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
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
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.
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
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
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.
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
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
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.
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
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
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
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 ..........
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Get full Course here:
www.ChemicalEngineeringGuy.com/Courses
The BASIC Aspen HYSYS Course will show you how to model and simulate Processes (From Petrochemical, to Ammonia Synthesis and Polymerisation).
Analysis of Unit Operation will help you in order to optimise the Chemical Plant.
This is helpful for students, teachers, engineers and researchers in the area of R&D and Plant Design/Operation.
The course is didactic, with a lot of applied theory and Workshops/Study cases.
At the end of the course you will be able to setup a simulation, run it, get results and more important, analysis of the process for further optimization.
Chemical Engineers
Process Engineers
Students related to engineering fields
Teachers willing to learn more about process simulation
Petrochemical Engineers
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
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
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
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
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.
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
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
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
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 ..........
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Introduction and Theoretical Aspects
Catalyst Reduction and Start-up
Normal Operation and Troubleshooting
Shutdown and Catalyst Discharge
Nickel Carbonyl Hazard
Modern Methanation Catalyst Requirements
Introduction High temperature shift Catalysts
Low temperature shift catalysts
Catalyst storage, handling, charging and discharging
Health and safety precautions
Reduction and start-up of high temperature shift catalysts
Operation of high temperature shift catalysts
Reduction and start-up of low temperature shift catalysts
Operation of low temperature shift catalysts
Get full Course here:
www.ChemicalEngineeringGuy.com/Courses
The BASIC Aspen HYSYS Course will show you how to model and simulate Processes (From Petrochemical, to Ammonia Synthesis and Polymerisation).
Analysis of Unit Operation will help you in order to optimise the Chemical Plant.
This is helpful for students, teachers, engineers and researchers in the area of R&D and Plant Design/Operation.
The course is didactic, with a lot of applied theory and Workshops/Study cases.
At the end of the course you will be able to setup a simulation, run it, get results and more important, analysis of the process for further optimization.
Chemical Engineers
Process Engineers
Students related to engineering fields
Teachers willing to learn more about process simulation
Petrochemical Engineers
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
Most modern ammonia processes are based on steam-reforming of natural gas or naphtha.
The 3 main technology suppliers are Uhde (Uhde/JM Partnership), Topsoe & KBR.
The process steps are very similar in all cases.
Other suppliers are Linde (LAC) & Ammonia Casale.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
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
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
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
Naphtha Steam Reforming Catalyst Reduction with MethanolGerard B. Hawkins
Procedure for Naphtha Steam Reforming Catalyst Reduction with Methanol
Scope
This procedure applies to the in situ reduction of VULCAN Series steam reforming catalysts using methanol cracking to form hydrogen over the catalyst in the steam reformer.
The procedure is likely to be applied to plants using only heavier feeds (e.g.: LPG and/or naphtha) and some combination of VULCAN Series catalysts.
Introduction
A small number of steam reforming plants do not have an available source of the commonly used reducing media (e.g.: hydrogen, hydrogen-rich off-gas, natural gas). These plants will usually operate on LPG and/or naphtha feed only where cracking of this hydrocarbon is not usually advised for reduction of the steam reforming catalyst ...
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
This Engineering Design Guide has several aims.
It is intended to take an experienced mechanical engineer through the steps necessary to specify a gear and to carry out an assessment of gears offered against a particular specification for pumps, fans and compressors driven by electric motors, steam turbines, combustion gas turbines or expanders. It is not part of this Engineering Design Guide to show how to decide that a gear is or is not necessary for a particular duty.
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingGerard B. Hawkins
Procedure for Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Scope
This procedure applies to the in situ reduction of VULCAN Series steam reforming catalysts using ammonia cracking to form hydrogen over the catalyst in the steam reformer. This procedure covers plants with a dry gas circulation loop for reduction. The procedure is likely to be applied to plants using only heavier feeds (e.g.: LPG and/or naphtha) and some combination of VULCAN Series catalysts.
Introduction
A small number of steam reforming plants do not have an available source of the commonly used reducing media (e.g.: hydrogen, hydrogen-rich off-gas, natural gas). These plants will usually operate on LPG and/or naphtha feed only where cracking of this hydrocarbon is not usually advised for reduction of the steam reforming catalyst. In such circumstances, the plant may be designed to use the installed steam reforming catalyst to crack ammonia to provide hydrogen for the reformer catalyst reduction....
(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENTGerard B. Hawkins
(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENT; Case Study: #0978766GB/H
CASE STUDY OVERVIEW
Syn Gas Sour Shift: Process Flow Diagram
AGR: Acid Gas to VULCAN SYSTEMS Sour Gas Shift
DESIGN BASIS:
ACID GAS REACTOR CATALYST SPECIFICATION
SOUR SHIFT CASE
SHIFT REACTOR CATALYST SPECIFICATIONS
COS REACTOR CATALYST SPECIFICATIONS
SWEET SHIFT CASE
SHIFT REACTOR CATALYST SPECIFICATIONS
PERFORMANCE SIMULATION RESULTS
SOUR SHIFT SECTION
1 Cases Considered
2 Catalyst Used
3 Client Requirements
4 Oxygen and Olefins
5 HCN
6 NH3
7 Arsine
8 Input Data Sour Shift Unit
9 Activity (PROPRIETARY)
10 Results
ADIABATIC SWEET SHIFT SECTION: HTS Reactor followed by LTS Reactor
1 Catalyst Used
2 Inlet Operating Temperature HTS Reactor
3 Feed Flow Rate, Inlet Operating Pressure and Feed Composition HTS Reactor
4 Inlet Operating Conditions LTS Reactor
5 Client Requirements
6 Results: Standard Case as Presented to the Client
7 Results: Inlet Operating Pressure HTS Reactor = 25.2 bara
8 Results: Addition of 100 kmol/h N2
COS HYDROLYSIS SECTION FOR SWEET SHIFT CASE
1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure
2 Inlet H2S and COS Levels
3 Equilibrium H2S and COS Levels (COS Hydrolysis Reaction)
4 Client Requirements
5 Results
H2S REMOVAL SECTION AFTER AGR UNIT
(2 Absorbent Beds (VULCAN VSG-EZ200) in Lead/Lag Arrangement)
1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure
2 Inlet H2S and COS Levels
3 Client Requirements (All Cases)
4 Results
ISOTHERMAL SWEET SHIFT SECTION: Alternative Approach
VULCAN Simulation Input Data
1 Enthalpy method
2 Cases considered
3 Feed stream data
4 Kinetics
5 Catalyst
6 Catalyst Activity relative to standard
7 Catalyst size and packing details
8 Catalyst pressure drop parameters
9 Catalyst Volume
10 Standard die-off rate
11 BFW Rate
12 Vapor fraction
13 Steam Temperature
14 Steam Pressure
15 Boiling Model
16 Volumetric UA
Isothermal Shift Simulations Results
APPENDIX
Characteristics of Acid Gas Removal Technologies
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.
Procedure for Steam Reforming Catalyst Reduction with LPG Feed
Scope
This procedure may be used for the reduction of VULCAN Series Catalysts for the general steam reforming of LPG.
It is strongly advised that this procedure is adopted only where there is no other option available to use hydrogen, a hydrogen-rich gas or natural gas for the reduction stage. Reduction using the cracking of heavier hydrocarbons carries an extreme risk of catastrophic carbon formation in the event of any error in execution of the procedure.
Introduction
LPG is not normally utilized for steam reforming catalyst reduction although it can be used successfully. Caution is required if heavier hydrocarbons are used for catalyst reduction. Although operators have been able to reduce catalysts by using heavier hydrocarbon cracking, this has only been adopted where no other reductant option is available. The risk of carbon formation greatly increases as the carbon number of the feed increases when the catalyst is in the unreduced state. For the purposes of this procedure, LPG may range from a hydrocarbon mixture which is predominantly propane to one which is predominantly butane.
