The document provides a procedure for reducing steam reforming catalysts using LPG feed instead of the preferred hydrogen or natural gas. It cautions that LPG reduction carries risks of carbon formation and requires close monitoring and control of steam to carbon ratios. The 11-step procedure involves purging oxygen, heating with steam, gradually introducing LPG at 5-10% of design rate while maintaining steam to carbon ratios of 30:1 to 7:1, and slowly ramping up LPG to design rates over 12-24 hours to fully reduce the catalyst. Frequent monitoring is needed to check for complete reduction and prevent carbon formation.
Determination of Inert Gas in Anhydrous Ammonia
ANHYDROUS AMMONIA: DETERMINATION OF INERT GASES
SCOPE AND FIELD OF APPLICATION
This packed-column GC method is suitable for the determination of hydrogen, nitrogen, oxygen, argon and carbon monoxide in anhydrous ammonia. The determinations of the gases are linear in the range O-100 ppm v/v.
Isothermal Methanol Converter (IMC) UA Distribution AnalysisGerard B. Hawkins
Isothermal Methanol Converter (IMC) UA Distribution Analysis - Case Study: #0630416GB/H; ACME Co. 9,000 MTD MeOH
This converter uses plates instead of tubes to remove the heat from the reaction gas. The use of the plates and the orientation allow the heat transfer within the converter to be more accurately controlled to follow the maximum rate line.
This case study examines the Radial Flow – Isothermal Methanol Converter (IMC) for ACME Co. 9,000 MTD, based on the Casale Isothermal Methanol Converter (IMC) design.
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 ...
BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto TitratorGerard B. Hawkins
BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto Titrator
1 SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of diethanolamine in Benfield Liquor.
2 PRINCIPLE
Diethanolamine is converted quantitatively into ammonia by boiling in the presence of sulfuric acid and copper sulfate. The ammonia is distilled from an alkaline medium and absorbed into boric acid. The solution is titrated with standard acid.
Integration of Rotary Positive Displacement Pumps into a ProcessGerard B. Hawkins
Integration of Rotary Positive Displacement Pumps into a Process
This Engineering Design Guide deals with:
(a) The specification of the pump duty for enquiries to be sent to pump vendors,
(b) The estimation of the characteristics and requirements of the pumps in order to provide preliminary information for design work by others.
It applies to pumps in Group 2 and 3 as defined in GBHE-EDS-MAC-21 Series, and is also an essential preliminary step for a pump in Group 1 whose final duty is negotiated with the chosen pump supplier.
It may be used for general-purpose pumps in Group 4; their duties when used in a support role are often inadequately defined, whereupon such pumps can be specified by reference to the manufacturer's data for a pump satisfactorily fulfilling the same process need.
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
Determination of Inert Gas in Anhydrous Ammonia
ANHYDROUS AMMONIA: DETERMINATION OF INERT GASES
SCOPE AND FIELD OF APPLICATION
This packed-column GC method is suitable for the determination of hydrogen, nitrogen, oxygen, argon and carbon monoxide in anhydrous ammonia. The determinations of the gases are linear in the range O-100 ppm v/v.
Isothermal Methanol Converter (IMC) UA Distribution AnalysisGerard B. Hawkins
Isothermal Methanol Converter (IMC) UA Distribution Analysis - Case Study: #0630416GB/H; ACME Co. 9,000 MTD MeOH
This converter uses plates instead of tubes to remove the heat from the reaction gas. The use of the plates and the orientation allow the heat transfer within the converter to be more accurately controlled to follow the maximum rate line.
This case study examines the Radial Flow – Isothermal Methanol Converter (IMC) for ACME Co. 9,000 MTD, based on the Casale Isothermal Methanol Converter (IMC) design.
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 ...
BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto TitratorGerard B. Hawkins
BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto Titrator
1 SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of diethanolamine in Benfield Liquor.
2 PRINCIPLE
Diethanolamine is converted quantitatively into ammonia by boiling in the presence of sulfuric acid and copper sulfate. The ammonia is distilled from an alkaline medium and absorbed into boric acid. The solution is titrated with standard acid.
Integration of Rotary Positive Displacement Pumps into a ProcessGerard B. Hawkins
Integration of Rotary Positive Displacement Pumps into a Process
This Engineering Design Guide deals with:
(a) The specification of the pump duty for enquiries to be sent to pump vendors,
(b) The estimation of the characteristics and requirements of the pumps in order to provide preliminary information for design work by others.
It applies to pumps in Group 2 and 3 as defined in GBHE-EDS-MAC-21 Series, and is also an essential preliminary step for a pump in Group 1 whose final duty is negotiated with the chosen pump supplier.
It may be used for general-purpose pumps in Group 4; their duties when used in a support role are often inadequately defined, whereupon such pumps can be specified by reference to the manufacturer's data for a pump satisfactorily fulfilling the same process need.
