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
High level introduction
Mainstream syngas = steam reforming processes
Ammonia; methanol; hydrogen/HyCO
Town gas
Steam reforming; low pressure cyclic
Direct reduction iron (DRI)
HYL type processes; Midrex type processes
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
High level introduction
Mainstream syngas = steam reforming processes
Ammonia; methanol; hydrogen/HyCO
Town gas
Steam reforming; low pressure cyclic
Direct reduction iron (DRI)
HYL type processes; Midrex type processes
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
This presentation covers frequent and costly incidents related to catalysts mal-operation with the focus of providing the plant operator with recommendations to avoid plant outages and catalyst losses.
Pre-reformer in the flowsheet
* positioned upstream of the steam reformer
* uses a specialized high activity catalyst based on Ni
* reaction involves conversion of hydrocarbons to a mix of CH4, CO, CO2 and H2
Pre-reformers - sometimes included at the original design stage
- also can be added to existing units to uprate the plant
Need to remove poisons prior to entering downstream catalyst beds, including
Pre reformers
Primary reformers
HTS
LTS
Note : no Secondary - poisons do not stick as temperature is too high
Note that methanator is a purification step
Removes CO and CO2 which poisons synthesis catalyst
Why have a Secondary Reformer ?
Need nitrogen to make ammonia
Wish to make primary as small as possible
Wish to minimise methane slip since methane is an inert in the ammonia synthesis loop
Other methods of achieving this
Braun Purifier process
Can address all these with an air blown secondary
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
If it can go wrong – it will
If something looks odd – it is
Apparent safe systems can fail
Issues include
Metal dusting
Methanol or hydrogen fires
Intent changes
Methanation
“Safe Systems”
The value of selecting the right catalyst
Selecting the key performance criteria
Sources of data:
Plant data
Laboratory reactor data
Catalyst characterization
Recommendations
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
UlSD Hydrotreater Challenges Overcome to Improve on Stream Factor - MEPEC 2013Alpesh Gurjar
The presentation outlines the experience in overcoming the challenges that faced and the lessons learned, to achieve safe, reliable and profitable Diesel Hydrotreater (2HDU) operation, while meeting all throughput and yield targets and product specifications. The 2HDU success over the 6½ years clearly demonstrated the importance and value of in-house process engineering expertise and experience, while working as a part of cross-functional team.
Purpose
Key to good performance
Problem Areas
Catalysts, heat shields and plant up-rates
Burner Guns
Development of High Intensity Ring Burner
Case Studies
Conclusions
This presentation covers frequent and costly incidents related to catalysts mal-operation with the focus of providing the plant operator with recommendations to avoid plant outages and catalyst losses.
Pre-reformer in the flowsheet
* positioned upstream of the steam reformer
* uses a specialized high activity catalyst based on Ni
* reaction involves conversion of hydrocarbons to a mix of CH4, CO, CO2 and H2
Pre-reformers - sometimes included at the original design stage
- also can be added to existing units to uprate the plant
Need to remove poisons prior to entering downstream catalyst beds, including
Pre reformers
Primary reformers
HTS
LTS
Note : no Secondary - poisons do not stick as temperature is too high
Note that methanator is a purification step
Removes CO and CO2 which poisons synthesis catalyst
Why have a Secondary Reformer ?
Need nitrogen to make ammonia
Wish to make primary as small as possible
Wish to minimise methane slip since methane is an inert in the ammonia synthesis loop
Other methods of achieving this
Braun Purifier process
Can address all these with an air blown secondary
Reformer Tube design principles
- Larsen Miller Plot
- Larsen Miller & Tube Design
- Design Margins - Stress Data Used
- Max Allowable & Design Temperature
- Tube Life
- Effect of Temperature on Life
- Material Types
HK40: 25 Cr / 20 Ni
HP Modified: 25 Cr / 35 Ni + Nb
Microalloy: 25 Cr / 35 Ni + Nb + Ti
- Alloy Developments
- Comparison of Alloys
Manufacturing Technology
- Welds
Failure mechanisms
- Failure Mechanisms - Creep
- Creep Propagation
- Common Failure Modes
- Uncommon Failure Modes
- Failure by Creep
- Creep Rupture - Cross Section
- Failure at Weld
Actions to Take if Tube Fails
- Pigtail Nipping
Inspection techniques
Classification of Problems
- Visual Examination
- Girth Measurement
- Ultrasonic Attenuation
- Radiography
Eddy Current Measurement
LOTIS Tube Inspection
LOTIS Compared to External Inspection
If it can go wrong – it will
If something looks odd – it is
Apparent safe systems can fail
Issues include
Metal dusting
Methanol or hydrogen fires
Intent changes
Methanation
“Safe Systems”
The value of selecting the right catalyst
Selecting the key performance criteria
Sources of data:
Plant data
Laboratory reactor data
Catalyst characterization
Recommendations
Equilibrium Effects
- Methane Steam
- Water Gas Shift
Relationship of Kp to Temperature
Relationship of WGS Kp to Temperature
Effect of Temperature on Methane Slip
Approach to Equilibrium
Reaction Path and Equilibrium
Effect of Pressure Increase
Operating Parameters
- Pressure
- Temperature
- Feed Rate
- Steam to Carbon
Effect of Exit Temperature Spread
Useful Tools
Calculating ATM
UlSD Hydrotreater Challenges Overcome to Improve on Stream Factor - MEPEC 2013Alpesh Gurjar
The presentation outlines the experience in overcoming the challenges that faced and the lessons learned, to achieve safe, reliable and profitable Diesel Hydrotreater (2HDU) operation, while meeting all throughput and yield targets and product specifications. The 2HDU success over the 6½ years clearly demonstrated the importance and value of in-house process engineering expertise and experience, while working as a part of cross-functional team.