SMR PRE-REFORMER DESIGN
Case Study #0618416GB/H
Contents
1. SMR Pre-Reformer Design
2. Inlet Baffle Design
3. Outlet Collector
4. Hold Down Grating
5. Floating Hold Down Screen
6. Catalyst Drop Out Nozzle
7. Thermowell Detail
8. Technical Performance requirements
9. SMR Pre-Reformer Isolation
Technical Review and Commentary on Proposed Design
APPENDIX
A. Operating / Mechanical Data
B. Materials Specifications
C. Fabrication and Inspection Requirements
D. Weights
E. Nozzle Data
F. Instrument Connections
G. Manholes
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.
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
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
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
Use and Applications of Membranes
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL
4.1 What is a Membrane Process?
4.2 What does a Membrane look like?
4.3 Why use Membranes?
4.4 Membrane Types and Polymers Used
5 REVERSE OSMOSIS
5.1 Principles of Reverse Osmosis
5.2 Limitations
5.3 Performance
5.4 Costs
5.5 Worked Example
5.6 Applications
6 MICROFILTRATION AND ULTRAFILTRATION
6.1 Microfiltration
6.2 Ultrafiltration
7 PERVAPORATION
7.1 Classes of Application
7.2 Characteristics
7.3 Costs
7.4 Example - Lurgi Design
7.5 Application - Stripping Organics from Water
8 GAS SEPARATION AND VAPOR PERMEATION
8.1 Gas Separation
8.2 Vapor Permeation
9 LESS COMMON MEMBRANE PROCESSES
9.1 Dialysis
9.2 Electrodialysis
9.3 Electrolysis
9.4 Salt Splitting
10 BIBLIOGRAPHY
TABLES
1 UTILITY CONSUMPTION AND COST COMPARISON
Fluid Separation
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 A SEPARATION LOGIC TREE
5 METHODS OF DISTILLATION
5.1 Fractional Distillation
5.2 Azeotropic Distillation
5.3 Extractive Distillation
6 LIQUID-LIQUID EXTRACTION
7 OTHER COMMERCIAL METHODS OF SEPARATION
7.1 Adsorption
7.2 Fractional Crystallization
7.3 Ion Exchange
7.4 Membrane Processes
7.4.1 Ultrafiltration
7.4.2 Reverse Osmosis
7.4.3 Pervaporation
7.4.4 Liquid Membranes
7.4.5 Gas Permeation
7.4.6 Dialysis
7.4.7 Electrodialysis
7.5 Supercritical Fluid Extraction
7.6 Dissociation Extraction
7.7 Foam Fractionation
7.8 Clathration
7.9 Chromatography
8. OTHER METHODS OF SEPARATION
8.1 Precipitation
8.2 Paper Chromatography
8.3 Ligand Specific Chromatography
8.4 Electrophoresis
8.5 Isoelectric Focusing
8.6 Thermal Diffusion
8.7 Sedimentation Ultracentrifugation
8.8 Isopycnic Ultracentrifugation
8.9 Molecular Distillation
8.10 Gel Filtration
APPENDICES
A AT A GLANCE CHART BASED ON FENSKE, UNDERWOOD
B A GENERALIZED y - x DIAGRAM
C TEMPERATURE - COMPOSITION DIAGRAMS FOR
AZEOTROPIC MIXTURES
D A TYPICAL y - x DIAGRAM FOR EXTRACTIVE DISTILLATION (SOLVENT FREE BASIS)
E RAPID ESTIMATION OF LIQUID-LIQUID EXTRACTION REQUIREMENTS
F LIQUID - LIQUID EXTRACTION - THE USE OF EXTRACT REFLUX
G SELECTIVITIES REQUIRED FOR EQUAL PLANT COSTS
FIGURE
1 SEPARATION LOGIC TREE
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
Hygiene: Estimating and Understanding Personal Exposure to Inhalation of Vapo...Gerard B. Hawkins
Hygiene: Estimating and Understanding Personal Exposure to Inhalation of Vapors on Chemical Plants
It is a vital aspect of chemical plant design and operation to minimize any contact of the operating and maintenance personnel with the chemicals on the plant. Often the most significant route of exposure to chemicals is by inhalation, and in this case it is relatively easy to measure exposure. This has led to the development of standards which indicate levels of exposure which should minimize any risk to health. These will be called Occupational Exposure
Limits (OELs) in this Guide as a generic name...
0 INTRODUCTION
The four main sources of Fugitive Emissions on most plants are valves, machine seals, re-makable joints and pressure relief devices. Other possible sources include open-ended lines, sampling connections, drains and vents.
Sometimes special precautions are taken to minimize Fugitive Emissions, for example the use of bellows seal valves. However, generally no special precautions are taken and the subsequent Fugitive Emissions to atmosphere represent a significant amount of plant losses.
Regulatory requirements covering Fugitive Emissions exist in many countries and therefore a leak reduction program should be implemented. Fugitive Emissions also represent financial losses to the business as well as potential damage to the environment.
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
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
METHANOL PLANT - SHALE GAS FEED PRETREATMENT
CASE STUDY #091406
Case Background
A Methanol plant operator would like to examine the technical feasibility of using Shale Gas as a feedstock to their Methanol plant.
The first step in the Methanol production process is gas pretreatment. The purpose of gas pretreatment is to make the gas suitable for the downstream processes. There are two groups of compounds that are usually present in natural gas and that should be removed during pretreatment—the associate NGL and the sulfur-containing compounds. Some natural gas reservoirs may also have other trace components that must be removed, but these are not discussed here.
This case study examines the impact of CO2 (Carbon Dioxide) on the pre-treatment section design, performance and efficiency of ACME Methanol Plant’ feed gas pre-treatment section.
Case 1: Normal Shale Gas
Case 2: “Bad Gas”
Case 3: Low CO2
Case 4: High CO2
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
Overflows and Gravity Drainage Systems
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 OUTLINE OF THE PROBLEM
5 DESIGNING FOR FLOODED FLOW
6 DESIGNING NON-FLOODED PIPELINES
6.1 Vertical Pipework
6.2 From the Side of a Vessel
6.3 Established (uniform) Flow in Near-horizontal Pipes
6.4 Non-uniform Flow
7 NON-FLOODED FLOW IN COMPLEX SYSTEMS
8 ENTRAINING FLOW
9 SIMPLE TANK OVERFLOWS
9.1 Venting of the Tank
10 BIBLIOGRAPHY
11 NOMENCLATURE
TABLE
1 GEOMETRICAL FUNCTIONS OF PART-FULL PIPES
FIGURES
1 TYPICAL SEQUENCE OF SURGING FLOW
2 DESIGNING FOR FLOODED FLOW
3 CAPACITY OF SLOPING PIPELINES
4 OVERFLOW FROM SIDE OF VESSEL
5 METHODS OF AVOIDING LARGE CIRCULAR SIDE
OVERFLOWS
6 CAPACITY OF A GENTLY SLOPING PIPE AS A FUNCTION OF LIQUID DEPTH
7 COMPLEX PIPE SYSTEMS
8 REMOVAL OF ENTRAINED GASES
Reciprocating Compressors - Protection against Crank Case ExplosionsGerard B. Hawkins
Reciprocating Compressors - Protection against Crank Case Explosions
1 SCOPE
2 OIL MIST/AIR MIXTURE EXPLOSIONS
3 PREVENTION AND PROTECTION
3.1 Design
3.2 Maintenance and Operation
FIGURES
1 FLAMMABILITY LIMITS AND SPONTANEOUS IGNITION REGION FOR MIXTURES OF LUBRICATING OIL VAPOR IN AIR.
Data Sources For Calculating Chemical Reaction EquilibriaGerard B. Hawkins
Data Sources For Calculating Chemical Reaction Equilibria
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THEORY
5 BIBLIOGRAPHY
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.
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
Similar to PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs) (20)
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
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
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
Burner Design, Operation and Maintenance on Ammonia Plants
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
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
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
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
"Impact of front-end architecture on development cost", Viktor TurskyiFwdays
I have heard many times that architecture is not important for the front-end. Also, many times I have seen how developers implement features on the front-end just following the standard rules for a framework and think that this is enough to successfully launch the project, and then the project fails. How to prevent this and what approach to choose? I have launched dozens of complex projects and during the talk we will analyze which approaches have worked for me and which have not.
Let's dive deeper into the world of ODC! Ricardo Alves (OutSystems) will join us to tell all about the new Data Fabric. After that, Sezen de Bruijn (OutSystems) will get into the details on how to best design a sturdy architecture within ODC.