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
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.
Reactor Modeling Tools – Multiple Regressions
CONTENTS
0 INTRODUCTION
1 SCOPE
2 THEORY
3 EXCEL 2007: MULTIPLE REGRESSIONS
3.1 Overview
3.2 Multiple Regression Using the Data Analysis ADD-IN
3.3 Interpret Regression Statistics Table
3.4 Interpret ANOVA Table
3.5 Interpret Regression Coefficients Table
3.6 Confidence Intervals for Slope Coefficients
3.7 Test Hypothesis of Zero Slope Coefficients ("Test of Statistical Significance")
3.8 Test Hypothesis on a Regression Parameter
3.8.1 Using the p-value approach
3.8.2 Using the critical value approach
3.9 Overall Test of Significance of the Regression Parameters
3.10 Predicted Value of Y Given Regressors
3.11 Excel Limitations
4 SPECIAL FEATURES REQUIRING MORE SOPHISTICATED TECHNIQUES
5 USER INFORMATION SUPPLIED
A SUBROUTINE
B DATA
C RESULTS
6 EXAMPLE
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....
Low Temperature Shift Catalyst Reduction Procedure
VSG-C111 as supplied contains copper oxide; it is activated for the low temperature shift duty by reducing the copper oxide component to metallic copper with hydrogen. The reaction is highly exothermic. In order to achieve maximum activity, good performance and long life, it is essential that the reduction is conducted under correctly controlled conditions. Great care must be taken to avoid thermal damage during this critical operation.
Determination of Residue and Oil in Anhydrous AmmoniaGerard B. Hawkins
Plant Analytical Techniques
Determination of Residue and Oil in Anhydrous Ammonia
This method is suitable for the determination of residue and oil in anhydrous ammonia.
FIELD OF APPLICATION
This method may be applied to standard and premium grade anhydrous ammonia having residue content in the range 10-5000 micrograms per gram and oil content in the range l-500 micrograms per gram
TEMPERATURE MEASUREMENT:
RESISTANCE ELEMENTS AND THERMOCOUPLES
SPECIFICATION OF FUNCTION
DESCRIPTION OF FLUID
NORMAL OPERATING TEMPERATURE
REQUIRED TEMPERATURE RANGE
ALARM SETTINGS
TRIP SETTINGS
FLUID VELOCITY
REYNOLDS NUMBER
LINE SIZE
LINE REFERENCE
EQUIPMENT REFERENCE
NOZZLE SIZE
MINIMUM DESIGN PRESSURE
CORRESPONDING TEMPERATURE
MAXIMUM DESIGN PRESSURE
CORRESPONDING TEMPERATURE
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
"SEDIMENTATION"
INTRODUCTION - THE PHENOMENON OF SEDIMENTATION
Sedimentation is the physical process whereby solid particles, of greater density than their suspending medium, will tend to separate into regions of higher concentration under the influence of gravity. As a solids/liquids separation technique it therefore possesses the great advantage of utilizing a natural, and therefore costless, driving force. This section of the suspension processing Guide is Intended to provide an Introduction to the science of the subject, and the means to judge where and how best to exploit sedimentation as a separation (or other processing) technique.
As a scientific discipline the subject of sedimentation is vast with perspectives ranging from the field of chemical engineering through to theoretical physics being covered In the literature [1-11]. Good reviews of the subject, with a bias towards the engineering aspects, have been written by Fitch and Koz [12, 13]. A short summary of some of the more relevant contributions from the literature is also provided in GBHE-SPG-PEG-302 “Basic Principles & Test Methods”, of the Suspensions Processing Guides.
.
The sedimentation process is traditionally divided into ..."
Chemical Process Conception
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 PRODUCT STRATEGY
4.1 General
4.2 Market for the Product
4.3 Production Costs
4.4 Process Technology
5 PRELIMINARY PROCESS INFORMATION
6 REACTION AND REACTOR
6.1 Batch vs Continuous
6.2 Multiple Reactors
7 RECYCLE
7.1 Recycle Structure
7.2 Classification of Chemicals
7.3 Effect of Recycle
7.4 Preliminary Estimation of Conversion
8 REACTOR TYPE AND PERFORMANCE
8.1 Conversion-Yield Effects
8.2 Heat Effects
8.3 Equilibrium Effects
8.4 Kinetic Effects
8.5 More Help with Reactor Design
9 SEPARATION SYSTEM
10 REVIEW
11 BIBLIOGRAPHY AND REFERENCES
11.1 Preliminary Flowsheeting
11.2 Physical Properties
11.3 Reactors
11.4 Separation
11.5 Costing
APPENDICES
A BASIC REACTOR SYSTEM DESIGN
B DISCUSSION BETWEEN A CHEMIST AND A
CHEMICAL ENGINEER
C BASIC SEPARATION STRATEGY
TABLES
1 CLASSIFICATION OF MATERIALS
FIGURES
1 FLOWCHART OF THE ITERATIVE PROCEDURE REQUIRED IN PROCESS AND PRODUCT SELECTION AND DEVELOPMENT
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.