Virtual Commissioning and Real-Time Training for Increasing PerformanceGSE Systems, Inc.
This presentation discusses the gas conversion of an existing coal power plant and how using a high-fidelity simulator for virtual commissioning can increase plant performance and profits.
Technical overview of the research questions and findings as well as a discussion of targeted recommendations for utility energy efficiency programs and operator learning.
Pre-reforming
Flow-schemes
Feed-stocks
Catalyst handling, loading & start-up
Benefits of a pre-reformer
Case studies
Effects upon primary reformer
Data analysis
Reactor temperature profiles
Catalyst management
Summary
Pressure Relief Systems Vol 2
Causes of Relief Situations
This Volume 2 is a guide to the qualitative identification of common causes of overpressure in process equipment. It cannot be exhaustive; the process engineer and relief systems team should look for any credible situation in addition to those given in this Part which could lead to a need for pressure relief (a relief situation).
Pressure Relief Systems
BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6
The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy GasesGerard B. Hawkins
GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases
This Process Safety Guide has been written with the aim of assisting process engineers, hazard analysts and environmental advisers in carrying out gas dispersion calculations. The Guide aims to provide assistance by:
• Improving awareness of the range of dispersion models available within GBHE, and providing guidance in choosing the most appropriate model for a particular application.
• Providing guidance to ensure that source terms and other model inputs are correctly specified, and the models are used within their range of applicability.
• Providing guidance to deal with particular topics in gas dispersion such as dense gas dispersion, complex terrain, and modeling the chemistry of oxides of nitrogen.
• Providing general background on air quality and dispersion modeling issues such as meteorology and air quality standards.
• Providing example calculations for real practical problems.
SCOPE
The gas dispersion guide contains the following Parts:
1 Fundamentals of meteorology.
2 Overview of air quality standards.
3 Comparison between different air quality models.
4 Designing a stack.
5 Dense gas dispersion.
6 Calculation of source terms.
7 Building wake effects.
8 Overview of the chemistry of the oxides of nitrogen.
9 Overview of the ADMS complex terrain module.
10 Overview of the ADMS deposition module.
11 ADMS examples.
12 Modeling odorous releases.
13 Bibliography of useful gas dispersion books and reports.
14 Glossary of gas dispersion modeling terms.
Appendix A : Modeling Wind Generation of Particulates.