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
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.
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
Key Trends Shaping the Future of Infrastructure.pdfCheryl Hung
Keynote at DIGIT West Expo, Glasgow on 29 May 2024.
Cheryl Hung, ochery.com
Sr Director, Infrastructure Ecosystem, Arm.
The key trends across hardware, cloud and open-source; exploring how these areas are likely to mature and develop over the short and long-term, and then considering how organisations can position themselves to adapt and thrive.
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
Connector Corner: Automate dynamic content and events by pushing a buttonDianaGray10
Here is something new! In our next Connector Corner webinar, we will demonstrate how you can use a single workflow to:
Create a campaign using Mailchimp with merge tags/fields
Send an interactive Slack channel message (using buttons)
Have the message received by managers and peers along with a test email for review
But there’s more:
In a second workflow supporting the same use case, you’ll see:
Your campaign sent to target colleagues for approval
If the “Approve” button is clicked, a Jira/Zendesk ticket is created for the marketing design team
But—if the “Reject” button is pushed, colleagues will be alerted via Slack message
Join us to learn more about this new, human-in-the-loop capability, brought to you by Integration Service connectors.
And...
Speakers:
Akshay Agnihotri, Product Manager
Charlie Greenberg, Host
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.
Essentials of Automations: Optimizing FME Workflows with Parameters
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs)
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 Engineering Guide:
GBHE-PEG-015
PRACTICAL GUIDE ON THE
REDUCTION OF DISCHARGES TO
ATMOSPHERE OF VOLATILE
ORGANIC COMPOUNDS (VOCs)
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
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
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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
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FOREWORD
This guide has been prepared on behalf of RENALT ENERGY and is issued as
one of a series of Process Safety Guides by GBH ENTERPRISES (GBHE).
Its purpose is to provide process engineers, and others, who are faced with
the problem of handling and treating VOC emissions from process plant, with
advice on the methods available to minimize SHE impact. It recommends best
practice based on current knowledge and experience from both inside and
outside of GBHE. Hopefully it will make a useful contribution to achieving
environmental objectives.
1 INTRODUCTION
The purpose of this Practical Guide is to assist the selection of the
appropriate process route to reduce the discharge to atmosphere of
Volatile Organic Compounds (VOCs). It must not be used as a process
engineering design guide to actually design equipment; advice should
always be sought for this purpose, and Hazard Studies should be carried
out for all modifications of equipment.
2 THE NEED FOR VOC CONTROL
Photochemical oxidants, notably ozone, are formed indirectly by the
action of sunlight on NO2. The chemical reactions involved are complex
and multi-stage. The presence of hydroxyl radicals and VOCs in the
atmosphere causes a shift in the atmospheric equilibrium towards much
higher concentrations of ozone.
VOCs can be classified according to their Photochemical Ozone Creation
Potential (POCP) [2] [3]. The POCPs for a number of VOCs are shown in
Appendix 1.
Photochemical oxidants can damage crops, trees and other vegetation as
well as affect the human respiratory function. Ozone is strongly implicated
in widespread forest damage across Europe.
Ozone and most VOCs are "greenhouse" gases, in some cases with
"greenhouse potentials" more than a million times that of CO2 on a w/w
basis.
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In particular, it has been estimated that ozone is responsible
for up to 10% of potential global warming. Therefore, there are concerns
on the rising trends of concentrations of ozone and VOCs in the
troposphere.
The World Health Organization has developed air quality guidelines for
ozone of 150 - 200 μg/m3
(1-hr exposure time) and 100 - 120 μg/m3 (8-hr
exposure time).
Legislative discharge limits for VOCs should always be determined from
the local Environmental Agency. The limit for small volumetric
emissions is likely to be of the order of 50 mg/m3
whereas that for
large volumetric discharges could be based on the mass discharge rate as
well as the VOC concentration.
This practical guide is aimed at the discharge of VOCs from discrete
vents. Also of great importance is the discharge directly to atmosphere
from diffuse and fugitive sources and, in addition, the discharge of VOCs
dissolved in aqueous effluents. However, these discharges are not
covered in this practical guide.
3 CONTROL AT SOURCE
It is important to eliminate or, where this is not possible, to reduce the size
of the end-of-pipe abatement problem by controlling the VOC discharge at
source.
Some examples of techniques are given below.
3.1 Choice or Solvent
Where a solvent is being used in a process, the problem of VOC
discharge can sometimes be avoided or reduced by using no solvent,
using a water-based solvent or by using a solvent with lower volatility.
3.2 Venting Arrangements
Subject to considerations of safety, cross-contamination and plant
layout, a number of stock tanks can sometimes be connected to a
common venting system to reduce the overall volumetric vent flow rate.
This is particularly effective when transfers are made between the stock
tanks in question.
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Similarly, the vent on a road tanker or other transportable container
that is being loaded or off-loaded to a stock tank should, wherever
possible, be connected (i.e. back-balanced) to the stock tank vent
system.
3.3 Nitrogen Blanketing
Where there is a need to inert the vapor space in a stock tank by using
nitrogen in order to keep out oxygen or moisture, this should be achieved
by means of a pressure-controlled nitrogen supply to the tank and a
pressure-controlled relief on the tank rather than a continuous nitrogen
sweep.
3.4 Pump Versus Pneumatic Transfer
Transfer by pump, rather than pneumatically, reduces significantly the
emission of vapor after the transfer and often of mist at the end of the
transfer.
3.5 Batch Charging
The charging of material through an open lid or charge port into a reactor
or other vessel containing VOCs usually results in VOC losses to
atmosphere.
If the vessel is at or above atmospheric pressure these losses occur
locally, if the vessel is under some vacuum there will be an ingress of air
which could result in a discharge of VOC to atmosphere at a point remote
from the charge point.
If the material to be charged is liquid or can be dissolved in a liquid, a
closed charging system should be used. Where this is not possible, a
charge hopper should be considered with a narrow entry point from the
hopper to the vessel in which there is a rotary, baIl or slide valve.
Where an open lid or charge port does have to be used, hardware
systems or procedures should be applied to ensure that the vessel is open
only during the charging operation. Also, if the vessel is under any
pressure, the pressure should be let down prior to charging through a
vent abatement or recovery system and not through the charge port. If a
draught ventilation system is used for occupational hygiene purposes, it
should be switched off either automatically or manually when the charge
port or vessel lid is closed.
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3.6 Reduction of Volumetric Flow
The flow rate of inerts must be minimized. The following examples are all
common sources of flows often containing VOCs at saturation level:-
Unnecessary purging, draughting, poorly designed or faulty
pneumocators, valves on nitrogen blowing or blanketing systems that are
passing or left open.
3.7 Stock Tank Design
The liquid inlet should, wherever possible, be below the liquid level in
the stock tank so as to minimize the disturbance of the vapor space.
This reduces the chance of the out breathing vapor being saturated with
VOC.
4 DISCHARGE MEASUREMENT
4.1 By Inference or Calculation
Often the concentration and quantity of VOC(s) discharged can be
calculated or inferred indirectly from other data. For example volumetric
flow-rates can sometimes be determined from nitrogen usage or from fan
characteristics, average VOC discharge rates can sometimes be
determined from solvent usage rates, and VOC concentrations can
sometimes be calculated from a knowledge of operating temperatures and
vapor pressure data. However, caution is strongly advised especially
where batch operations are concerned.
Experience has shown that initial estimates of VOC losses based on
calculated rather than measured data can be as much as an order of
magnitude too low.
4.2 Flow Monitoring Equipment
The main types of portable equipment suitable for measuring the flow of
gases in vent pipes and ducts are shown in the following table. Prices
are typically in the range $1,650 to $3,300.
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Care should be taken as only some hand-held instruments are
intrinsically safe but many of the others could be used providing that
adequate precautions are adopted and local site regulations are
observed.
Some manufacturers offer an instrument and data logger that can be used
with a plug-in pitot tube, vane anemometer, hot-wire anemometer,
temperature and humidity probe or other probes in a single unit. Whilst
more expensive than any of these individual items, the added flexibility of
low cost probes plus a data logging facility in a single unit can offer
advantages.