Determination of Residue on Evaporation in Anhydrous AmmoniaGerard B. Hawkins
Determination of Residue on Evaporation in Anhydrous Ammonia
1 SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of the residue left after evaporation i.e., the non-volatile material in ammonia solution.
2 PRINCIPLE
A known weight of sample is evaporated to dryness in a platinum dish on a steam bath. The increase in mass of the dish is measured.
Determination of Oxygen in Anhydrous Ammonia
SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of trace amounts of oxygen in Liquefied anhydrous ammonia.
The trace oxygen analyzer provides for trace oxygen analysis in decade steps ranging from 0 - 10 to 0 - 10,000 ppm v/v (full scale).
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
Catalytic Reforming technology - Infographics
IFP Fixed-bed Semi-regenerative Unit Revamps, Troubleshooting
IFP (CCR) Technology Optimization
In trying to determine the potential benefits from revamping a Fixed-bed Semi-Regenerative catalytic reformer, a refiner must evaluate several areas of operation:
— What is the unit operating objective?
— What degrees of freedom are available for revamp /optimization?
— Can refinery margins, and the discretionary capital budgeting program support the revamp / optimization?
Refiners must select the catalytic reformer operating point that will maximize profit within the following:
1) the mechanical constraints of the unit and
2) the short term unit operating objectives.
projects that improve operating profit are compared with the required capital investment.
This is done using discounted cash flow, or one of a number of other capital budgeting analysis tools, and those projects with the greatest return are put at the top of the capital budget list.
Biological Systems: A Special Case
Up till now we have discussed various aspects of the separation and processing of fine solids without too much reference (except in the examples) to the specifics of the properties of the materials concerned. Though the material properties are the dominant influence on efficient process design and operation, it has been postulated that the necessary characteristics for process selection and optimization can be found fairly readily using easily-applicable rheological and other techniques. This underlying assumption also seems to hold good for biological suspensions; however, certain aspects of the behavior of these systems are sufficiently specialized for them to merit a separate discussion viz:
1 TYPES OF BIOLOGICAL SEPARATION
1.1 Whole-Organism Case
1.2 Part-Cell Separations
1.3 Isolation of Individual Molecular Species
2 SETTING ABOUT DEVISING AN EFFECTIVE
PROCESS FOR SEPARATION OF A BIOLOGICAL MATERIAL
2.1 Whole-Organism Case
2.1.1 Characterization of Biopolymers in the Liquor
2.1.2 Release of Internal Water
2.2 Part -Cell Separations
2.2.1 Selectivity
2.2.2 Cost
2.3 Isolation of Individual Molecular Species
3 Examples
3.1 Effective Design and Operation of a Process for Harvesting of Single Cell Protein
3.2 Harvesting of Mycoprotein for Human Consumption
3.3 Thickening of a Filamentous Organism Suspension
3.4 Separation of Poly-3-hydroxybutyrate Polymer (PHB) from Alcaligenes Eutrophus Biomass
3.5 Isolation of Organic Acid Produced by an Enzymatic Process
4 REFERENCES
Table
Figures
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.
Reactor Modeling Tools – Multiple Regressions
CONTENTS
0 INTRODUCTION
1 SCOPE
2 THEORY
3 EXCEL 2007: MULTIPLE REGRESSIONS
3.1 Overview
3.2 Multiple Regression Using the Data Analysis ADD-IN
3.3 Interpret Regression Statistics Table
3.4 Interpret ANOVA Table
3.5 Interpret Regression Coefficients Table
3.6 Confidence Intervals for Slope Coefficients
3.7 Test Hypothesis of Zero Slope Coefficients ("Test of Statistical Significance")
3.8 Test Hypothesis on a Regression Parameter
3.8.1 Using the p-value approach
3.8.2 Using the critical value approach
3.9 Overall Test of Significance of the Regression Parameters
3.10 Predicted Value of Y Given Regressors
3.11 Excel Limitations
4 SPECIAL FEATURES REQUIRING MORE SOPHISTICATED TECHNIQUES
5 USER INFORMATION SUPPLIED
A SUBROUTINE
B DATA
C RESULTS
6 EXAMPLE
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....
Low Temperature Shift Catalyst Reduction Procedure
VSG-C111 as supplied contains copper oxide; it is activated for the low temperature shift duty by reducing the copper oxide component to metallic copper with hydrogen. The reaction is highly exothermic. In order to achieve maximum activity, good performance and long life, it is essential that the reduction is conducted under correctly controlled conditions. Great care must be taken to avoid thermal damage during this critical operation.