APPENDIX B TABLE OF PROPERTY VALUES FOR SPECIFIC CHEMICALS
Theory of Carbon Formation in Steam Reforming
Contents
1 Introduction
2 Underpinning Theory
2.1 Conceptualization
2.2 Reforming Reactions
2.3 Carbon Formation Chemistry
2.3.1 Natural Gas
2.3.2 Carbon Formation for Naphtha Feeds
2.3.3 Carbon Gasification
2.4 Heat Transfer
3 Causes
3.1 Effects of Carbon Formation
3.2 Types of Carbon
4 What are the Effects of Carbon Formation?
4.1 Why does Carbon Formation Get Worse?
4.1.1 So what is the Next Step?
4.2 Consequences of Carbon Formation
4.3 Why does Carbon Form where it does?
4.3.1 Effect on Process Gas Temperature
4.4 Why does Carbon Formation Propagate Down the Tube?
4.4.1 Effect on Radiation on the Fluegas Side
4.5 Why does Carbon Formation propagate Up the Tube?
5 How do we Prevent Carbon Formation
5.1 The Role of Potash
5.2 Inclusion of Pre-reformer
5.3 Primary Reformer Catalyst Parameters
5.3.1 Activity
5.3.2 Heat Transfer
5.3.3 Increased Steam to Carbon Ratio
6 Steam Out
6.1 Why does increasing the Steam to Carbon Ratio Not Work?
6.2 Why does reducing the Feed Rate not help?
6.3 Fundamental Principles of Steam Outs
TABLES
1 Heat Transfer Coefficients in a Typical Reformer
2 Typical Catalyst Loading Options
FIGURES
1 Hot Bands
2 Conceptual Pellet
3 Naphtha Carbon Formation
4 Heat Transfer within an Reformer
5 Types of Carbon Formation
6 Effect of Carbon on Nickel Crystallites
7 Absorption of Heat
8 Comparison of "Base Case" v Carbon Forming Tube
9 Carbon Formation Vicious Circle
10 Temperature Profiles
11 Carbon Pinch Point
12 Carbon Formation
13 Effect on Process Gas Temperature
14 How does Carbon Propagate into an Unaffected Zone?
15 Movement of the Carbon Forming Region
16 Effect of Hot Bands on Radiative Heat Transfer
17 Effect of Potash on Carbon Formation
18 Application of a Pre-reformer
19 Effect of Activity on Carbon Formation
Calculation of an Ammonia Plant Energy Consumption: Gerard B. Hawkins
Calculation of an Ammonia Plant Energy Consumption:
Case Study: #06023300
Plant Note Book Series: PNBS-0602
CONTENTS
0 SCOPE
1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION
2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION
3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES
4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT
5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS
6 CALCULATION OF MP STEAM EXPORT
7 CALCULATION OF LP STEAM IMPORT
8 DETERMINATION OF ELECTRIC POWER CONSUMPTION
9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL
10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS
11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES
12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES
13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL
14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT
Ammonia Plant Technology
Pre-Commissioning Best Practices
GBHE-APT-0102
PICKLING & PASSIVATION
CONTENTS
1 PURPOSE OF THE WORK
2 CHEMICAL CONCEPT
3 TECHNICAL CONCEPT
4 WASTES & SAFETY CONCEPT
5 TARGET RESULTS
6 THE GENERAL CLEANING SEQUENCE MANAGEMENT
6.6.1 Pre-cleaning or “Physical Cleaning
6.6.2 Pre-rinsing
6.6.3 Chemical Cleaning
6.6.4 Critical Factors in Cleaning Success
6.6.5 Rinsing
6.6.6 Inspection and Re-Cleaning, if Necessary
7 Systems to be treated by Pickling/Passivation
Ammonia Plant Technology
Pre-Commissioning Best Practices
Piping and Vessels Flushing and Cleaning Procedure
CONTENTS
1 Scope
2 Aim/purpose
3 Responsibilities
4 Procedure
4.1 Main cleaning methods
4.1.1 Mechanical cleaning
4.1.2 Cleaning with air
4.1.3 Cleaning with steam (for steam networks only)
4.1.4 Cleaning with water
4.2 Choice of the cleaning method
4.3 Cleaning preparation
4.4 Protection of the devices included in the network
4.5 Protection of devices in the vicinity of the network
4.6 Water flushing procedure
4.6.1 Specific problems of water flushing
4.6.2 Preparation for water flushing
4.6.3 Performing a water flush
4.6.4 Cleanliness criteria
4.7 Air blowing procedure
4.7.1 Specific problems of air blowing
4.7.2 Preparation for air blowing
4.7.3 Performing air blowing
4.7.4 Cleanliness checks
4.8 Steam blowing procedure
4.8.1 Specific problems of steam blowing
4.8.2 Preparation for steam blowing
4.8.3 Performing steam blowing
4.8.4 Cleanliness checks
4.9 Chemical cleaning procedure
4.9.1 Specific problems of cleaning with a chemical solution
4.9.2 Preparation for chemical cleaning
4.9.3 Performing a chemical cleaning
4.9.4 Cleanliness criteria
4.10 Re-assembly - general guideline
4.11 Preservation of flushed piping
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS Gerard B. Hawkins
DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS
CONTENTS
1 INTRODUCTION
1.1 Purpose
1.2 Scope of this Guide
1.3 Use of the Guide
2 ENVIRONMENTAL ISSUES
2.1 Principal Concerns
2.2 Mechanisms for Ozone Formation
2.3 Photochemical Ozone Creation Potential
2.4 Health and Environmental Effects
2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits
3 VENTS REDUCTION PHILOSOPHY
3.1 Reduction at Source
3.2 End-of-pipe Treatment
4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA
4.1 General
4.2 Identification of Vent Sources
4.3 Characterization of Vents
4.4 Quantification of Process Vent Flows
4.5 Component Flammability Data Collection
4.6 Identification of Operating Scenarios
4.7 Quantification of Flammability Characteristics for Combined Vents
4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes
4.9 Tabulation of Data