4.3 Analytical Instruments
The main types of equipment suitable for analyzing VOC concentrations
are shown below. It should be noted that there are wide differences in
features, measuring ranges, complexity and costs.
(i) Mass Spectrometers
These are moveable rather than truly mobile versions of laboratory
Mass Spectrometers but require fairly large vacuum pumps for their
operation.
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They could be permanently housed in a laboratory or in a purpose-
designed mobile van with long sample lines connecting to the
vents. They are expensive analyzers but are capable of analyzing
most gas mixtures in concentrations from ppm(s) up to 100%
subject, in general, to the number of components not exceeding
about 5.
(ii) Gas Chromatography
Equipment has become available recently that is mobile and more
compact than Mass Spectrometer units. Maintenance requirements
associated with this type of equipment has traditionally been high
but self diagnostic features are now becoming standard. These
units can measure a similar range of gases and concentrations to
Mass Spectrometers and give better quantitative results with
organic mixtures but are not as good for identifying individual
components. Gas sampling techniques for vent or area monitoring
can be simplified by using adsorption tubes or syringes full of
the gas which can be taken to the Gas Chromatograph located
away from the plant.
(iii) Infra-Red Analyzers
These are semi-portable units. Their operation is based on the
different absorbance of infra-red energy by different compounds.
They are capable of detecting a wide range of compounds but only
up to about four components in a mixture. The maximum
concentration limit is about 3000 ppm for a limited range of
materials but is much less for most components.
(iv) Photo Ionization
These are portable units using ultra-violet light which ionizes the
VOCs and the unabsorbed UV light is detected and measured and
compared with a similar beam passing through a reference gas.
They are limited to concentrations in the range 0.1 to 2000 ppm
and UV lamps of different energy levels are required to cover the
range of materials that can be detected.
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(v) Flame Ionization
These are portable units that use a hydrogen flame to cause
ionization of the gas phase and then measure the current
generated as the positive ions reach an electrode. They give an
output reading regardless of the VOC(s) detected which is correct if
the only VOC present is that which was used for calibration
purposes. Nevertheless, they are useful, if used with care, for
providing indicative concentrations of VOCs not used in the
calibration or for mixtures of VOCs.
This method is particularly suitable for measuring hydrocarbons
(as methane equivalents) but is less sensitive to other organics.
The units require the use of fuel cylinders as well as calibration
gases all of which makes the units more difficult to use than
would first appear.
Intrinsically safe versions are available which may make these units
worth considering for difficult access areas despite the above
disadvantages.
4.4 Vent Emissions Database
The database is a system which allows a plant or site to store information
from vent surveys and rapidly produce documentary evidence for total
annual emissions. This is particularly useful when year on year
comparative data is required.
Emissions are totaled by site, area, plant, unit or material and emission
data sheets can be printed for individual plant items.
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5 ABATEMENT TECHNOLOGY
5.1 Available Options
The following options are available
(i) Condensation
(ii) Adsorption
(iii) Absorption
(iv) Thermal incineration
(v) Catalytic oxidation
(vi) Biological filters
(vii) Membranes
(viii) Combinations of (i) to (vii)
Section 5.2 discusses the main factors to be considered when choosing
the preferred option and some details of the options are presented in
Sections 5.3 to 5.9 below.
Some process technologies that are still at the development stage are
outlined in Section 5.10.
Further background reading on available technical options can be found
in the BASF technical information guide "Recovery of organic solvents
from off-gas streams" [7].
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5.2 Selection of Preferred Option
5.2.1 Main Issues and Factors
When determining the optimum VOC abatement system for a plant or site,
the following inter-related issues should be considered
(1) What modifications can be made to plant and/or procedures to
reduce the VOC emission at source.
(2) Which technology to use for abatement.
(3) Whether to treat individual vents locally or whether they should
be collected together for a common treatment on a plant or site
basis. In some cases it may be appropriate to use a combination of
these with concentration or bulk removal being done locally and
final abatement being done on a central basis. Whilst there are
economies of scale for common treatment plant, this may be
outweighed by the need for extra costs for fans, blowers and
piping. If the various streams contain similar VOCs but at
different concentrations, mixing them could prove more expensive
than treating them separately. Also, the mixing of streams
containing different VOCs can require complex treatment plant.
For example, if there is a number of vents to be treated that
comprise some containing substantial flows of VOC hydrocarbons
and others containing small flows of halogenated or nitrated
organics, it is possible that it would be better to segregate the
halogenated and nitrated organics for separate treatment and to
collect the hydrocarbons for common treatment in a simple
incinerator.
(4) Whether to recover VOCs for recycle back into the process or to
destroy them.
(5) Whether new site services such as steam or refrigeration are
required.
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Information on the following factors is generally required to enable the preferred
treatment option to be selected :-
(a) Volumetric flow of inerts
(b) VOC concentration(s)
(c) Calorific value of the VOC(s)
(d) Commercial value of the VOC(s)
(e) Removal efficiency required
(f) Water solubility of the VOC(s)
(g) VOC volatility
(h) Biodegradability of the VOC(s)
(i) VOC freezing point
(j) Chemical reactivity of VOC(s) e.g. hydrolysis, polymerization, flammability,
susceptibility to oxidation (e.g. aldehydes and ketones), peroxide
formation (from ethers).
(k) Number of VOCs present
(l) Presence of dust, moisture, metals, heavy organics
(m) Configuration of existing plant
(n) Availability of site services, e.g. steam, aqueous effluent treatment plant
(0) Site policy
(p) Statutory requirements
5.2.2 Feasibility and Characteristics of Different Technologies
Table 1 indicates the feasibility (also see Section 5.2.3 below) of different
abatement technologies and Table 2 shows some of their characteristics.
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TABLE 1 FEASIBLE APPLICATION OF DIFFERENT TECHNOLOGIES
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NOTES
(1) Boiling point > 35 o
C
(2) Boiling point < 200 o
C
(3) Distillation needed so unlikely to be cost effective
(4) Molecular weight < 100
(5) High incineration temperature followed by flue gas cleaning required
(6) Must be biodegradable
(7) Not ethers (form peroxides)
(8) Approximate guide only. Also see Figures 1, 2, 3 and 4. The VOC mass flow rate is sometimes more
important than the VOC concentration.
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TABLE 2 CHARACTERISTICS OF DIFFERENT TECHNOLOGIES
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NOTES FOR TABLE 2
WASTE PROBLEMS
(1) Disposal of spent adsorbent
(2) Disposal of contaminated water
(3) Disposal of contaminated water if flue gas scrubbing installed
(4) Disposal of bio sludge
(5) Production of NOx
OPERATING PROBLEMS
(6) Hydrolysis of halogenated VOCs
(7) Polymerization of some unsaturated VOCs
(8) Concern over dioxin formation from chlorinated hydrocarbons (CHCs)
(9) Risk of catalyst poisoning and de-activation
(10) Possible hydrate or ice formation
OTHER NOTES
(11) Concentrates VOC, not a recovery process per se
(12) Cooling is required if flue gas cleaning is required
(13) Connection to steam services may be required if steam is raised for export
(14) dcost/dconc becomes +ve for VOC concentrations so high that dilution is required
(15) dcost/dconc = gradient of graph of cost versus inlet VOC concentration
(16) Post-recovery treatment, such as azeotropic distillation, drying and/or re-stabilization may be required
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5.2.3 Economic Applicability of Different Technologies
Figures 1, 2, 3 and 4 indicate the typical economic regimes for which
each technique is applicable for the main classes of VOCs :hydrocarbon,
oxygenated hydrocarbons and chlorinated hydrocarbons. The derivation of
Figures 1, 2, 3 and 4 takes into account factors (a) to (h) in Section 5.2.1.
For some of the technologies available, there is not yet sufficient cost
information to assess their region of applicability and these will be added
later. As these figures are, necessarily, based on a large number of
assumptions, they must only be used as a guide. The assumptions are
listed in Section 5.2.3.1, use of the figures is explained in Section 5.2.3.2,
notes on the figures are given in Section 5.2.3.3 and cost correlations
used to generate the figures.
5.2.3.1 Assumptions Implicit in Figures 1, 2, 3 and 4
(1) The total cost for each technology is calculated as installed
capital plus three times the annual operating costs. A credit is
made against operating costs for any VOC recovered.
