This document discusses design guidelines for propylene splitters. It begins with an introduction to factors that affect tower efficiency like pressure, geometry, flow rates, and compositions. It then discusses typical field efficiencies for different tower types based on published data. The document reviews how pressure, viscosity, and volatility affect efficiency based on O'Connell correlations. It also discusses the effects of pressure on tray and packing efficiencies. The document concludes with discussions on best practices for tray and splitter design and considerations for high versus low pressure splitters.
Technology Economics: Propylene via Propane Dehydrogenation, Part 2Intratec Solutions
Intratec Solutions LLC, the unrivalled provider of techno-economic assessments for chemical and allied industries, is proud to announce the publication of Propylene Production via Propane Dehydrogenation, Part 2.
In this report, the propylene production via a propane dehydrogenation (PDH) process similar to Lummus CATOFIN® is reviewed. Both the capital investment and the operating costs are presented for a plant constructed on the US Gulf Coast and China. Process consumptions were validated through a comparison with publicly available information about Petrologistic’s PDH unit, located in Texas and based on CATOFIN® technology.
The economic analysis presented in this report is based on a plant fully integrated with a petrochemical complex and capable of producing 590 kta of polymer grade propylene. The estimated CAPEX for such a plant on the US Gulf Coast is USD 492 million. While China presents the lowest CAPEX, the USA presents the most advantageous operational margins, due to the rise of shale gas and reduction in propane prices. The attractiveness of propane dehydrogenation is proven by the calculated internal rate of return of more than 30% in the United States.
Know more at http://www.intratec.us/publications/propylene-production-via-propane-dehydrogenation-2
Natural gas condensates can form liquid slugs in transmission lines. This presentation describes alternative modelling strategies to determine slug volumes
(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
Processing of petroleum types of refluxKarnav Rana
PROCESSING OF PETROLEUM :TYPES OF REFLUX
arrangements of distillation towers
Pump back reflux and pump around reflux
Side stripping columns
process refining & petrochemicals
Technology Economics: Propylene via Propane Dehydrogenation, Part 2Intratec Solutions
Intratec Solutions LLC, the unrivalled provider of techno-economic assessments for chemical and allied industries, is proud to announce the publication of Propylene Production via Propane Dehydrogenation, Part 2.
In this report, the propylene production via a propane dehydrogenation (PDH) process similar to Lummus CATOFIN® is reviewed. Both the capital investment and the operating costs are presented for a plant constructed on the US Gulf Coast and China. Process consumptions were validated through a comparison with publicly available information about Petrologistic’s PDH unit, located in Texas and based on CATOFIN® technology.
The economic analysis presented in this report is based on a plant fully integrated with a petrochemical complex and capable of producing 590 kta of polymer grade propylene. The estimated CAPEX for such a plant on the US Gulf Coast is USD 492 million. While China presents the lowest CAPEX, the USA presents the most advantageous operational margins, due to the rise of shale gas and reduction in propane prices. The attractiveness of propane dehydrogenation is proven by the calculated internal rate of return of more than 30% in the United States.
Know more at http://www.intratec.us/publications/propylene-production-via-propane-dehydrogenation-2
Natural gas condensates can form liquid slugs in transmission lines. This presentation describes alternative modelling strategies to determine slug volumes
(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
Processing of petroleum types of refluxKarnav Rana
PROCESSING OF PETROLEUM :TYPES OF REFLUX
arrangements of distillation towers
Pump back reflux and pump around reflux
Side stripping columns
process refining & petrochemicals
Yokogawa, globally recognized leader in a number of process control fields, has authored an e-book which provides useful insight into how operators of combustion based equipment and systems can improve efficiency and enhance safety by employing modern technology.
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!
Natural Gas (from a natural reservoir or associated to a crude production) can contain acid gas (H2S and/or CO2)..