4.10 Hazard Study and Risk Assessment
4.11 Note on Aqueous / Organic Wastes
4.12 Complexity of Systems
4.13 Summary
5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS
5.1 General
5.2 Process Design of Vent Headers
5.3 Liquid in Vent Headers
5.4 Materials of Construction
5.5 Static Electricity Hazard
5.6 Diversion Systems
5.7 Snuffing Systems
6 SAFE DESIGN OF THERMAL OXIDISERS
6.1 Introduction
6.2 Design Basis
6.3 Types of High Temperature Thermal Oxidizer
6.4 Refractories
6.5 Flue Gas Treatment
6.6 Control and Safety Systems
6.7 Project Program
6.8 Commissioning
6.9 Operational and Maintenance Management
APPENDICES
A GLOSSARY
B FLAMMABILITY
C EXAMPLE PROFORMA
D REFERENCES
DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE
TABLE
1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED
TO ETHYLENE AS UNITY
FIGURES
1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM
2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN
3 SCHEMATIC OF DIVERSION SYSTEM
4 CONVENTIONAL VERTICAL THERMAL OXIDIZER
5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER
6 THERMAL OXIDIZER WITH STAGED AIR INJECTION
7 DOWN-FIRED UNIT WITH WATER BATH QUENCH
8 FLAMELESS THERMAL OXIDATION UNIT
9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY
10 TYPICAL PROJECT PROGRAM
11 TYPICAL FLAMMABILITY DIAGRAM
12 EFFECT OF DILUTION WITH AIR
13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...Gerard B. Hawkins
PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF AQUEOUS ORGANIC EFFLUENT STREAMS
CONTENTS
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
3.1 IPU
3.2 AOS
3.3 BODs
3.4 COD
3.5 TOC
3.6 Toxicity
3.7 Refractory Organics/Hard COD
3.8 Heavy Metals
3.9 EA
3.10 Biological Treatment Terms
3.11 BATNEEC
3.12 BPEO
3.13 EQS/LV
3.14 IPC
3.15 VOC
3.16 F/M Ratio
3.17 MLSS
3.18 MLVSS
4 DESIGN/ECONOMIC GUIDELINES
5 EUROPEAN LEGISLATION
5.1 General
5.2 Integrated Pollution Control (IPC)
5.3 Best Available Techniques Not Entailing Excessive Costs (BATNEEC)
5.4 Best Practicable Environmental Option (BPEO)
5.5 Environmental Quality Standards(EQS)
6 IPU EXIT CONCENTRATION
7 SITE/LOCAL REQUIREMENTS
8 PROCESS SELECTION PROCEDURE
8.1 Waste Minimization Techniques (WMT)
8.2 AOS Stream Definition
8.3 Technical Check List
8.4 Preliminary Selection of Suitable Technologies
8.5 Process Sequences
8.6 Economic Evaluation
8.7 Process Selection
APPENDICES
A DIRECTIVE 76/464/EEC - LIST 1
B DIRECTIVE 76/464/EEC - LIST 2
C THE EUROPEAN COMMISSION PRIORITY CANDIDATE LIST
D THE UK RED LIST
E CURRENT VALUES FOR EUROPEAN COMMUNITY ENVIRONMENTAL QUALITY STANDARDS AND CORRESPONDING LIMIT VALUES
F ESTABLISHED TECHNOLOGIES
G EMERGING TECHNOLOGY
H PROPRIETARY/LESS COMMON TECHNOLOGIES
J COMPARATIVE COST DATA
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...Gerard B. Hawkins
PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs)
FOREWORD
CONTENTS
1 INTRODUCTION
2 THE NEED FOR VOC CONTROL
3 CONTROL AT SOURCE
3.1 Choice or Solvent
3.2 Venting Arrangements
3.3 Nitrogen Blanketing
3.4 Pump Versus Pneumatic Transfer
3.5 Batch Charging
3.6 Reduction of Volumetric Flow
3.7 Stock Tank Design
4 DISCHARGE MEASUREMENT
4.1 By Inference or Calculation
4.2 Flow Monitoring Equipment
4.3 Analytical Instruments
4.4 Vent Emissions Database
5 ABATEMENT TECHNOLOGY
5.1 Available Options
5.2 Selection of Preferred Option
5.3 Condensation
5.4 Adsorption
5.5 Absorption
5.6 Thermal Incineration
5.7 Catalytic Oxidation
5.8 Biological Filtration
5.9 Combinations of Process technologies
5.10 Processes Under Development
6 GLOSSARY OF TERMS
7 REFERENCES
Appendix 1. Photochemical Ozone Creation Potentials
Appendix 2. Examples of Adsorption Preliminary Calculations
Appendix 3. Example of Thermal Incineration Heat and Mass Balance
Appendix 4. Cost Correlations
Getting the Most Out of Your Refinery Hydrogen PlantGerard B. Hawkins
Getting the Most Out of Your Refinery Hydrogen Plant
Contents
Summary
1 Introduction
2 "On-purpose" Hydrogen Production
3 Operational Aspects
4 Uprating Options on the Steam Reformer
4.1 Steam Reforming Catalysts and Tube Metallurgy
4.2 Oxygen-blown Secondary Reformer
4.3 Pre-reforming
4.4 Post-reforming
5 Downstream Units
6 Summary of Uprating Options
7 Conclusions
EMERGENCY ISOLATION OF CHEMICAL PLANTS
CONTENTS
1 Introduction
2 When should Emergency Isolation Valves be Installed
3 Emergency Isolation Valves and Associated Equipment
3.1 Installations on existing plant
3.2 Actuators
3.3 Power to close or power to open
3.4 The need for testing
3.5 Hand operated Emergency Valves
3.6 The need to stop pumps in an emergency
3.7 Location of Operating Buttons
3.8 Use of control valves for Isolation
4 Detection of Leaks and Fires
5 Precautions during Maintenance
6 Training Operators to use Emergency Isolation Valves
7 Emergency Isolation when no remotely operated valve is available
References
Glossary
Appendix I Some Fires or Serious Escapes of Flammable Gases or Liquids that could have been controlled by Emergency Isolation Valves
Appendix II Some typical Installations
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Generative AI Deep Dive: Advancing from Proof of Concept to ProductionAggregage
Join Maher Hanafi, VP of Engineering at Betterworks, in this new session where he'll share a practical framework to transform Gen AI prototypes into impactful products! He'll delve into the complexities of data collection and management, model selection and optimization, and ensuring security, scalability, and responsible use.