(2) The capital cost is the budget installed cost of the technology
package plus 10% for civil. It does not include costs for services
and piping up to the VOC abatement unit boundary or costs to raise
the standards of design or construction over and above those of the
equipment supplier.
(3) All general services, including power, gas, cooling water and steam
import/export, are assumed to be available.
(4) Other facilities such as an existing biological treatment unit or spare
refrigeration capacity are assumed not to be available.
(5) The voc is assumed to be in an air stream.
(6) Air regenerative adsorption is evaluated in combination with
thermal incineration.
(7) If adsorption, catalytic combustion or thermal incineration is used
and the VOC concentration > 25% LEL, the vent stream to be
treated is diluted with air to achieve < 25% LEL.
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(8) The volumetric flow rate of the stream to be treated and the VOC
concentration are steady.
(9) The values of other variables are those given.
5.2.3.2 Use of Figures 1, 2, 3 and 4
In general, water-cooled condensation should be considered for the
pre-treatment of streams with high dew points; the VOC concentration that
can be achieved can be calculated from vapor pressure data. Such typical
concentrations for the common classes of VOCs are shown in Figure 5 for
a saturation temperature of 32 o
C.
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For all the technologies considered except refrigerated condensation,
the capital and operating costs are mainly functions of the flow rate and
the VOC inlet concentration. Hence it is possible to display singularly
defined economic boundaries around these technology regimes as shown
by solid lines in Figures 1, 2, 3 and 4. However, costs for refrigerated
condensation are mainly functions of the flow rate and the VOC exit
concentration. Hence there is no upper concentration boundary for
refrigerated condensation and the lower concentration boundary varies
according to the VOC exit temperature.
These boundaries have been drawn for an economic refrigerant
temperature and are shown as dotted lines in Figures 1, 2, 3 and 4. When
using refrigerated condensation to recover VOCs, it is usually necessary
to use another technology downstream in order to achieve an acceptably
low VOC concentration. The dotted lines on Figures 1, 2, 3 and 4 show
the economically optimum VOC concentration leaving the refrigerated
condenser and entering the downstream treatment unit. This optimum
VOC concentration depends on the VOC boiling point, the recovery value
of the VOC and the abatement technology used. Hence there is a number
of dotted lines on each figure. The recovery value is either the fuel value
or the product value whichever is the higher. (See Note (1) in Section
5.2.3.3) If the VOC inlet concentration is only 2 or 3 times higher than that
shown by the appropriate dotted line, it is unlikely that refrigerated
condensation would be worth installing.
5.2.3.3 Examples for use of figures 1,2,3,4:
(1) VOC Inlet Stream:
Hydrocarbon concentration = 0.001 kg/m3
Flow rate = 1000 Nm3
/hr
Which technology should be used?
Plot the given co-ordinates on Figure 1. The point lies in the region
for Steam Regenerative Adsorption.
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(2) VOC Inlet Stream:
Hydrocarbon concentration = 0.1 kg/m3
Flow rate = 1000 Nm3
/hr
Boiling point = 80 o
C
Which technology should be used?
Plot the given concentration and flow rate on Figure 1. The
plotted point lies in the refrigeration region. Draw a horizontal
line from the point until it reaches the dotted line for a boiling point
of 80 o
C. Drop a vertical line to the concentration axis and read off
the value. It should be approximately 0.012. This means that the
exit concentration from the refrigerated condenser will be 0.012
kg/m3
. Therefore, another technology should be used downstream
to remove the rest of the hydrocarbons.
5.2.3.4 Notes on Figures 1, 2, 3 and 4
(1) The economics of steam regenerative adsorption and thermal
incineration depend very much on the value placed on the
recovered VOC which, in turn, depends on whether the recovered
VOC is burned as a fuel or is recycled as product. Therefore two
typical cases for hydrocarbon VOCs are presented, one at $100/te
value in Figure 1 (fuel) and the other at $200/te in Figure 2
(product).
(2) The economics of steam regenerative adsorption for water soluble
oxygenates varies very much from case to case because of
distillation costs. If these are low then steam regenerative costs
could be economic in the area of Figure 3 shown for catalytic
combustion.
(3) The difference in costs between catalytic combustion and thermal
incineration is always quite small for non-halogenated VOCs.
Therefore, the costs of both options should be assessed. At
pressures above atmospheric, catalytic combustion could show a
cost advantage.
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(4) Thermal incineration using regenerative heat recovery and air
regenerative adsorption followed by incineration tend to be more
costly than thermal incineration using recuperative heat recovery
when treating non-chlorinated VOCs. However, the economics of
the first two technologies improve when support fuel costs are
higher than assumed or when steam export has no value or is
expensive to implement.
(5) Air regenerative adsorption can be attractive in concentrating
VOCs before passing to a central abatement system. Also, it is
particularly useful as a primary treatment process to smooth out
mass flow rates of VOCs especially in batch operations.
(6) Thermal incineration tends to be much more expensive than steam
regenerative adsorption for treating chlorinated hydrocarbon
(CHC) VOCs and so does not appear on Figure 4. Therefore, whilst
there may be some problems in using steam regenerative
adsorption, it may be worth significant effort to resolve them.
It should be noted that the above cost difference can be reduced
if a value can be put on the Hel produced.
(7) Air regenerative adsorption followed by thermal incineration
tends to be significantly cheaper than thermal incineration on
its own for chlorinated hydrocarbon VOCs.
5.3 Condensation
5.3.1 Indirect Condensation
5.3.1.1 Process Technology
Conventional condensation using cooling water at, say, 20 o
C or even
refrigeration at - l5 o
C is unlikely to reduce VOC concentrations low
enough for direct discharge to atmosphere. However, it can sometimes
be used advantageously as a pre-treatment upstream of adsorption or
thermal incineration. Where the dew point of the gas stream is well above
the coolant temperature, this technique can often enable a large
proportion of the VOC to be recovered for recycling and, in so doing,
render the gas stream suitable for viable adsorption or thermal
incineration.
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The presence of moisture does not favor cryogenic condensation,
particularly where ice or hydrates could form and foul the heat transfer
surfaces. For the same reason, the freezing point of the VOC must be
considered. It should also be noted that condensation of VOCs from dilute
streams at low temperatures can give rise to 'fogs' or aerosols due to
premature cooling.
Liquid nitrogen can be used as a once-through refrigerant for very low
loadings and can be a very attractive option if liquid nitrogen is vaporized
continuously on the site for other purposes.
Conventional design procedures for heat exchangers with partial
condensation should be used as the basis of design.
Air Products offer their CRYO-CONDAP packaged unit designed to
recover VOCs from inert gas (nitrogen) drying systems such as film
coating and laminating machines as shown in Figure 6. The nitrogen
stream laden with VOC from the processing machine is pre-cooled in a
recuperator and then passes through a refrigerated condenser and thence
to a separator before returning through the recuperator shell to the
processing machine. A proportion of gas stream from the separator is
drawn through a cryogenic condenser by means of an injector driven by
nitrogen evaporated from stock. The ejector efflux is used to provide
sealant gas to the labyrinth seals on the processing machine.
Cryo-Condap® technology for VOC recovery
A 150 SCFM (standard cubic foot per minute) Cryo-Condap installation with redundant low
temperature condensers.
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5.3.2 Direct Condensation
5.3.2.1 Process Technology
Direct cryogenic condensation can avoid problems of icing up of
condenser tubes where the gas stream contains moisture. The gas stream
is bubbled through a vessel containing the same liquid VOC as is to be
condensed. The liquid VOC is refrigerated.
Means must be provided to remove the ice crystals from the condenser
vessel and either separate them from the liquid VOC or melt them and
separate the water and VOC. If the ice crystals are more dense than
the liquid voc they can be removed via a conical base to the vessel
as shown in Figure 7.
5.3.3 Combination of Direct and Indirect Condensation
5.3.3.1 Process Technology
An example of this type of system is the Sulzer 'APOVAC' as shown in
Figure 8. In this unit a liquid ring vacuum pump is used to draw the
VOC-laden vent stream into a two-stage condensation train. The pump
is primed with the VOC to be condensed and the discharge from the pump
comprises a two-phase mixture so that the first stage of condensation is
essentially direct contact. Exhaust gas from the gas-liquid separator under
the primary condenser feeds to the second stage indirect condenser.