The Gas Sweetening Process aims to remove part or all of the acid gas.
all process involve in petroleum to get final products from crude oil like LPG, petrol, diesel, jet fuel, kerosene,neptha, heavy neptha, coke and petroleum products
Reactor Arrangement for Continuous Vapor Phase ChlorinationGerard B. Hawkins
Reactor Arrangement for Continuous Vapor Phase Chlorination
CONTENTS
1 BACKGROUND
2 REACTOR
3 CHEMICAL SYSTEM
4 PROCESS CHEMISTRY
5 KINETICS EXPERIMENTS AND MODELING
6 INTERPRETATION OF KINETICS INFORMATION
7 OPERATING CONDITIONS AND REACTOR DESIGN
8 REACTOR STABILITY AND CONTROL
FIGURES
1 POSTULATED REACTION PATHS FOR PROGRESSIVE CHLORINATION OF B-PICOLINE 3
2 CHLORINATION OF b-PICOLINE: MODEL PREDICTIONS OF PRODUCT DISTRIBUTION IN FULLY-MIXED REACTOR
3 TWO-STAGE REACTOR: RATE OF CHLORINATION OF b-PICOLINE
DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE
Propylene Production by Propane Dehydrogenation (PDH)Amir Razmi
In this article a description about different processes which are commercialized to produce propylene via Propane dehydrogenation were presented.
To receive more reports about cost estimation analysis and other reports (about the propylene and PDH ) contact the author.
Using Aspen HYSYS Upstream for Sizing and Scheduling of Gathering SystemsProcess Ecology Inc
This presentation covers the process of sizing and scheduling of Gathering Systems, including how to approach challenges by using model development and automation and interpretation of the results. Additionally, we compare between HYSYS Hydraulics and HYSYS Dynamics.
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petroleum-refining/
COURSE DESCRIPTION:
The main scope of the course is to create strong basis and fundamentals regarding the processes in the Petroleum Refining. We take a look to the Oil&Gas Industry briefly and continue directly with the Refining Process. We then make a focus in each individual unit operation in the refinery.
Learn about:
* Oil& Gas Industry
* Difference between Petroleum Refining vs. Petrochemical Industry
* Overview of the most important operations and products
* Market insight (supply/demand) as well as (production/consumption)
* Several Petroleum Refineries around the World
Unit Operations & Processes
* Refining and Fractionation
* Atmospheric Distillation Column
* Vacuum Distillation
* Hydrotreating (Hydrogenation)
* Blending
* Reforming
* Isomerization
* Alkylation
* Steam Cracking
* Fluid Catalytic Cracking
* Gas Sweetening (Hydrodesulfurization)
* Coking
Components:
* Fuel Gas / Natural Gas
* Liquified Petroleum Gases (LPG)
* Propane, Butane
* Sulfur / Hydrogen Sulfide
* Gasoline / Automotive Gas Oil
* Naphtha Cuts (Light/Heavy)
* Kerosene
* Diesel
* Gasoil
* Lubricants
* Vacuum Residues
* Asphalt
* Coke
NOTE: This course is focused for Process Simulation
At the end of the course you will feel confident in the Petroleum Refining Industry. You will know the most common Process & Unit Operations as well as their distribution, production and importance in daily life.
----
Please show the love! LIKE, SHARE and SUBSCRIBE!
More likes, sharings, suscribers: MORE VIDEOS!
-----
CONTACT ME
Chemical.Engineering.Guy@Gmail.com
www.ChemicalEngineeringGuy.com
http://facebook.com/Chemical.Engineering.Guy
You speak spanish? Visit my spanish channel -www.youtube.com/ChemEngIQA
Plasticization rates can be greatly increased with the use of grooved feed extrusion. Grooved feed extruders can be used in a wide range of extrusion processes for higher output rates. This technology has doubled plasticization rates for some resins and processes as compared to smooth bore extruders.
This paper will compare the performance of three different screw geometries while processing fractional melt HDPE. One of the main methods of evaluation will be the comparison of internal pressure profiles over the entire length of the screw at eleven different locations down the length of the barrel at two L/D apart.
Yokogawa, globally recognized leader in a number of process control fields, has authored an e-book which provides useful insight into how operators of combustion based equipment and systems can improve efficiency and enhance safety by employing modern technology.
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!
Natural Gas (from a natural reservoir or associated to a crude production) can contain acid gas (H2S and/or CO2)..