Communications Mining Series - Zero to Hero - Session 1DianaGray10
This session provides introduction to UiPath Communication Mining, importance and platform overview. You will acquire a good understand of the phases in Communication Mining as we go over the platform with you. Topics covered:
• Communication Mining Overview
• Why is it important?
• How can it help today’s business and the benefits
• Phases in Communication Mining
• Demo on Platform overview
• Q/A
Why You Should Replace Windows 11 with Nitrux Linux 3.5.0 for enhanced perfor...SOFTTECHHUB
The choice of an operating system plays a pivotal role in shaping our computing experience. For decades, Microsoft's Windows has dominated the market, offering a familiar and widely adopted platform for personal and professional use. However, as technological advancements continue to push the boundaries of innovation, alternative operating systems have emerged, challenging the status quo and offering users a fresh perspective on computing.
One such alternative that has garnered significant attention and acclaim is Nitrux Linux 3.5.0, a sleek, powerful, and user-friendly Linux distribution that promises to redefine the way we interact with our devices. With its focus on performance, security, and customization, Nitrux Linux presents a compelling case for those seeking to break free from the constraints of proprietary software and embrace the freedom and flexibility of open-source computing.
How to Get CNIC Information System with Paksim Ga.pptxdanishmna97
Pakdata Cf is a groundbreaking system designed to streamline and facilitate access to CNIC information. This innovative platform leverages advanced technology to provide users with efficient and secure access to their CNIC details.
Epistemic Interaction - tuning interfaces to provide information for AI supportAlan Dix
Paper presented at SYNERGY workshop at AVI 2024, Genoa, Italy. 3rd June 2024
https://alandix.com/academic/papers/synergy2024-epistemic/
As machine learning integrates deeper into human-computer interactions, the concept of epistemic interaction emerges, aiming to refine these interactions to enhance system adaptability. This approach encourages minor, intentional adjustments in user behaviour to enrich the data available for system learning. This paper introduces epistemic interaction within the context of human-system communication, illustrating how deliberate interaction design can improve system understanding and adaptation. Through concrete examples, we demonstrate the potential of epistemic interaction to significantly advance human-computer interaction by leveraging intuitive human communication strategies to inform system design and functionality, offering a novel pathway for enriching user-system engagements.
Sudheer Mechineni, Head of Application Frameworks, Standard Chartered Bank
Discover how Standard Chartered Bank harnessed the power of Neo4j to transform complex data access challenges into a dynamic, scalable graph database solution. This keynote will cover their journey from initial adoption to deploying a fully automated, enterprise-grade causal cluster, highlighting key strategies for modelling organisational changes and ensuring robust disaster recovery. Learn how these innovations have not only enhanced Standard Chartered Bank’s data infrastructure but also positioned them as pioneers in the banking sector’s adoption of graph technology.
Alt. GDG Cloud Southlake #33: Boule & Rebala: Effective AppSec in SDLC using ...James Anderson
Effective Application Security in Software Delivery lifecycle using Deployment Firewall and DBOM
The modern software delivery process (or the CI/CD process) includes many tools, distributed teams, open-source code, and cloud platforms. Constant focus on speed to release software to market, along with the traditional slow and manual security checks has caused gaps in continuous security as an important piece in the software supply chain. Today organizations feel more susceptible to external and internal cyber threats due to the vast attack surface in their applications supply chain and the lack of end-to-end governance and risk management.
The software team must secure its software delivery process to avoid vulnerability and security breaches. This needs to be achieved with existing tool chains and without extensive rework of the delivery processes. This talk will present strategies and techniques for providing visibility into the true risk of the existing vulnerabilities, preventing the introduction of security issues in the software, resolving vulnerabilities in production environments quickly, and capturing the deployment bill of materials (DBOM).