Determination of Residue and Oil in Anhydrous AmmoniaGerard B. Hawkins
Plant Analytical Techniques
Determination of Residue and Oil in Anhydrous Ammonia
This method is suitable for the determination of residue and oil in anhydrous ammonia.
FIELD OF APPLICATION
This method may be applied to standard and premium grade anhydrous ammonia having residue content in the range 10-5000 micrograms per gram and oil content in the range l-500 micrograms per gram
TEMPERATURE MEASUREMENT:
RESISTANCE ELEMENTS AND THERMOCOUPLES
SPECIFICATION OF FUNCTION
DESCRIPTION OF FLUID
NORMAL OPERATING TEMPERATURE
REQUIRED TEMPERATURE RANGE
ALARM SETTINGS
TRIP SETTINGS
FLUID VELOCITY
REYNOLDS NUMBER
LINE SIZE
LINE REFERENCE
EQUIPMENT REFERENCE
NOZZLE SIZE
MINIMUM DESIGN PRESSURE
CORRESPONDING TEMPERATURE
MAXIMUM DESIGN PRESSURE
CORRESPONDING TEMPERATURE
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
"SEDIMENTATION"
INTRODUCTION - THE PHENOMENON OF SEDIMENTATION
Sedimentation is the physical process whereby solid particles, of greater density than their suspending medium, will tend to separate into regions of higher concentration under the influence of gravity. As a solids/liquids separation technique it therefore possesses the great advantage of utilizing a natural, and therefore costless, driving force. This section of the suspension processing Guide is Intended to provide an Introduction to the science of the subject, and the means to judge where and how best to exploit sedimentation as a separation (or other processing) technique.
As a scientific discipline the subject of sedimentation is vast with perspectives ranging from the field of chemical engineering through to theoretical physics being covered In the literature [1-11]. Good reviews of the subject, with a bias towards the engineering aspects, have been written by Fitch and Koz [12, 13]. A short summary of some of the more relevant contributions from the literature is also provided in GBHE-SPG-PEG-302 “Basic Principles & Test Methods”, of the Suspensions Processing Guides.
.
The sedimentation process is traditionally divided into ..."
Chemical Process Conception
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 PRODUCT STRATEGY
4.1 General
4.2 Market for the Product
4.3 Production Costs
4.4 Process Technology
5 PRELIMINARY PROCESS INFORMATION
6 REACTION AND REACTOR
6.1 Batch vs Continuous
6.2 Multiple Reactors
7 RECYCLE
7.1 Recycle Structure
7.2 Classification of Chemicals
7.3 Effect of Recycle
7.4 Preliminary Estimation of Conversion
8 REACTOR TYPE AND PERFORMANCE
8.1 Conversion-Yield Effects
8.2 Heat Effects
8.3 Equilibrium Effects
8.4 Kinetic Effects
8.5 More Help with Reactor Design
9 SEPARATION SYSTEM
10 REVIEW
11 BIBLIOGRAPHY AND REFERENCES
11.1 Preliminary Flowsheeting
11.2 Physical Properties
11.3 Reactors
11.4 Separation
11.5 Costing
APPENDICES
A BASIC REACTOR SYSTEM DESIGN
B DISCUSSION BETWEEN A CHEMIST AND A
CHEMICAL ENGINEER
C BASIC SEPARATION STRATEGY
TABLES
1 CLASSIFICATION OF MATERIALS
FIGURES
1 FLOWCHART OF THE ITERATIVE PROCEDURE REQUIRED IN PROCESS AND PRODUCT SELECTION AND DEVELOPMENT
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.
Determination of Residue on Evaporation in Anhydrous AmmoniaGerard B. Hawkins
Determination of Residue on Evaporation in Anhydrous Ammonia
1 SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of the residue left after evaporation i.e., the non-volatile material in ammonia solution.
2 PRINCIPLE
A known weight of sample is evaporated to dryness in a platinum dish on a steam bath. The increase in mass of the dish is measured.
Determination of Oxygen in Anhydrous Ammonia
SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of trace amounts of oxygen in Liquefied anhydrous ammonia.
The trace oxygen analyzer provides for trace oxygen analysis in decade steps ranging from 0 - 10 to 0 - 10,000 ppm v/v (full scale).
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
Catalytic Reforming technology - Infographics
IFP Fixed-bed Semi-regenerative Unit Revamps, Troubleshooting
IFP (CCR) Technology Optimization
In trying to determine the potential benefits from revamping a Fixed-bed Semi-Regenerative catalytic reformer, a refiner must evaluate several areas of operation:
— What is the unit operating objective?
— What degrees of freedom are available for revamp /optimization?
— Can refinery margins, and the discretionary capital budgeting program support the revamp / optimization?
Refiners must select the catalytic reformer operating point that will maximize profit within the following:
1) the mechanical constraints of the unit and
2) the short term unit operating objectives.
projects that improve operating profit are compared with the required capital investment.
