This eliminates both the need for any specialist procedures for catalyst
removal as well as the need to double handle the material after its
discharge.
◦ The oxidized catalyst is suitable for immediate loading into drums or other
suitable containers for shipping off-site.
30. The process has been carried out several times around the world.
The procedure takes approx' 24 to 36 hours.
A significant feature of the oxidation procedure is that the catalyst
is not completely oxidized after just one pass of the exotherm front
through the catalyst bed. It is only 90% oxidised, although the
exact extent of oxidation is a function of the temperature at which it
takes place.
The catalyst can never be completely oxidised, operators need to
be aware that the catalyst still has the capability to absorb O2 from
the atmosphere, so appropriate precautions must be taken during
entry into a vessel containing oxidised catalyst.
31. At completion of production, cool the converter to about
150°C
Letdown the synthesis loop pressure. Purge the synthesis
loop with N2 according to the standard plant procedure.
Hydrogen concentration in the loop must be reduced to
below 2 mol.% before any oxygen is introduced. The loop
H2 analyser may need recalibrating to a range of 1 - 10 %
32. Maintain the loop with inert N2 at just above atmospheric
pressure to prevent ingress of air.
◦ Ensure that all lines around the synthesis loop not associated with the
oxidation procedure are closed to eliminate the unwanted flow of fluids
in or out of the loop. The level of isolation required are double block
and bleed, slip plating or physical blinding.
◦ Any methanol left in the catchpot/separator should be completely
drained from the vessel before isolation.
◦ If air is to be supplied to the converter via an external air compressor,
an indication of flow will be needed, either at the air compressor or via
a plant gauge that has been recalibrated for the purpose.
33. Connect up an oxygen analyser upstream and
downstream of the converter. This can be done with one
analyser and a field switch. Lag time must be minimised in
obtaining samples.
Establish loop circulation with N2. Pressure up to about
100 - 150 psig.
Commission start up heater to maintain the catalyst bed at
150°C. This temperature should be maintained inlet the
converter for the first stage of the oxidation.
Check H2 concentration in the loop. H2 concentration
should be monitored continuously throughout the
procedure.
34. If H2 concentration is below 2 mol.% (NB H2 absorbed will be
released from the catalyst, so purging may be required to
reduce H2 below 2 mol.%), connect air supply and admit air
to a concentration of 0.5 mol.% O2 at the inlet to the
converter. Check that no O2 slip is being seen exit the
converter.
◦ The exotherm associated with the reaction is equivalent to about 100-
120°C per mol.% of O2 inlet the converter. A temperature rise will be seen
after only a few minutes, which will go progressively down the converter -
similar to that seen during catalyst reduction.
◦ Monitor temperature rises, O2 and H2 analysis and air rate regularly and
that they are giving consistent information. Do not increase the oxygen
concentration until inconsistencies have been satisfactorily resolved.
35. Once air addition has started, the loop will either require
periodic purging, or a continuous small purge, to maintain
the pressure at about 100 - 150 psig.
Continue at these conditions until the exotherm is
monitored exit the final catalyst bed.
Increase air addition rate in step-wise intervals, 0.5%
increments over say 30 to 60 minutes, towards a
maximum of 1.5 mol.%, while not exceeding a maximum
average temperature at any level of 250°C and any
individual temperature exceeding 275°C.
36. As the oxidation proceeds, the reaction front moves down
the catalyst beds. As the reaction front passes, the
temperature will fall at each level. When the temperature
exit the final bed begins to fall the reaction has almost
proceeded to completion. Isolate the air. Raise the
converter inlet to 200°C and maintain at this temperature.
Repeat from 'If H2 concentration is below 2 mol.%........'
When the final bed exit temperature falls after the second
air cycle, the oxygen level exit the converter should be
observed, for oxygen slipping from the converter. Maintain
O2 at its current level by reducing the air flowrate in step-
wise amounts, then isolate.
37. Recalibrate O2 analyser to read say 2 mol.% to 20 mol.% range.
Slowly add O2 to the loop to raise the concentration to 10 mol.% at
200°C. This should be done in increments of 2 mol.% allowing time
at each stage to check that conditions are stable. Maintain inlet
temperature at 200°C and loop pressure 100-150 psig. Ensure that
the average peak temperature at any level does not exceed 250°C,
and any single thermocouple does not exceed 275°C. Maintain O2
level at 9-10 mol.% by batchwise addition of air, until there is no
longer movement on the thermocouples. Isolate and shut down the
air compressor.
The converter needs to be cooled down prior to catalyst discharge.
This should be done, as much as possible, with O2 level maintained
at 10 mol.%. Allow converter to cool at up to 50°C/hr.
38. Fully reduced Cu crystallite
First exposure to oxygen.
Outer layers start to oxidize.
As oxidation continues, oxygen
penetrates throughout.
Later, the oxide layer at the
surface virtually stops any
further oxygen diffusion.
39. Raising the temperature speeds
up the solid diffusion process
and so oxidation resumes...
only to stop again when the thickness of
the oxide layer has increased and halts
any further oxygen diffusion.
Complete Oxidation Can Never Occur
40. Cool catalyst as much as possible, at least to less than
50°C, preferably to less than 40°C.
The above procedure should result in a converter full of
oxidised catalyst. However, COMPLETE oxidation CANNOT
be guaranteed, and the charge of catalyst may still be highly
active. Appropriate precautions should be taken during
vessel entry and catalyst discharge.
In the event of any unusual conditions, high exotherm, high
H2 levels etc., the air supply should be isolated immediately.
41. 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 Product for its own
particular purpose. GBHE gives no warranty as to
the fitness of the Product 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 for loss or damage resulting from reliance
on this information. Freedom under Patent,
Copyright and Designs cannot be assumed.