Speakers:
Bob Boule
Robert Boule is a technology enthusiast with PASSION for technology and making things work along with a knack for helping others understand how things work. He comes with around 20 years of solution engineering experience in application security, software continuous delivery, and SaaS platforms. He is known for his dynamic presentations in CI/CD and application security integrated in software delivery lifecycle.
Gopinath Rebala
Gopinath Rebala is the CTO of OpsMx, where he has overall responsibility for the machine learning and data processing architectures for Secure Software Delivery. Gopi also has a strong connection with our customers, leading design and architecture for strategic implementations. Gopi is a frequent speaker and well-known leader in continuous delivery and integrating security into software delivery.
Encryption in Microsoft 365 - ExpertsLive Netherlands 2024Albert Hoitingh
In this session I delve into the encryption technology used in Microsoft 365 and Microsoft Purview. Including the concepts of Customer Key and Double Key Encryption.
In the rapidly evolving landscape of technologies, XML continues to play a vital role in structuring, storing, and transporting data across diverse systems. The recent advancements in artificial intelligence (AI) present new methodologies for enhancing XML development workflows, introducing efficiency, automation, and intelligent capabilities. This presentation will outline the scope and perspective of utilizing AI in XML development. The potential benefits and the possible pitfalls will be highlighted, providing a balanced view of the subject.
We will explore the capabilities of AI in understanding XML markup languages and autonomously creating structured XML content. Additionally, we will examine the capacity of AI to enrich plain text with appropriate XML markup. Practical examples and methodological guidelines will be provided to elucidate how AI can be effectively prompted to interpret and generate accurate XML markup.
Further emphasis will be placed on the role of AI in developing XSLT, or schemas such as XSD and Schematron. We will address the techniques and strategies adopted to create prompts for generating code, explaining code, or refactoring the code, and the results achieved.
The discussion will extend to how AI can be used to transform XML content. In particular, the focus will be on the use of AI XPath extension functions in XSLT, Schematron, Schematron Quick Fixes, or for XML content refactoring.
The presentation aims to deliver a comprehensive overview of AI usage in XML development, providing attendees with the necessary knowledge to make informed decisions. Whether you’re at the early stages of adopting AI or considering integrating it in advanced XML development, this presentation will cover all levels of expertise.
By highlighting the potential advantages and challenges of integrating AI with XML development tools and languages, the presentation seeks to inspire thoughtful conversation around the future of XML development. We’ll not only delve into the technical aspects of AI-powered XML development but also discuss practical implications and possible future directions.
UiPath Test Automation using UiPath Test Suite series, part 6DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 6. In this session, we will cover Test Automation with generative AI and Open AI.
UiPath Test Automation with generative AI and Open AI webinar offers an in-depth exploration of leveraging cutting-edge technologies for test automation within the UiPath platform. Attendees will delve into the integration of generative AI, a test automation solution, with Open AI advanced natural language processing capabilities.
Throughout the session, participants will discover how this synergy empowers testers to automate repetitive tasks, enhance testing accuracy, and expedite the software testing life cycle. Topics covered include the seamless integration process, practical use cases, and the benefits of harnessing AI-driven automation for UiPath testing initiatives. By attending this webinar, testers, and automation professionals can gain valuable insights into harnessing the power of AI to optimize their test automation workflows within the UiPath ecosystem, ultimately driving efficiency and quality in software development processes.
What will you get from this session?
1. Insights into integrating generative AI.
2. Understanding how this integration enhances test automation within the UiPath platform
3. Practical demonstrations
4. Exploration of real-world use cases illustrating the benefits of AI-driven test automation for UiPath
Topics covered:
What is generative AI
Test Automation with generative AI and Open AI.
UiPath integration with generative AI
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
GraphSummit Singapore | The Art of the Possible with Graph - Q2 2024Neo4j
Neha Bajwa, Vice President of Product Marketing, Neo4j
Join us as we explore breakthrough innovations enabled by interconnected data and AI. Discover firsthand how organizations use relationships in data to uncover contextual insights and solve our most pressing challenges – from optimizing supply chains, detecting fraud, and improving customer experiences to accelerating drug discoveries.
In his public lecture, Christian Timmerer provides insights into the fascinating history of video streaming, starting from its humble beginnings before YouTube to the groundbreaking technologies that now dominate platforms like Netflix and ORF ON. Timmerer also presents provocative contributions of his own that have significantly influenced the industry. He concludes by looking at future challenges and invites the audience to join in a discussion.
Climate Impact of Software Testing at Nordic Testing DaysKari Kakkonen
My slides at Nordic Testing Days 6.6.2024
Climate impact / sustainability of software testing discussed on the talk. ICT and testing must carry their part of global responsibility to help with the climat warming. We can minimize the carbon footprint but we can also have a carbon handprint, a positive impact on the climate. Quality characteristics can be added with sustainability, and then measured continuously. Test environments can be used less, and in smaller scale and on demand. Test techniques can be used in optimizing or minimizing number of tests. Test automation can be used to speed up testing.