This is done using discounted cash flow, or one of a number of other capital budgeting analysis tools, and those projects with the greatest return are put at the top of the capital budget list.
Biological Systems: A Special Case
Up till now we have discussed various aspects of the separation and processing of fine solids without too much reference (except in the examples) to the specifics of the properties of the materials concerned. Though the material properties are the dominant influence on efficient process design and operation, it has been postulated that the necessary characteristics for process selection and optimization can be found fairly readily using easily-applicable rheological and other techniques. This underlying assumption also seems to hold good for biological suspensions; however, certain aspects of the behavior of these systems are sufficiently specialized for them to merit a separate discussion viz:
1 TYPES OF BIOLOGICAL SEPARATION
1.1 Whole-Organism Case
1.2 Part-Cell Separations
1.3 Isolation of Individual Molecular Species
2 SETTING ABOUT DEVISING AN EFFECTIVE
PROCESS FOR SEPARATION OF A BIOLOGICAL MATERIAL
2.1 Whole-Organism Case
2.1.1 Characterization of Biopolymers in the Liquor
2.1.2 Release of Internal Water
2.2 Part -Cell Separations
2.2.1 Selectivity
2.2.2 Cost
2.3 Isolation of Individual Molecular Species
3 Examples
3.1 Effective Design and Operation of a Process for Harvesting of Single Cell Protein
3.2 Harvesting of Mycoprotein for Human Consumption
3.3 Thickening of a Filamentous Organism Suspension
3.4 Separation of Poly-3-hydroxybutyrate Polymer (PHB) from Alcaligenes Eutrophus Biomass
3.5 Isolation of Organic Acid Produced by an Enzymatic Process
4 REFERENCES
Table
Figures
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
(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
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
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.
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
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
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
Study 2: Front-End Engineering Design and Project DefinitionGerard B. Hawkins
Study 2: Front-End Engineering Design and Project Definition
CONTENTS
2.0 PURPOSE
2.0.1 Team
2.0.2 Timing
2.0.3 Documentation
HAZARD STUDY 2: APPLICATION
2.1 Study of Process and Non-Process Activities
2.2 Study of Programmable Electronic Systems (PES)
2.3 Risk Assessment
2.4 Defining the Basis for Safe Operation
2.5 Review of Hazard Study 2
APPENDICES
Appendix A Hazard Study 2 Method
A.1 Significant Hazards Flowsheet
A.2 Event Guide Diagram
A.3 Consequence Guide Diagram
A.4 Typical Measures to Reduce Consequences
Appendix B Programmable Electronic Systems (PES) Guide Diagram
Appendix C Risk Assessment
C.1 Risk Assessment Procedure
C.2 Risk Matrix
C.3 Risk Matrix Guidance for Consequence Categories – Safety and Health Incidents
C.4 Risk Matrix Guidance for Consequence Categories – Environmental Incidents
Appendix D Key Hazards and Control Measures
Appendix E Content of Hazard Study 2 Report Package.
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).
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
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
Air / Steam Regeneration Procedure for Primary Reforming CcatalystGerard B. Hawkins
VULCAN Series VSG-Z101 Primary Reforming
Air steam regeneration procedures can be used either on start-up of a reformer after it has cooled, or can be done in the shut down process.
AIR STEAM REGENERATION ON SHUT DOWN
AIR STEAM REGENERATION ON START-UP
VULCAN Series VSG-Z101 Primary Reforming
Initial Catalyst Reduction
Activating (reducing) the catalyst involves changing the nickel oxide to nickel, represented by:
NiO + H2 <==========> Ni + H2O
Natural gas is typically used as the hydrogen source. When it is, the catalyst reduction and putting the reformer on-line are accompanied in the same step.
Methanation catalysts are almost always manufactured and transported in the oxidized form, and therefore they must be reduced in the reactor to give nickel metal in order to make them active. The reduction is usually carried out in process gas and occurs by the two reactions:
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
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
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
Gas Mixing
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 RECOMMENDATIONS FOR GAS MIXING:
PLUG FLOW
5 RECOMMENDATIONS FOR GAS MIXING:
BACKMIXED INITIAL ZONE
6 BIBLIOGRAPHY
Psychrometry
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 PSYCHROMETRIC CHARTS
5 EXAMPLE CALCULATION
6 CHARTS FOR SPECIFIC SYSTEMS
7 BIBLIOGRAPHY
FIGURES
1 GROSVENOR CHART (Humidity vs. Temperature)
FOR AIR-WATER VAPOR AT 1.0133 bar
2 MOLLIER CHART (Enthalpy vs. Humidity) FOR
NITROGEN-TOLUENE VAPOR AT 100 kPa
Design and Operation of NHT Strippers to Protect Catalytic Reformers Gerard B. Hawkins
Common Reformer Problems
Purpose of NHT Stripper
Typical Design
Instrumentation of NHT Stripper
Other Design Issues
Indications of Problems in the NHT
Response to Reformer Upsets
Temperature excursions in hydrogenation reactors may have several causes, the most common ones being:-
i) Loss of recycle quench system. This could be either the liquid or gas stream. The condition is made worse if the make-up gas keeps flowing.
ii) Excessive temperatures. The loss of cooling medium ........