The Gas Sweetening Process aims to remove part or all of the acid gas.
all process involve in petroleum to get final products from crude oil like LPG, petrol, diesel, jet fuel, kerosene,neptha, heavy neptha, coke and petroleum products
Reactor Arrangement for Continuous Vapor Phase ChlorinationGerard B. Hawkins
Reactor Arrangement for Continuous Vapor Phase Chlorination
CONTENTS
1 BACKGROUND
2 REACTOR
3 CHEMICAL SYSTEM
4 PROCESS CHEMISTRY
5 KINETICS EXPERIMENTS AND MODELING
6 INTERPRETATION OF KINETICS INFORMATION
7 OPERATING CONDITIONS AND REACTOR DESIGN
8 REACTOR STABILITY AND CONTROL
FIGURES
1 POSTULATED REACTION PATHS FOR PROGRESSIVE CHLORINATION OF B-PICOLINE 3
2 CHLORINATION OF b-PICOLINE: MODEL PREDICTIONS OF PRODUCT DISTRIBUTION IN FULLY-MIXED REACTOR
3 TWO-STAGE REACTOR: RATE OF CHLORINATION OF b-PICOLINE
DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE
Propylene Production by Propane Dehydrogenation (PDH)Amir Razmi
In this article a description about different processes which are commercialized to produce propylene via Propane dehydrogenation were presented.
To receive more reports about cost estimation analysis and other reports (about the propylene and PDH ) contact the author.
Using Aspen HYSYS Upstream for Sizing and Scheduling of Gathering SystemsProcess Ecology Inc
This presentation covers the process of sizing and scheduling of Gathering Systems, including how to approach challenges by using model development and automation and interpretation of the results. Additionally, we compare between HYSYS Hydraulics and HYSYS Dynamics.
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petroleum-refining/
COURSE DESCRIPTION:
The main scope of the course is to create strong basis and fundamentals regarding the processes in the Petroleum Refining. We take a look to the Oil&Gas Industry briefly and continue directly with the Refining Process. We then make a focus in each individual unit operation in the refinery.
Learn about:
* Oil& Gas Industry
* Difference between Petroleum Refining vs. Petrochemical Industry
* Overview of the most important operations and products
* Market insight (supply/demand) as well as (production/consumption)
* Several Petroleum Refineries around the World
Unit Operations & Processes
* Refining and Fractionation
* Atmospheric Distillation Column
* Vacuum Distillation
* Hydrotreating (Hydrogenation)
* Blending
* Reforming
* Isomerization
* Alkylation
* Steam Cracking
* Fluid Catalytic Cracking
* Gas Sweetening (Hydrodesulfurization)
* Coking
Components:
* Fuel Gas / Natural Gas
* Liquified Petroleum Gases (LPG)
* Propane, Butane
* Sulfur / Hydrogen Sulfide
* Gasoline / Automotive Gas Oil
* Naphtha Cuts (Light/Heavy)
* Kerosene
* Diesel
* Gasoil
* Lubricants
* Vacuum Residues
* Asphalt
* Coke
NOTE: This course is focused for Process Simulation
At the end of the course you will feel confident in the Petroleum Refining Industry. You will know the most common Process & Unit Operations as well as their distribution, production and importance in daily life.
----
Please show the love! LIKE, SHARE and SUBSCRIBE!
More likes, sharings, suscribers: MORE VIDEOS!
-----
CONTACT ME
Chemical.Engineering.Guy@Gmail.com
www.ChemicalEngineeringGuy.com
http://facebook.com/Chemical.Engineering.Guy
You speak spanish? Visit my spanish channel -www.youtube.com/ChemEngIQA
Plasticization rates can be greatly increased with the use of grooved feed extrusion. Grooved feed extruders can be used in a wide range of extrusion processes for higher output rates. This technology has doubled plasticization rates for some resins and processes as compared to smooth bore extruders.
This paper will compare the performance of three different screw geometries while processing fractional melt HDPE. One of the main methods of evaluation will be the comparison of internal pressure profiles over the entire length of the screw at eleven different locations down the length of the barrel at two L/D apart.
Reducing Shipping Vibration of Compressors in Roof Top Air-conditioning Units...HCL Technologies
This white paper is intended primarily for Designers / Engineers who are dealing with vibration related issues during Product design and wish to understand how vibrations on the basepan of a roof top unit could be minimized. This paper covers the overview of Modal Analysis, response of components within a roof top unit, different techniques used to minimize the response of the compressor on the basepan, evaluation of design alternatives and benefits of reducing the response level of the compressor
Getting in the Zone, Oilfield Technology, December 2018tmtallant
Matt Meiners, Enventure Global Technology, USA, explores how advancements in expandable liners are helping to improve zonal isolations when refracturing.