Climate Impact of Software Testing at Nordic Testing Days
Revamps for Modern Hydrogen Plants
1. Revamps for Modern Hydrogen
Plants
By
Gerard B. Hawkins
Managing Director, CEO
2. Introduction
This presentation highlights some of the
retrofits that can be applied to
• Improve efficiency
• Increase production
Safety
Efficiency
Reliability
Throughput
Environment
3. Retrofits for Modern Hydrogen
Plants
For modern hydrogen plants, efficiency
is generally good
However still drivers to maximize profit
and therefore must improve either
• Plant efficiency
• Plant production rate
4. Site Circumstances
Hydrogen plants have a wide range of site
circumstances
Is there value for steam on the site ?
What are the downstream users ?
What is the contract basis for the H2 supply
When conducting a revamp these need to be
carefully considered
GBHE is in a unique position to fully
understand these issues and design revamps
accordingly
5. Plant Limitations
Need to address plant limitations,
such as
• Reformer pressure drop
• Maximum tube wall temperature
• Coil design temperatures in duct
• Fan capacity
6. Basis for Study
Modern style plant with
• Top Fired SMR - 368 tubes
• Steam to carbon of 3.0
• Duct heat recovery is feed preheat,
steam raising and combustion air
preheat
• HTS
• PSA for product hydrogen purification
9. Plant Limitations
Three areas that can limit plant
performance
Reformer
Convection Section
Cooling, HTS
and PSA
10. Change Catalyst Shape and Size
By optimizing catalyst size can
• Reduce pressure drop by up to 28%
• Reduce carbon formation potential
• Increase production by 4%
By changing to VULCAN Series VSG-
Z101 can
• Reduce CH4 slip and increase production by
4%
• Reduce carbon formation potential
• Reduce pressure drop by 22%
11. Reduce Steam to Carbon Ratio
By reducing SC ratio by 0.6 can
• Reduce steam addition
• Increase steam export
• Reduce pressure drop
• Gain 2-4 GJ/mmSCF
• Increase production by 2%
But must be aware of
• Metal dusting of WHB
• Increased potential for carbon formation
12. Raise Outlet Reformer
Temperature
Many operators run to a false tube
wall or outlet header temperature
By analysis of reformer operation,
this limitation can be eliminated
Improves production by 2-4%
At margin loss of efficiency
Some of this efficiency can be
recouped by other revamps
13. Rebalancing Firing
On Terraced Wall or Side Fired
reformers, the firing can be rebalanced
Either improves efficiency or steam
raising capacity on in some cases can
increase rate
Parameter Units Case A Case B Case C
Firing at Top % 50 40 60
Firing at Bottom % 50 60 40
Steam Export Mt/hr 0 -3 +3
Efficiency GJ/mmSCF 418 410 426
14. Reformer Re-tubes
The reformer tubes do have to be
replaced and therefore have to be
considered as a consumable
By replacing with an improve metallurgy,
a thinner wall tube can be used
This provides a wide range of process
and operability benefits
15. Reformer Re-tubes
Parameter Units Case A
Base
Case B
New Tubes
Case C
Uprate
Tube material N/A HP HP Mod HP Mod
Tube OD mm 152 152 152
Tube ID mm 130 134 135
Catalyst “P” “P” “P”
H2 Production mmSCF 100 100 105
Efficiency GJ/mmSCF 406 405 407
16. Addition of a Pre-Reformer
MP Steam
Existing
Reformer
Natural Gas
Synthesis Gas
Pre-reformer
New Reheat
Coil
17. Addition of a Pre-Reformer
To obtain maximum benefit requires
• Reheat of effluent - an achieve very high
preheat and reheat temperature with latest
generation of pre-reforming catalyst.
• Can recover more heat from duct and
reduce furnace duty significantly
• Must model effect on duct to ensure that
existing demands for heat are fulfilled (HP
Steam Raising)
Can allow for efficiency improvements of up to
13 GJ/mmSCF
Or rate increases of 7%
18. Addition of an ATR
Existing
Reformer
NG Preheater NG/Steam
Preheater
MUG Cooler
Oxygen Preheater
Steam Drum
MP Boiler
Natural Gas Make Up Gas
Condensate
19. Addition of an ATR or Secondary
Either in parallel (ATR) or in series
(secondary)
• Parallel ATR has less impact on the main
plant
• Main plant can run when ATR off line
Can increase production rate by 20%
• More can be achieved depending on plant
design
Require an oxygen plant (8 mt/hr)
Energy efficiency improved by 5 GJ/mmSCF
20. Addition of an AGHRPR
Can add a AGHR as a post reformer
Reduces steam export by 20-40%
Depending on plant design allows for
plant rate increases of between 10-30%
Also potential energy efficiency gains
Steam
Hydrocarbon
Feed HDS
Fuel
Steam
Generation
and
Superheating
Steam
Generation
and
Superheating
Combustion
Air
Pre-heat
Reformed
Gas
Process
Additional gas + steam feed
Gas
Heated
Post-
Reformer
Waste
Heat
Boiler
HDS
Preheat
Mixed
Feed
Preheat
21. VULCAN SG Delta Retrofit for Shift
Vessels
By installing a specialised support
system can reduce pressure drop
significantly
GBHE can offer the VULCAN SG Delta
which can reduce pressure drop by
around 50%
Allows plant rate increases of up to
3%
22. Other Options
Add LTS and gain 7% production
Use ROG or other streams as a feed
Preheat fuel
Reduction in excess air in reformer
Add saturator and recover low grade
heat into the process
23. Hydrogen Plant Revamp Capacity
Increases
What capacity
increase is required ?