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
Fouling Resistances for Cooling Water
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 GENERAL
5 COOLING WATER FOULING
6 CHROMATE SYSTEMS
6.1 General
6.2 Constraints
6.3 Requirements
6.4 Fouling resistances
7 NON-CHROMATE SYSTEMS
7.1 General
7.2 Requirements and Constraints
7.3 Fouling resistances
8 UNTREATED COOLING WATER
9 MATERIALS OTHER THAN MILD STEEL
APPENDICES
A FOULING RESISTANCES FOR COOLING WATER
B FOULING FILM THICKNESS
Integration of Special Purpose Reciprocating Compressors into a ProcessGerard B. Hawkins
1 SCOPE
2 CHOICE OF COMPRESSOR TYPE
2.1 Parameters
2.2 Preliminary Choice of Machine Type
2.3 Review of Other Types of Compressor
3 CHOICE OF NUMBER OF COMPRESSORS
3.1 Influence of Reliability Classification
3.2 Driver Considerations
3.3 Deterioration of Standby Machines
4 EFFECTS OF PROCESS GAS COMPOSITION
4.1 Particulate Contamination
4.2 Droplets in Suspension
4.3 Polymer Deposit
4.4 Molecular Weight Variation
4.5 Compressibility Variation
4.6 Gas Dryness
4.7 Gas Solution in Lubricating Oil for Cylinder and Gland
5 THROUGHPUT REGULATION
5.1 Inlet Line Throttle Valve
5.2 Inlet Line Cut-off Valve
5.3 Compressor Inlet Valve Lifter
5.4 Clearance Volume Variation
5.5 Speed Variation
5.6 Bypass
5.7 Hybrid Regulation Systems
6 PRINCIPAL FEATURES
6.1 Calculate Discharge Gas Temperature
6.2 Choice of Number of Stages
6.3 Configuration
6.4 Valve Operation Limit on Piston Speed
6.5 Limits for Mean Piston Speed
6.6 Estimation of Volumetric Efficiency
6.7 Estimation of Crankshaft Rotational Speed
6.8 Calculation of Piston Diameter
6.9 Choice of Number of Cylinders
7 DRIVER TYPE
7.1 Electric Motors
7.2 Steam Turbines
7.3 Special Drivers
8 VESSELS
APPENDICES
A RELIABILITY CLASSIFICATION
B CONDITIONS FOR LUBRICATED CYLINDERS AND GLANDS
C ESTIMATE OF LUBE OIL CONTAMINATION OF PROCESS GAS
D INFLUENCE OF GAS COMPOSITION AND MACHINE CONSTRUCTION
ON FILLED PTFE PISTON RING SEALS
E LIMITS ON GAS TEMPERATURES
FIGURES
1 SELECTION CHART
2 DESIGN SEQUENCE 1 - ESTIMATE NUMBER OF STAGES
3 DESIGN SEQUENCE 2 - ESTIMATE CYLINDER SIZES
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.
Similar to Steam Reforming Catalyst Reduction with LPG Feed (20)
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
Ammonia Plant Technology
Pre-Commissioning Best Practices
GBHE-APT-0102
PICKLING & PASSIVATION
CONTENTS
1 PURPOSE OF THE WORK
2 CHEMICAL CONCEPT
3 TECHNICAL CONCEPT
4 WASTES & SAFETY CONCEPT
5 TARGET RESULTS
6 THE GENERAL CLEANING SEQUENCE MANAGEMENT
6.6.1 Pre-cleaning or “Physical Cleaning
6.6.2 Pre-rinsing
6.6.3 Chemical Cleaning
6.6.4 Critical Factors in Cleaning Success
6.6.5 Rinsing
6.6.6 Inspection and Re-Cleaning, if Necessary
7 Systems to be treated by Pickling/Passivation
EMERGENCY ISOLATION OF CHEMICAL PLANTS
CONTENTS
1 Introduction
2 When should Emergency Isolation Valves be Installed
3 Emergency Isolation Valves and Associated Equipment
3.1 Installations on existing plant
3.2 Actuators
3.3 Power to close or power to open
3.4 The need for testing
3.5 Hand operated Emergency Valves
3.6 The need to stop pumps in an emergency
3.7 Location of Operating Buttons
3.8 Use of control valves for Isolation
4 Detection of Leaks and Fires
5 Precautions during Maintenance
6 Training Operators to use Emergency Isolation Valves
7 Emergency Isolation when no remotely operated valve is available
References
Glossary
Appendix I Some Fires or Serious Escapes of Flammable Gases or Liquids that could have been controlled by Emergency Isolation Valves
Appendix II Some typical Installations
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
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
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
UiPath Test Automation using UiPath Test Suite series, part 3DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 3. In this session, we will cover desktop automation along with UI automation.