HOW TO CONTROL PRILLING TOWER DUST EMISSION.pdfPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling
routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission
control system in prilling tower is a considerable burden. It not only presents a substantial investment
but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of
strong demand for environment friendliness and effective use of power it is then an issue of utmost
importance to pick the legally emission control solution, the one that can guarantee, if not a full
return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea
dust and ammonia, wet processes are generally applied. The available technologies vary with regard to
the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is
directly proportional to temperature. Dust emission can control by internal and external process. In
India generally followed internal routs. The pollution control Board sample should be ok just thinking
so. Either reduction of plant load or bypassing the recovery system at the time of sampling or
manipulating data. It is the bitter truth. In reality dust emission control system should be installed in
prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all
urea plants. Number of Revamp Companies are available in market.
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
Engineering Practice Magazine - January 2020Karl Kolmetz
How to Design and Optimize Sieve Trays
Key Process Considerations for Pipeline Design Basis
How Does Cycles Increase in Cooling Towers Save Money?
Chernobyl Lessons in Process Safety
Adding Value to the Crude Oil –
Distillation Process Unit
When a new extruder is installed, or a new screw mounted in an existing machine, do you know what the expected throughput rate is going to be? You should. If you don’t baseline your extruder, then how are you going to set realistic expectations for its performance? If extrusion screws are designed properly, they typically will be able to withstand the maximum torque available from the extruder and the resin being processed. The extruder should operate at approximately 90% of its full available torque, based on 100% pellet feedstock, which typically will be the worst-case scenario. By using today’s barrier screw technology, higher throughput rates, lower melt temperatures, and better power efficiencies can be obtained. This article will provide some basic insight to help processors to determine if they are obtaining the maximum production rates from their extruders, providing that they have adequate downstream cooling and handling equipment in the extrusion system.
Since the early 1990’s INGEO™ resins have made enormous improvements in the process ability of their bio-polymer resins. In the early days, when the resin was first being manufactured at pilot plant levels, extrusion processing of INGEO™ was very difficult.
Today, natural additives are being used to improve the process ability of these resins. Several new lubricant additive packages were tested to determine which package produced the best overall performance and process improvements. The process data was used to quantify the process ability of the various additive packages.
The data was then compared to the internal pressure data that was collected to analyze and determine the best overall additive package.
Changes are inevitable during the life cycle of any manufacturing facility. Changes occur design, construction, operation, decommissioning, mothballing and demolition. MOC is a critical success factor of any Process Safety Management (PSM) Program. It ensures that each proposed change undergoes the appropriate level of technical and EHS review any change does not inadvertently introduce new hazards or unknowingly increase the risk of existing hazards.
Building Operational Excellence in Petroleum Refining Training CourseKarl Kolmetz
There are many aspects of building operational excellence. Partial list may include;
1. Health, Safety and the Environment
2. Reliability – Continuity of Operations
3. Quality
4. Cost
5. People Development
Optimizing Petroleum Refining FCC Unit Operations TrainingKarl Kolmetz
The success of every company depends of each employee's understanding of
the key business components. Employee training and development will unlock
the companies' profitability and reliability. When people, processes and
technology work together as a team developing practical solutions, companies
can maximize profitability and assets in a sustainable manner. Training and
development is an investment in future success - give yourself and your
employees the keys to success
Water Treatment Unit Selection, Sizing and Troubleshooting Karl Kolmetz
Freshwater uses for manufacturing, food production, domestic and public needs,
recreation, hydroelectric power production, and flood control. The primary sources of
freshwater are rainfall in cisterns and water jars; groundwater from springs, artesian
wells, and drilled or dug wells; surface water from lakes, rivers, and streams;
desalinized seawater or brackish groundwater; and reclaimed wastewater.
Some water supplies may also contain disinfections by-products, inorganic
chemicals, organic chemicals, and radionuclides. Specialized methods for controlling
formation or removing them can also be part of water treatment.