A coolant supply is required which is usually refrigerated and is fed
through the second stage then the first stage in series (i.e. counter-
currently).
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5.3.3.2 Applications
On account of the integral vacuum pump, the APOVAC system is
particularly suited to duties where the exhaust gas from the indirect
condenser can be re-circulated to the process and pick up more VOC
such as in pressure filter drying applications. Re-circulating nitrogen
containing high VOC loadings without risks of fire or explosions and
without a vent to atmosphere can be used.
5.4 Adsorption
5.4.1 Process Technology (see Figure 9)
5.4.1.1 Introduction
Adsorption is the most widely adopted technique for solvent recovery
and granulated active carbon (GAC) is the predominant adsorbent.
For very low duties, say 5 kg/day VOCs, such as deodorizing vents,
small disposable cartridges of activated carbon may suffice. For higher
duties it is usually only viable to install beds that can be regenerated. For
duties up to about 20 kg/day VOCs, it may be more economic to utilize off-
site re-activation through a merchant operator rather than regenerate in
situ. For higher duties, regeneration in-situ might be more appropriate.
This enables VOC recovery although post treatment of the recovered
VOCs is usually needed to dry them, to separate mixtures of recovered
VOCs or to re-formulate solvent mixtures including the need to add fresh
stabilizer. In-situ regeneration is generally suitable for VOCs that can be
recovered as liquids at ambient conditions. It can be costly to recover
VOCs with boiling points below about O·C and, for these materials, off-site
re-activation or thermal incineration are usually the best options as
compared with recovery into pressurized and/or refrigerated storage.
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A system based on in-situ regeneration typically comprises three
carbon beds with two beds operating in series whilst the third bed is
regenerated or is on standby. When breakthrough is detected between
the two operating beds, the first is taken off line for regeneration,
the second is transferred to the duty of first operating bed and the
third bed is put on line as the second-in-line operating bed. The
three-bed system with two beds operating in series has the added
benefit of coping well with wide fluctuations in VOC loading. It is
also helpful where there is a mixture of VOCs present with widely
differing adsorption behavior likely to lead to preferential adsorption with
possible elution from the first bed of less adsorbable materials.
Before a bed is put on line for the first time or after regeneration it should
be conditioned by cooling, if necessary, and drying in order to release the
active sites on the particles. In addition, the gas may need pre-treatment
before adsorption. The sequence, then, is as follows:-
Gas pre-treatment
Adsorption as primary bed
Breakthrough detection
Desorption
Bed conditioning (drying and cooling)
Stand by
Adsorption as secondary bed
5.4.1.2 Gas Pre-treatment
(i) Pre-filtration
Particulate matter must be removed from the gas stream by, say,
filtration to prevent clogging of the carbon bed.
(ii) De-humidification
Although water vapor is not actually adsorbed, condensation in the
carbon pores acts as a barrier and reduces adsorption capacity,
This problem of humidity can occur in vents from aqueous
scrubbers. It is normally solved by slightly cooling the vent to
condense some of the water followed by re-heating to, say, 5°C
above the dew point.
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(iii) Dilution
VOC adsorption is an exothermic process and so it may be
necessary to dilute the VOC in the gas stream, usually to about
40g/m3
, in order to reduce the adiabatic temperature rise across
the bed which might otherwise severely limit the bed's adsorptive
capacity. Occasionally internal cooling within the bed is used
instead of dilution. It should be noted that it might be necessary to
dilute the VOC content to 25% LEL regardless of the adsorption
process in order to avoid flammability risks in the gas stream
upstream of the adsorber.
5.4.1.3 Adsorption
Typically, a bed of granular activated carbon is held in a cylindrical vessel
that is orientated either vertically or horizontally. The gas stream
containing VOCs is passed through the adsorbent at a superficial velocity
of about 12-20 m/min normally downwards if in a vertical bed in order to
avoid elutriation of fines. VOCs diffuse through the carbon pore structure
and are subsequently adsorbed at sites, appropriate to the nature of the
VOC molecule, normally in the adsorbent micro pores.
As with all diffusion processes, a concentration profile is developed in the
carbon bed and this moves down stream through the bed as a
concentration 'wave-front' until breakthrough occurs. In practice, the bed is
usually taken off-line after a set operating time pre-determined in order to
avoid breakthrough. The VOC-laden gas stream is then directed to a
second adsorption bed whilst the saturated carbon in the first bed is either
regenerated in situ or removed for contract recovery or disposal.
Good gas distribution is necessary in order to avoid hot spots during
adsorption and also, often more importantly, to achieve effective
regeneration.
Adsorption can sometimes be inappropriate if the VOC is likely to undergo
chemical change during adsorption or desorption. In particular, the
polymerization of monomers can cause bed blockages and the thermal
breakdown of chlorinated hydrocarbons can release HCl which can result
in corrosion.
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Varying concentrations of VOCs can result in partial desorption or
movement of the concentration profile down-stream in the bed during
periods of high inerts flow rates and low VOC concentrations. This can
be problematical with odorous VOCs. However, the installation of a back-
up adsorption bed in series with the main adsorber usually solves the
problem.
5.4.1.4 Regeneration, Re-activation and Disposal
(i) In-situ Regeneration by Steam Desorption
This is an attractive option for VOCs immiscible with water.
Steam, normally low-pressure, is blown counter-currently through
the carbon bed in order to strip the VOC from the carbon
surface. Steam and VOG vapors are then condensed and, for
VOCs immiscible with water, the recovered VOC separated by
decanting. For low boiling point VOCs or if inerts are present, it may
be necessary to pass the exhaust steam from the condenser
through the adsorber on line. Also, the aqueous condensate will be
saturated with VOC and may require treatment before discharge.
Steam regeneration is usually for about 30 minutes which typically
strips 50% to 60% of the adsorbed VOC. The bed then requires
drying with, say, hot air and then cooling with, say, cold air before
being made available for adsorption. Drying and cooling normally
takes 20 to 30 minutes. Another 20 to 30 minutes should be
allowed in the cycle for change over and contingency. Therefore,
the total time required for regeneration is about 30+30+30 = 90
minutes. It is important to check that the estimated adsorption time
for a regenerated bed is longer than the regeneration time. If this
not the case, then it may be necessary to install several beds in
series.
Typically, 2 kg to 4 kg steam are required for every kg of VOC
stripped. About 1/3 of this is required to warm the bed, about 1/3 to
volatilize the VOC and about 1/3 acts as carrier to transport the
VOC from the bed.
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When selecting materials of construction, consideration must be
given to the possibility of hydrolysis of VOCs, e.g. chlorinated
hydrocarbons, to acids.
(ii) In-situ Hot Gas Regeneration
This technique may be required for VOCs miscible with water to
avoid the need for costly separation, say by distillation, from water
following steam regeneration. It is also applicable where it is
necessary to recover the VOC(s) in a dry form or where adsorption
is used to concentrate the VOC(s) before thermal incineration or
catalytic oxidation. (Also see Section 5.9.2.)
The VOC is stripped from the carbon bed by a stream of hot gas
which is usually air or nitrogen although hot process gas could used
if it is available. However, air or process gas containing oxygen
should not be used for flammable VOGs on fixed adsorption beds.
The stripping gas is then passed through one or more condensers
to recover the bulk of the VOC. The condenser vent is then
recycled back to the adsorber on line.
Hot gas regeneration can be used for low volatility VOCs only if
a suitable grade of carbon can be identified. It is not a widely used
technique.
(iii) Pressure Swing
Adsorption takes place at the gas stream pressure and desorption
is achieved by volatilization at a lower pressure or under vacuum.
Pressure swing adsorption (PSA) is used widely for bulk process
gas separations, e.g. hydrogen recovery and air purification.
However, it can also be used for reducing high concentrations of
light VOCs in vent gases. Because the VOCs are stripped off the
adsorbent into a gas stream, PSA is always combined with a
downstream recovery process such as condensation. In general,
for PSA to be considered suitable, the VOC molecular weight
should be below about 100 and VOC concentration should be
between about 1% and 10% v/v.