Topics covered:
UI automation Introduction,
UI automation Sample
Desktop automation flow
Pradeep Chinnala, Senior Consultant Automation Developer @WonderBotz and UiPath MVP
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
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
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.
State of ICS and IoT Cyber Threat Landscape Report 2024 previewPrayukth K V
The IoT and OT threat landscape report has been prepared by the Threat Research Team at Sectrio using data from Sectrio, cyber threat intelligence farming facilities spread across over 85 cities around the world. In addition, Sectrio also runs AI-based advanced threat and payload engagement facilities that serve as sinks to attract and engage sophisticated threat actors, and newer malware including new variants and latent threats that are at an earlier stage of development.
The latest edition of the OT/ICS and IoT security Threat Landscape Report 2024 also covers:
State of global ICS asset and network exposure
Sectoral targets and attacks as well as the cost of ransom
Global APT activity, AI usage, actor and tactic profiles, and implications
Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
Malware and malicious payload trends
Cyberattack types and targets
Vulnerability exploit attempts on CVEs
Attacks on counties – USA
Expansion of bot farms – how, where, and why
In-depth analysis of the cyber threat landscape across North America, South America, Europe, APAC, and the Middle East
Why are attacks on smart factories rising?
Cyber risk predictions
Axis of attacks – Europe
Systemic attacks in the Middle East
Download the full report from here:
https://sectrio.com/resources/ot-threat-landscape-reports/sectrio-releases-ot-ics-and-iot-security-threat-landscape-report-2024/
LF Energy Webinar: Electrical Grid Modelling and Simulation Through PowSyBl -...DanBrown980551
Do you want to learn how to model and simulate an electrical network from scratch in under an hour?
Then welcome to this PowSyBl workshop, hosted by Rte, the French Transmission System Operator (TSO)!
During the webinar, you will discover the PowSyBl ecosystem as well as handle and study an electrical network through an interactive Python notebook.
PowSyBl is an open source project hosted by LF Energy, which offers a comprehensive set of features for electrical grid modelling and simulation. Among other advanced features, PowSyBl provides:
- A fully editable and extendable library for grid component modelling;
- Visualization tools to display your network;
- Grid simulation tools, such as power flows, security analyses (with or without remedial actions) and sensitivity analyses;
The framework is mostly written in Java, with a Python binding so that Python developers can access PowSyBl functionalities as well.
What you will learn during the webinar:
- For beginners: discover PowSyBl's functionalities through a quick general presentation and the notebook, without needing any expert coding skills;
- For advanced developers: master the skills to efficiently apply PowSyBl functionalities to your real-world scenarios.
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.
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.
Neuro-symbolic is not enough, we need neuro-*semantic*Frank van Harmelen
Neuro-symbolic (NeSy) AI is on the rise. However, simply machine learning on just any symbolic structure is not sufficient to really harvest the gains of NeSy. These will only be gained when the symbolic structures have an actual semantics. I give an operational definition of semantics as “predictable inference”.
All of this illustrated with link prediction over knowledge graphs, but the argument is general.
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
Speakers:
👨🏫 Andras Palfi, Senior Product Manager, UiPath
👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
Generating a custom Ruby SDK for your web service or Rails API using Smithyg2nightmarescribd
Have you ever wanted a Ruby client API to communicate with your web service? Smithy is a protocol-agnostic language for defining services and SDKs. Smithy Ruby is an implementation of Smithy that generates a Ruby SDK using a Smithy model. In this talk, we will explore Smithy and Smithy Ruby to learn how to generate custom feature-rich SDKs that can communicate with any web service, such as a Rails JSON API.
Generating a custom Ruby SDK for your web service or Rails API using Smithy
Steam Reforming Catalyst Reduction with LPG Feed
1. GBH Enterprises, Ltd.
Steam Reforming Catalyst Reduction with
LPG Feed
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the Product for
its own particular purpose. GBHE gives no warranty as to the fitness of the
Product for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability for loss, damage or personnel injury
caused or resulting from reliance on this information. Freedom under Patent,
Copyright and Designs cannot be assumed.
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
2. 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.
Reduction Using LPG
The probability of success is greatly enhanced by increasing the care taken
during the reduction, over and above that used for hydrogen or natural gas
reduction. The operator must be confident that both steam and hydrocarbon flow
metering are properly calibrated and accurate during the reduction procedure as
one of the prevalent causes of inadvertent carbon formation during this
procedure arises from metering errors. It is therefore important that the
flowmeters be span checked and if possible calibrated for the conditions that will
be utilized during the catalyst reduction. All changes to feed rates and
temperatures should be carried out with extreme care. When increasing feed
rate, ensure that the steam rate is increased before the feed rate is increased.