Water treatment processes are applied to surface water sources. Typically, a water
treatment plant (WTP) undergoes a series of processes which include the units
presedimentation, rapid mix, flocculation, sedimentation, filtration, adsorption, and
disinfection, with appropriate chemical feeds and residual treatment processes
Ammonia Plant Selection Sizing and Troubleshooting Karl Kolmetz
Ammonia is produced basically from water, air, and energy. The energy source is
usually hydrocarbons, thus providing hydrogen as well, but may also be coal or
electricity. Steam reforming of light hydrocarbons is the most efficient route, with
about 77% of world ammonia capacity being based on natural gas.
The total energy consumption for the production of ammonia in a modern steam
reforming plant is 40-50% above the thermodynamic minimum. More than half of the
excess consumption is due to compression losses. The practical minimum
consumption is assumed to be 130% of the theoretical minimum.
This guideline covers items in making an ammonia plant. Starting from the raw
material, equipment, manufacturing process and the economics of ammonia plant.
Process Equipment Malfunctions offers the chance to develop proven techniques for
finding and fixing process plant problems and contains details on failure identification.
One of the most important traits that process operators, maintenance personnel, and
engineers can have is the ability to diagnose equipment and process upsets and
respond accordingly quickly and accurately.
Troubleshooting is a step-by-step procedure whose purpose is to identify a problem
quickly and easily in a system or process. Troubleshooting is an art, but a good portion
is a learned skill, which is enhanced by experience and operator capability. A good
operator will work at developing troubleshooting skills and abilities. A good
troubleshooter is worth his or her weight in gold to a company.
Pressure Vessel Selection Sizing and Troubleshooting Karl Kolmetz
Vessels are a vital part of the operational units in the process industries. A vessel is
a container in which materials are processed, treated, or stored. Without this type of
equipment, the process industries would be unable to create and store large
amounts of Product. Pressure vessels used in industry are leak-tight pressure
containers, usually cylindrical or spherical in shape, with different head
configurations.
The process engineer should have some knowledge of the mechanical design of
vessels. For example, the process engineer may have to make a preliminary design
of vessels for a cost estimate. A vessel consists of a cylindrical shell and end caps,
called heads. For safety, vessel design is governed by codes.
Advanced Training for Pressure Relieving and Flaring SystemsKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relief Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
operations, engineering, maintenance and support personnel.
Optimizing Petroleum Refining Unit Operations Training CourseKarl Kolmetz
Many aspects of petroleum refining operations management can be improved
including, product recoveries, purities and energy utilization, and safety. This
cannot be achieved without first an understanding of basic fundamental
principles of design and operation. These principles need to be understood in
advance of operating and trouble shooting a process unit operation for the
manager or problem solving to be effective.
This seminar focuses on the core building blocks of the petroleum refining
process systems, equipment and economics. This program will emphasize the
refining process unit operation fundamentals, safe utilization of these
fundamentals by operations, engineering, maintenance and support personnel.
Introduction to Pressure Relieving and Flaring Systems Training CourseKarl Kolmetz
Each company needs to have people trained in key areas of safety. These
include;
1. Hazard Analysis
2. Relieve Valve Design
3. Reliving Cases Design
4. Flare System Design
This seminar focuses on the core building blocks of the relieving and flaring
process systems, equipment and economics. This program will emphasize the
process unit operation fundamentals, safe utilization of these fundamentals by
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for the manager or problem solving to be effective.
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In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
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Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
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A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
3. KLM Technology Group
Solutions, Standards and Software
Based in USA since 1995,
KLM is a technical consultancy
group, providing specialized
training, services and equipment
to improve process plant
operational efficiency, profitability
and safety.
4. KLM Technology Group
Solutions, Standards and Software
Training Classes
Kolmetz Handbook of Process Equipment Design
Engineering Software
Process Optimization Studies
HAZOP Facilitation
Engineering Support
An Engineering Resource
KLM Core Business
6. DESIGN GUIDELINES FOR
PROPYLENE SPLITTERS EFFICIENCIES
1. Introduction
2. General Tray Efficiency
3. Issues that affect tower efficiency and capacity
4. Best Practices
5. Conclusions
7. 1. Introduction
Actual field tray efficiencies are affected by many factors,
these include;
a. tower pressure
b. geometry and design of contacting equipment,
c. flow rates and flow paths of the liquid and vapor streams,
d. composition and properties of the vapor and liquid
streams,
8. All these items may affect tray efficiencies and there
are field examples were some have greatly impacted
tray efficiencies.