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PSA does not normally achieve very low exit VOC concentrations;
3000 ppm is not untypical, but energy consumption is very low.
PSA for VOC removal from vent streams requires the use of
special grades of carbon.
The initial market demand that generated a large need for PSA
carbons came from the control of hydrocarbon emissions from
automobile fuel tanks. Applications in major processing plant came
via gasoline vapor recovery in loading and storage, then vent
processing in polymer plants and has now evolved to include
several applications in petroleum production. Figure 10 shows a
simplified flowsheet for gasoline recovery on a refining or terminal
installation and Figure 11 shows hydrocarbon recovery from a
stripping nitrogen stream in a polyethylene plant.
PSA systems for recovery of VOCs in emissions are marketed in
Europe by BOC. The BOC system uses a process feed gas e.g.
oxygen or nitrogen to regenerate the adsorbent by partial pressure
swing.
(iv) Off-site Regeneration by Contract Re-activation
Off-site contract re-activation should be considered where in-situ
regeneration is technically difficult or expensive to provide, e.g. if
the adsorbent has suffered significant loss of activity through VOC
polymerization or in-situ regeneration is required only, say, four
times per year.
Carbon is 're-activated' typically with steam at about 800 o
C in
a multiple hearth or rotary furnace. The VOCs are essentially
pyrolyzed and the flue gases are thermally oxidized. This service is
offered by some carbon suppliers.
Re-activated carbon is delivered by tanker in quantities up to
20 m3
and is discharged pneumatically to a holding vessel whilst
spent carbon is transferred pneumatically to the empty tanker.
The adsorber vessel is then re-filled with the re-activated charge
and put back into service.
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(v) Disposal to Landfill and Thermal Incineration
Where the adsorbed material is acceptable, landfill is often the
cheapest disposal option. Current landfill prices are about $85/te in
some areas of the world but this figure is rising rapidly. Thermal
incineration costs about $825/te but can vary considerably
according to the nature of adsorbed material, e.g. a halogenated
hydrocarbon could cost more than $825/te but a simple
hydrocarbon would likely cost much less.
5.4.1.5 Bed Conditioning
Following steam regeneration, the adsorbent bed must be dried and
cooled in order to achieve efficient adsorption. Similarly, an adsorbent bed
must be cooled after hot gas regeneration.
Drying is usually achieved by passing warm air through the bed. It is
important to ensure adequate steam desorption of flammable VOCs
before conditioning with air otherwise there could be a risk of fire.
Drying is usually followed by a period of blowing cold" air to reduce the
bed temperature. Typically drying and cooling takes about 20 minutes with
a volumetric air flow approximately equal to the flow through the bed
during the absorption phase. The early part of the drying stage normally
produces a plume of steam containing some VOC. It is recommended that
this be recycled for about 2 minutes through the condenser to the
adsorber inlet.
5.4.2 Adsorbents
Although there is a miscellany of commercially-available adsorbents,
for general, non-selective organics recovery, activated carbon is the
most common in industrial use. The main reasons for this are cost, which
is typically $4 - 6/kg compared with about $25/kg for an equivalent resin,
and the ability of carbon to separate organics from water and water vapor.
In order to achieve an acceptable pressure drop through the bed and to
reduce the elutriation of fine particles, the carbon is normally supplied in
pellet form. Carbon fiber woven into a fabric or formed into a "paper" can
be a convenient adsorbent for some applications, 'e.g. the Durr Epocure-
KPR rotor system for concentrating VOCs in air streams (see Figure 12).
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(Also see Section 5.9.2.) Fluidized bed systems are offered by
some suppliers including Lurgi who supply the Kontisorbon
process.
The most commonly used carbons are based on coal or wood
charcoal although coconut charcoal is sometimes used.
Resins and polymers have been developed for carbon-type
applications but they are generally tailored for more selective
adsorption. Amberlite, supplied by Rohm and Haas, and Bono
Pore, supplied by Chematur, are two of the more popular resins.
For preliminary design purposes, the bulk density of activated
carbon can usually be taken to be 450 kg/m3
.
Molecular sieves are used commercially for some VOC applications
but are normally restricted to simple hydrocarbons such as aliphatic
chlorinated hydrocarbons.
5.4.3 Basis of Design
The process engineering design of an adsorption unit is based largely on
equilibrium data and the bed 'breakthrough' characteristics.
Equilibrium data are represented in the form of adsorption isotherms
which are correlations between the adsorptive capacity (weight of VOC
adsorbed per unit weight of adsorbent) and the concentration or partial
pressure of the VOC in the gas phase at constant temperature. The effect
of temperature is shown by plotting separate isotherms as shown in Figure
13. Generally, adsorptive capacity increases with increased molecular
weight of the VOC, increased polarity, increased degree of cyclization (i.e.
aromatic VOCs are more readily adsorbed than aliphatic VOCs) and
decreased vapor pressure.
It is emphasized that an isotherm determined for one proprietary carbon is
likely to be different for a different grade of carbon or ostensibly the same
grade from a different supplier. Furthermore, the effects of humidity must
be recognized.
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Adsorption isotherms are drawn for freshly supplied carbon. The
actual working capacity of a bed regenerated in situ is significantly
lower than that determined from the adsorption isotherm because the
regeneration step does not restore the virgin bed conditions. The
degree of desorption must be balanced against the steam consumption
and the time allowed in the operating cycle for desorption.
Adsorption beds are generally designed for superficial linear velocities of
12 to 20 m/min and, typically, this results in a wave-front of only about 5 to
8 cm which is usually insignificant as compared to the total bed height.
The volume of adsorbent bed required can be estimated from a
knowledge of the adsorption capacity, the VOC feed rate and the cycle
time. (See example in Appendix 4)
Some typical design data are shown below :-
Maximum VOC inlet concentration 40 g/m3
Pressure drop across bed 12" wg
Superficial linear velocity in bed 12 to 20 m/min
Cyclic capacity 10 to 20 % w/w
Once-through capacity up to 50% w/w
Regeneration steam usage - 3 kg/kg VOC
Minimum cycle time 1.5 hours
Maximum Relative Humidity 50%
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FIGURE 13: TYPICAL ADSORPTION ISOTHERMS
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5.4.4 Costs
Typical costs for activated carbon are $4/kg to $6/kg as compared to
about $25/kg for an equivalent resin. Re-activated carbon (see 5.4.1.4 (vi)
above) costs about $3/kg.
Operating costs cover:
Carbon replacement
Steam @ 3 kg/kg VOC
Cooling water
Air to condition bed @ 50·C and a flow rate - adsorbing flow rate for
20 mins.
Other services, e.g. instrument air
Manpower
Maintenance, say 4% of capital
5.4.5 Suppliers
(i) Adsorbent manufacturers who also provide an engineering service
(ii) Engineering contractors who build units and supply suitable
adsorbents
(a) Steam Regeneration
(b) Hot Gas Regeneration
(c) Pressure Swing Adsorption
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(iii) Choice
The choice is very often dictated by the technical features or
uncertainties of the process.
For a relatively simple application, e.g. a single solvent for which
adsorption capacity, bed characteristics, etc., are well established,
e.g. ketones, chlorinated hydrocarbons, etc" no experimental work
would be necessary and one of the engineering contractors would
likely be able to design and supply the plant.
For a complicated system and sophisticated materials of
construction, design data would likely have to be generated and
this could be done by one of the adsorbent suppliers on their test
facilities. Individual suppliers have built up experience with specific
solvents, e.g. some European companies have considerable
experience with acetone, including the potential fire and explosion
hazards whereas the German companies have more experience of
dealing with chlorinated hydrocarbons.
5.5 Absorption
5.5.1 Introduction
The only known information available within GBH Enterprises is that
supplied by Corning Process Systems. Their process was developed in
Germany in 1985 by their sister company 'QVF Glass'. The absorbent
used is a polyethylene ether which is miscible with water.
The process is based on a conventional gas scrubbing tower to absorb
VOCs followed by a conventional steam stripper to regenerate the
absorbent liquor and recover the absorbed VOCs (see Figure 14).
It is claimed that the process can deal with a wide range of VOCs up
to 50-100 g/m3
Corning have activity coefficients for design purposes for
30 to 50 compounds.