>15%
Front End
Catalyst size
change
VULCAN SG Delta
SC Reduction
Change reformer
exit temperature
<5%
Front End
Catalyst shape and
size change
Pre-reformer
Re-tube
Add LTS
5-15%
Front End
ATR
AGHRPR
24. Hydrogen Plant Revamp Selector
Efficiency Improvements
What efficiency improvement
is required ?
>15 GJ/mmSCF<5 GJ/mmSCF
Front End
ATR
SC ratio change
Fuel preheat
Excess air
optimization
5-15 GJ/mmSCF
Front End
Pre-reformer
Saturator
Front End
Optimized reformer
catalyst loading
Re-tube
VULCAN SG Delta
25. Problems and Pitfalls
Contractor and Contract
Must carefully select partners
• Must have domain knowledge
Design and operations
• Must have correct tools
• Must be able to supply correct level of detail
for study
Must select appropriate contract type
• LSTK or Reimbursable
• Both have advantages and disadvantages
26. Problems and Pitfalls
Modelling Capability
Must use correct tools
Model the whole plant using a flowsheeting
package
• Must include all unit operations
• Must develop a robust base case
• Must validate against plant data
• Must understand deviations
• Then develop the retrofit case
27. Problems and Pitfalls
Retrofit Details
The customer and engineering contractor
must determine
• Precise scope for retrofit
• Responsibilities
• Key deliverables
• A detailed and consistent design basis
• Time scale and milestones
• Review schedules
Summarize as Good Project Management
28. Problems and Pitfalls
Design Basis
Engineering contractor must conduct on
site visit
• Must work with client
• Collect representative plant data
• Model and understand plant data
• Discuss discrepancies and eliminate
• Identify bottlenecks
• Identify opportunities for improvement
These form the core of the design basis
29. Problems and Pitfalls
HAZOPs and Commissioning
Must use systematic review method to
highlight potential problems with retrofit
• HAZOPs are a well proven system
• Requires time and buy in from all parties
• Results as good as quality of people !
Retrofit will change plant parameters
• Must update PFDs and P&IDs
• Must update operating instructions
• Must take additional care during start up
30. What Can GBHE Offer?
Detail catalyst unit operation models
such as the Industry leading VULCAN
REFORMER SIMULATION program
• Also models for other catalyst unit
operations
Detail non-catalyst unit operation
models such as
• Heat exchange programs
• Finite Element Analysis
• CFD modelling
One stop shop
31. What Can GBHE Offer?
Domain Knowledge
• Operations
Many staff have operations
background
Troubleshooting clients plants
• Design
Many staff have detailed
engineering background
Engineers work on design daily
Work with leading contractors
on front end and detailed
design issues
Catalysts
Consulting
Services
Domain
Knowledge
32. What Can GBHE Offer?
Can supply any level of detail for
retrofit
Scoping studies
• Front End
• What are the best options
Front End Engineering
• Flowsheets and design of key components
Detailed Engineering
• Design of all components of retrofit
A one stop shop for your revamp
requirements
33. One Stop Shop Case Study
Re-tube – Present Model
Plant
Operator
Concept
Engineer
Tube
Supplier
Catalyst
Vendor
Tube
Installer
Catalyst
Handler
No Communication
Detailed
Engineer
34. One Stop Shop Case Study
Re-tube – “One Stop Shop” Model
Plant
Operator
GBHE
Concept Engineer
Tube
Supplier
Tube
Installer
Catalyst
Handler
Detailed
Engineer
Seamless
Minimum Cost
Maximum Benefit
35. Case Study - How GBHE Works
Strong position due to credibility from previous
work
Uprate projects
• Feasibility Process Uprate study on Naphtha 115%,
130% or 150% cases
• FEEP (Front End Engineering Package, what would be
needed?)
115% FEEP adopted
• Option evaluations and natural gas feed conversion
Followed by full Engineering Detail Design
Also additional design work on Desulfurization
Design Study
36. Conclusions
A number of revamps have been
presented that are suitable for
application to hydrogen plants
They address all the key limitations that
hydrogen plants typically suffer from
To take full benefit from some of these
retrofits, others may also be required
GBHE has all the right expertise and
knowledge to develop and design
revamps