Conversely when reducing feed rate, ensure that the feed rate is reduced before
the steam rate is reduced. Steam reformer operation must be extremely closely
monitored including very frequent visual inspection of the furnace including tube
appearance, flame stability and so forth.
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
3. 1.
Purge the plant free of oxygen using nitrogen, and heat the reformer
above the condensation temperature while still circulating nitrogen.
Steam may be added as soon as possible after the temperature of the
exit header is at least 50°C above the condensation temperature of
steam.
2.
The steam flow should be increased to approximately 50% of the design
rate (commensurate with plant design constraints) as soon as possible
to allow even firing of the furnace. During reduction of catalysts with LPG
operation at the correct steam ratio is critical. With too high a steam to
carbon ratio, the catalyst will not reduce whereas too low a steam to
carbon ratio will lead to carbon formation. During reduction, it is usual to
stay below design pressure to allow early introduction of steam without
condensation and to protect the tubes by providing an additional margin
against over temperature and hence failure. Therefore, the accuracy of
the steam flow meter must be verified for operation at approximately
50% of design rate and this lower pressure operation. The use of a
separate DP cell on the steam orifice calibrated for start-up conditions
may be considered.
3.
Nitrogen circulation may be stopped at any convenient time after steam
has been added and before LPG is introduced.
4.
Increase the reformer exit temperature to 750°C at an appropriate rate
dependent upon the allowable furnace heating rate. At all critical stages
during reduction it must be emphasized that the temperatures referred to
are those at the actual tube exit. Temperatures indicated by control room
instruments are inevitably lower than the true value because heat
losses. Allowance must be made for the discrepancy. Depending on
the location of the thermocouples, indicated values may be 25 -100°C
(45 – 180oF) lower than actual temperatures.
5.
Introduce the LPG feedstock at about 5% design rate. This will result in
a steam:carbon ratio of approximately 30:1. Increase the LPG feed rate
to 10% of design rate over a period of 1 hour. This will reduce the steam
to carbon ratio to approximately 15:1. At the same time, increase the
reformer exit temperature to the design level or 800oC (1472oF)
whichever is achieved first. The heat requirement in the furnace will
increase as the endothermic steam reforming reaction begins. As
catalyst reduction proceeds, the furnace firing should be trimmed to
maintain the necessary exit temperature.
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
4. The recycle hydrogen rate should be adjusted to give the recommended
hydrogen concentration for acceptable hydrodesulfurization as soon as
possible after feed has been introduced.
6.
Since at start up the LPG flow is very low (5% - 10% of design) the
accuracy of the flow meter should be verified at this low flow. The use of
a low range flow transmitter would decrease the risk of operating with
too high an LPG flow and low steam to carbon ratio. It should be noted
that when the LPG feedstock pumps are lined up and the discharge
pressure raised there may be a small leakage of LPG past the isolation
valves due to the high differential pressure. This may result in a
reduction in the reformer exit temperature as reforming reactions take
place. Small leaks are not likely to create carbon in the reformer due to
the very small leakage rates experienced but more serious leaks
introduce the possibility of severe carbon formation.
7.
Increase the LPG feed rate to give a steam to carbon ratio of 7:1. At a
steam flow of ~50% of design and a steam to carbon ratio of 7:1 this
corresponds to an LPG feed rate of approximately 20% of design.
8.
During catalyst reduction, the tube inlet temperature should be as high
as possible to promote maximum reduction at the inlet of the tubes.
9.
Hold the steam to carbon ratio at 7:1 for a period of approximately 12
hours, by which time the catalyst will be reduced. As the catalyst
reduces more LPG will be reformed. During this stage, the exit methane
and heavier hydrocarbons concentrations should be checked at hourly
intervals. Reduction should be complete when the exit methane
concentration reaches a low steady value and the presence of heavier
hydrocarbon cannot be detected.
At this point the reformer exit
temperature can be decreased to the design exit temperature, if a higher
temperature has been used to promote desulphurisation.
10. When the catalyst has been reduced, the LPG feedstock rate should be
increased slowly to the design steam ratio and flow rate. This should
take about 2-3 hours. Check the methane concentration in the reformer
exit gas after each change to ensure that it stays at a low steady value.
If the methane or heavier hydrocarbon concentration increases or the
tubes show hot zones, continue reduction for a further period at a steam
to carbon ratio of 7:1, before once again increasing the LPG flow to the
design steam to carbon ratio. When flow rates are being increased, it is
always important to increase the steam flow before the feed flow in order
to maintain the steam ratio at or above the design value.
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
5. 11. If the catalyst has not been fully reduced, the tubes may appear to be
hot. However, the catalyst should reach its fully reduced state after
approximately 24 hours normal operation. If this is not the case, it may
be necessary to stop the feed and restore reducing conditions for a few
hours.
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