This paper will review some case studies and
develop some design best practices.
1. Introduction
10. General Estimates of Field Tray Efficiency (We published
this data in a paper in 2005)
Demethanizer 65% Air Separation 90%
Deethanizer 70% C2 & C3 Splitter 85%
Depropanizer 75% Stabilizer 80%
Debutanizer 80% Hydrocarbon/Water 15%
Depentanizer 80% EB/Styrene 90%
Low alpha Aromatics 80% Alcohol - Water 75%
High alpha Aromatics 70% Amine Contactor 33%
1. Typical Cross Flowing Sieve Deck Trays
2. General Field Tray Efficiency
11. There is observed data that close boiling ideal binary
pairs require many stages of vapor/liquid contacting to
separate, but each stage has relatively high efficiency in
the field.
And the converse – that non-ideal binary pairs that have a
large boiling point difference require only a few stages to
separate in a process simulator, but each stage has
relatively low efficiency in the field.
Binary Pair ∆B.P. Equilibrium Stages Field Efficiency
Propane / Propylene 5.6 ºC (11.2 ºF) 120 Stages 85%
Benzene / Water 19.9 ºC (37.8 ºF) 5 Stages 20%
13. Overall Tray Efficiency
O’Connell Equation (1946)
Eo = 49.2 ( α µ ) -0.245
µ is viscosity of feed
α is relative volatility
both at average tower temperature.
when viscosity and/or relative volatility are
increased tray efficiency is decreased
14.
15. P
α
Effect of Pressure on
Efficiency per O’Connell
T µ
( α µ ) -0.245
For a fixed system (e.g. C3 splitter), efficiency
might go up with increase of operation pressure.
This is true for many systems.
Efficiency
16. This pressure effect can be seen
in C3 Splitters from the O’Connell
Equation and Field Data
PSIG O’Connell Field Tray Efficiency
250 88 75-85+% Numerous Papers
150 84 70-80% Observed data
100 81 65-75% Observed data
57 66% AIChE 2011
50 75 60-70% Observed data
Data for Cross Flowing Trays
Effect of Pressure on Field Trays
17. The end result is what counts – does the
tower meet capacity and product purities.
Each good vendor utilizes a tuned model that
give the proper end result.
There are over 200 C3 Splitter’s in operation.
O’Connell correlation works well for
predicting the effect of pressure on efficiency.
Effect of Pressure on Trays
18. Folklore and Myths can proclaim that lower
pressure gives higher efficiencies – you need
to review your system data – may not be true.
Effect of Pressure
19. This myth may have been developed from
packing data, where HETP is much higher at
lower pressures.
Effect of Pressure
20. Effect of Pressure on Packing
The field data for trays confirms that as pressure
increases the efficiency increases.
This is not the case for packing. There are two ideas of
why this might be happening.
PRESSURE
PACKING
EFFICIENCY
21. Effect of Pressure on Packing
The first idea - some studies have showed that at higher
pressures there appeared more liquid hold up on the
packing, creating a larger boundary layer – leading to
lower efficiency.
PRESSURE
PACKING
EFFICIENCY
22. Effect of Pressure on Packing
The second idea - there is a relationship between the
vapor density / the liquid density and packing efficiency.
At higher pressure the densities become closer
together, leading to backing mixing effect of the liquid
by the vapor - leading to lower efficiency.
PRESSURE
PACKING
EFFICIENCY
26. V1 V1 V1 V1
L4 L3 L2 L1
Cross Flowing Trays
V1 meets L1 – about 60 %
Efficiency
L1 becomes L2
V1 meets L3 – about 65%
Efficiency
Cross Flow Tray Efficiency
>=
Point Efficiency
Effect of Path Flow Length on Trays
27. Good Practices in Sieve Tray Designs
From Data Published by FRI at AIChE in 2007;
1. The best range of hole size for efficiency is
12.7 mm (1/2 inch) to 25 mm (1 inch).
2. The capacity of sieve trays decreases as
hole diameter becomes larger. This loss in
capacity is due to higher entrainment.
The best choice might be 12.7 mm.
28. From Data Published by FRI at AIChE in 2007;
1.The efficiency of the 8% open area sieve
tray is consistently higher than that of 14%
open area sieve tray.