It has been suggested that several absorbers could be sited local to
individual VOC discharge sources with a central desorber unit. This idea
has not yet been tried in practice.
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5.5.2 Absorption (See Figure 14)
Ambient inlet temperature is preferred, although higher temperatures
can be accommodated increasing the duty on the cooler in the
absorbent circulation system. The absorber operates at atmospheric
pressure.
Ideally, the absorption fluid temperature should be less than 20·C to
25°C in order to maintain a sufficiently low VOC vapor pressure.
Consequently, a chilled cooler may be required.
Suitable materials of construction for the column and the internals
must obviously be used but these need not necessarily be glass. High
performance structured packing (e.g. Sulzer) are usually used.
5.5.3 Desorption
Desorption of the VOC from the absorbent is effected by steam
stripping plus indirect heating. Sometimes water plus indirect
heating is used. The condensing temperature required is, of course,
dependent on the volatility. The stripping column operates at
-70 torr with the vacuum being provided by a once-through oil
vacuum pump or other means.
The means of separating the recovered VOC(s) in the stripping column
overhead product from the aqueous condensate necessarily depends on
the solubility of the VOC(s) in water and vice versa, the relative densities
of the VOC(s) and water and the need for the recovered VOC(s) to be dry.
The main service usage is steam on the desorber. Corning recommend
using 80 kg steam per 1000 m3
air (STP) for preliminary estimates.
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5.5.4 General Matters
The design should include heat recovery from the desorber bottoms
stream to the desorber feed.
The only storage capacity in the system for polyethylene ether is the
bottoms of the two columns which should be level controlled.
The polyethylene ether is stabilized with an amine to prevent
peroxide formation. This limits applications to non-acidic gases.
Start-up can be achieved from cold in about 20 minutes. This could be
reduced, if necessary, by adding a pre-heater in the desorber feed line.
There is some doubt as to whether polymerization problems could be
encountered with VOC monomers; this has yet to be tested.
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5.6 Thermal Incineration
5.6.1 Process Technology
Oxidation of hydrocarbon VOCs produces H20 and CO2, If the VOCs are
halogenated, hydrogen halides, e.g. HCl, are also produced provided
there is sufficient hydrogen available from the VOC(s), water vapor
or a support fuel such as methane. VOCs containing sulfur produce
SOx; organically bound nitrogen produces NOx or free nitrogen.
Heat can be recovered from the flue gas in recuperative or regenerative
systems. (See Section 5.6.1.5 below.)
Flue gas treatment may be required to remove acid gases such as HCl.
5.6.1.1 Excess Oxygen
In order to achieve complete oxidation, preliminary calculations should be
based on about 25% excess oxygen in the feed stream over and above
the stoichiometric requirement; this will usually result in about 4% v/v
oxygen in the flue gas. This excess oxygen must be added as combustion
air if it is not already available as free or combined oxygen in the gas
stream to be treated. (Also see NOx abatement in Section 5.6.1.2 below.)
If support fuel is required, about 25% excess combustion air for that
support fuel should also be used.
5.6.1.2 Combustion Temperature
A minimum combustion temperature of about 750°C is necessary to
achieve adequate destruction of most VOC(s) comprising carbon and
hydrogen or carbon, hydrogen and oxygen. However, 850·C is more
typical and is more likely to be required by the Authorities. 1100 o
C
to 1200 o
C is required for halogenated VOCs (see Section 5.6.1.7
below).
If the VOC(s) contain nitrogen, measures must be taken to avoid
unacceptable NOx levels. Short-flame low-NOx burner nozzles are
available for this purpose.
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In addition, in may be necessary to have a primary combustion chamber
operating under starved air conditions, say just below stoichiometric
requirements, followed by a secondary combustion chamber operating
with, say, 4% v/v oxygen in the flue gas. This configuration enables
combined nitrogen to be converted to elemental nitrogen in the primary
chamber followed by completion of the oxidation of carbon monoxide and
residual hydrocarbon species in the secondary chamber.
5.6.1.3 Residence Time
Residence time within the incineration chamber is typically 0.5 secs but
can be as high as 2 secs for halogenated VOCs. Linear velocity within the
incineration chamber is typically 12 to 15 m/s.
5.6.1.4 Turbulence
Turbulence is necessary to ensure a high degree of mixing between the
VOC(s), the combustion air and, if used, the support fuel. Radial mixing
should be high but axial mixing should be low otherwise a proportion of
the VOCs would experience a low residence time. This is usually achieved
by the use of radial-swirl burners sometimes together with longitudinal
baffles.
5.6.1.5 Heat Recovery Systems
Support fuel is generally required at start-up and during some up-set
conditions. In order to reduce or eliminate support fuel during normal
operation, the vent stream containing VOC(s) and/or the additional
combustion air (if required) is often pre-heated by recovering heat from the
flue gas leaving the incinerator using either recuperative or regenerative
heat exchange.
If the oxidation adiabatic temperature rise is greater than about 170°C, it is
often worth installing a recuperative heat exchanger to raise steam in
addition to any heat recovery into the inlet vent stream.
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(i) Recuperative Heat Recovery
Heat is recovered by indirect transfer from the hot flue gas leaving
the incinerator to the in-coming VOC stream/combustion air.
Standard shell-and-tube heat exchangers can be used but
sometimes an integral unit is used with the heat exchanger tubes
built around the combustion chamber (see Figure 15). Thermal
efficiencies (see Section 9) up to 0.7 or 0.8 can be achieved. If the
adiabatic temperature rise is greater than about 150°C,
recuperative heat recovery usually enables operation without
support fuel.
(ii) Regenerative Heat Recovery
These units operate batch-wise by heating up a matrix, e.g.
ceramic honey-comb or sand bed, by direct contact with hot flue
gas and then using the hot matrix to pre-heat the VOC
stream/combustion air. It is claimed that thermal efficiencies (see
Section 9) up to 0.95 can be achieved. Such high efficiencies
enable operation without support fuel at quite low adiabatic
temperature rises. Above adiabatic temperature rises of about
150°C, recuperative units tend to give lower overall costs than
regenerative units on account of much lower capital costs without
the need for support fuel. For adiabatic temperature rises less than
about 150°C, regenerative units tend to show a lower overall cost
because support fuel can be avoided. However, the resulting low
flue gas temperature usually precludes economic waste heat
recovery. There are two main variations of design of regenerative
heat recovery units:-
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The first and more common type of regenerative unit is illustrated in Figure
16. The incoming gas stream is heated by direct contact with a pre-heated
matrix CA) upstream of a combustion chamber. Burner nozzles supplied
with fuel are positioned in the combustion chamber for start-up purposes
and to provide support fuel if required during normal operation. Oxidation
of the VOC(s) begins in the hot matrix and is completed in the combustion
chamber. The flue gas from the combustion chamber passes through and
heats up a second matrix (B) before discharging to atmosphere. After a
pre-determined time, the direction of flow is reversed so that the in-coming
stream is pre-heated in matrix B whilst matrix A is heated by the flue gas
from the combustion chamber. Matrix A contains some untreated VOCs at
the time of change-over. In order to avoid these VOCs being discharged to
atmosphere when matrix B is put onto the upstream duty, a third matrix
(C) is often installed which then becomes the down-stream matrix to
enable matrix A to be purged within the sequence shown below.
Parallel streams can be used for large gas flows. However, it is possible to
design the sequence of matrix change-over's such that only one is being
purged or is on standby. Thus there is always an odd number of matrices.
In the second type of regenerative unit a single bed is used in which the
combustion takes place at the centre and the flow of gas is reversed about
once every two minutes on a time switch. (See Figure 17). The bed down-
stream of the combustion zone is heated by the hot flue gas whilst the in-
coming VOC stream/combustion air is pre-heated as it approaches the
combustion zone. During flow reversal, the VOC(s) in the upstream part of
the unit are purged to atmosphere and this limits the thermal efficiency
(see Section 9) to a maximum of about 90%. This type of regenerative bed
is often started up from cold using an electrical heater in the centre of the
bed to establish the temperature profile. Typically, the exhaust gas is
about 25 o
C hotter than the in-coming vent stream and the electricity
consumption for the heater and for blowers is about 0.01 kWh/m3
of vent
gas.