2. Open area should be in a range of ~6 - 16%.
Good Practices in Sieve Tray Designs
29. Multiple Down Comer
Has less Path Flow
Length And Lower
Efficiency
One rule is to keep the
Path Flow Length
Above 450 mm
(18 inches) to maintain
good efficiency
Effect of Path Flow Length on Trays
31. And the question everyone ask - How
much less efficient? You can hear
numbers from 2% to 20%
Folklore and Myths
Effect of Path Flow Length on Trays
32. There is some published data on Multiple Down Comer
Trays
Date Aug 92 June 95
Tower C2 Splitter C3 Splitter
Pressure 290 PSI 250 PSI
Reflux 237,834 kg 1,400,000 lb/hr
Trays 155 325
Capacity Gain 25% 35%
Efficiency 74% 74%
Effect of Path Flow Length on Trays
33. Multiple Down Comer Trays – Best Practices
1. Understand there is a loss in tray efficiency – but
because than may be installed on 18” trays spacing
or less, you can install more trays and possibility
increase overall tower efficiency – based on the
reflux to stages curves.
2. For the same tower shell diameter, capacity
increase can be greater than 35%.
3. If designed properly there can be an efficiency and
capacity increase.
Effect of Path Flow Length on Trays
34. Propylene Splitters
The types of internals that have been used in
propylene splitter columns are;
1. Conventional Cross Flowing Trays
2. Dual Flow Ripple Trays
3. Structured Packing
4. Multiple Downcomer Trays
5. High Capacity / Efficiency Trays
35. Propylene Splitters
The types of internals that have been used in
propylene splitter columns are;
1. Conventional Cross Flowing Trays
They work very well – about 85% efficiency in High
Pressure Propylene Splitter Service .
36. Propylene Splitters
The types of internals that have been used in
propylene splitter columns are;
2. Dual Flow Ripple Trays
Dual Flow Ripple Tray were installed in several
Propylene Splitters. There are two challenges of dual
flow trays.
a. Point Efficiency
b. Maldistribution – vapor will travel up one side and
the liquid will travel down the other side.
38. Propylene Splitters
The actual field efficiency was about 42%.
The vendor accounted for the low efficiency by
installing 248 trays.
39. Propylene Splitters
The types of internals that have been used in
propylene splitter columns are;
3. Structured Packing
Structured Packing was installed in two high pressure
Propylene Splitter with limited success. The packing
was removed and trays reinstalled.
40. Propylene Splitters
The types of internals that have been used in
propylene splitter columns are;
4. Multiple Downcomer Trays
There are many successful applications of Multiple
Downcomer Trays in Propylene Splitter Service
41. Propylene Splitters
The types of internals that have been used in
propylene splitter columns are;
5. High Capacity / Efficiency Trays
Many studies have shown that High Capacity /
Efficiency Trays can improve capacity up to 25% and
efficiency 7 to 10%. There is some published data in
Propylene Splitters of greater than 10% efficiency
increases.
42. Propylene Splitters
High Pressure Verses Low Pressure Splitters
There is a wide range of pressure choices for
Propylene Splitters – 50 PSIG to 300 PSIG
What might be guidelines to choose the best
pressure?
Folklore Verse Myths
44. Propylene Splitters
High Pressure Splitters
Advantages
a. Ability to utilize cooling water for overhead
condenser
b. Ability to utilize medium level heat – there is a
surplus in an Olefin Plant
Disadvantages
a. Capital Cost – thicker tower shell and foundation
46. Propylene Splitters
Low Pressure Splitters
Advantages
a. Capital Cost – thinner tower shell and foundation
b. Energy – if there is not a surplus of medium level
heat – the compressor can utilize the energy
needed for compression
Disadvantages
a. Capital and Maintenance Cost of a compressor
47. Propylene Splitters
Low Pressure Splitters
May need a study to determine best pressure for your
Splitter - one vendor recommends 90 PSIG and a
second vendor recommends 110 PSIG.
a. 90 PSIG is lower capital but higher energy cost
b. 110 PSIG is high capital but lower energy cost.
48. Conclusions
1. Field efficiency of trayed towers, may increase
with operational pressure, as shown in the
O’Connell correlation.
2. Field efficiency of packed towers, from the data
appears to going down with increasing
operational pressure.
3. Proper design and selection of trays, packings
and internals are critical for success of
distillation towers.