Study 5: Pre-commissioning Safety Review
CONTENTS
5.0 PURPOSE
5.0.1 Team
5.0.2 Timing
5.0.3 Preparation
5.0.4 Documentation
HAZARD STUDY 5: APPLICATION
5.1 TOUR OF THE PROJECT
5.2 REVIEW OF HAZARD STUDY 5
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
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).
How to Use the GBHE Mixing Guides
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE MIXING GUIDES
4.1 Mixing Guides
4.2 GBHE Mixing and Agitation Manual
5 DEVICE SELECTION
6 MIXING QUESTIONNAIRE
6.1 What is being mixed?
6.2 Why is it being mixed?
6.3 How is it to be mixed?
6.4 Is Heat Transfer Important?
6.5 Is Mixing Time Important?
6.6 Is Inventory Important?
6.7 Is Subsequent Phase Separation Important?
6.8 What Quantities?
6.9 What are the Selection Criteria?
6.10 What Data are required?
7 BASICS
7.1 Bulk Movement
7.2 Shear and Elongation
7.3 Turbulent Diffusion
7.4 Molecular Diffusion
7.5 Mixing Mechanisms
APPENDICES
A ROTATING MIXING DEVICES
B MIXING DEVICES WITHOUT MOVING PARTS
GE / Texaco Gasifier Feed to a Lurgi Methanol Plant and its Effect on Methano...Gerard B. Hawkins
GE / Texaco Gasifier Feed to a Lurgi Methanol Plant and its Effect on Methanol Production
CONTENTS
0 Methanol Synthesis Introduction
1 Executive Summary
2 Design Basis
2.1.1 Train I Design Basis
2.1.2 Train II Design Basis
2.1.3 Train III Design Basis
2.2 Design Philosophy
2.2.1 Operability Review
2.3 Assumptions
2.4 Train IV Flowsheet
2.4.1 CO2 Removal
3 Discussion
3.1 Natural Gas Consumption Figures
3.1.1 Base Case
3.1.2 Case 1 – Coal Gasification in Service
3.1.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.2 Methanol Production Figures
3.2.1 Base Case
3.2.2 Case 1 – Coal Gasification in Service
3.2.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.3 85% Natural Gas Availability
3.4 100% Natural Gas Availability
3.5 CO2 Emissions
3.5.1 Base Case
3.5.2 Case 1 – Coal Gasification in Service
3.5.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.6 Specific Consumption Figures
3.6.1 Base Case
3.6.2 Case 1 – Coal Gasification and CO2 Import
3.6.3 Case 2 – Coal Gasification and No CO2 Import
3.7 Train IV Synthesis Gas Composition
4 Further Work
5 Conclusion
APPENDIX
Important Stream Data – Material Balance Stream Data
Texaco Gasifier with HP Steam Raising Boiler
CHARACTERISTICS OF COAL
Material Balance Considerations
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
Study 5: Pre-commissioning Safety Review
CONTENTS
5.0 PURPOSE
5.0.1 Team
5.0.2 Timing
5.0.3 Preparation
5.0.4 Documentation
HAZARD STUDY 5: APPLICATION
5.1 TOUR OF THE PROJECT
5.2 REVIEW OF HAZARD STUDY 5
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
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).
How to Use the GBHE Mixing Guides
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE MIXING GUIDES
4.1 Mixing Guides
4.2 GBHE Mixing and Agitation Manual
5 DEVICE SELECTION
6 MIXING QUESTIONNAIRE
6.1 What is being mixed?
6.2 Why is it being mixed?
6.3 How is it to be mixed?
6.4 Is Heat Transfer Important?
6.5 Is Mixing Time Important?
6.6 Is Inventory Important?
6.7 Is Subsequent Phase Separation Important?
6.8 What Quantities?
6.9 What are the Selection Criteria?
6.10 What Data are required?
7 BASICS
7.1 Bulk Movement
7.2 Shear and Elongation
7.3 Turbulent Diffusion
7.4 Molecular Diffusion
7.5 Mixing Mechanisms
APPENDICES
A ROTATING MIXING DEVICES
B MIXING DEVICES WITHOUT MOVING PARTS
GE / Texaco Gasifier Feed to a Lurgi Methanol Plant and its Effect on Methano...Gerard B. Hawkins
GE / Texaco Gasifier Feed to a Lurgi Methanol Plant and its Effect on Methanol Production
CONTENTS
0 Methanol Synthesis Introduction
1 Executive Summary
2 Design Basis
2.1.1 Train I Design Basis
2.1.2 Train II Design Basis
2.1.3 Train III Design Basis
2.2 Design Philosophy
2.2.1 Operability Review
2.3 Assumptions
2.4 Train IV Flowsheet
2.4.1 CO2 Removal
3 Discussion
3.1 Natural Gas Consumption Figures
3.1.1 Base Case
3.1.2 Case 1 – Coal Gasification in Service
3.1.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.2 Methanol Production Figures
3.2.1 Base Case
3.2.2 Case 1 – Coal Gasification in Service
3.2.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.3 85% Natural Gas Availability
3.4 100% Natural Gas Availability
3.5 CO2 Emissions
3.5.1 Base Case
3.5.2 Case 1 – Coal Gasification in Service
3.5.3 Case 2 – Coal Gasification in Service – No CO2 Export
3.6 Specific Consumption Figures
3.6.1 Base Case
3.6.2 Case 1 – Coal Gasification and CO2 Import
3.6.3 Case 2 – Coal Gasification and No CO2 Import
3.7 Train IV Synthesis Gas Composition
4 Further Work
5 Conclusion
APPENDIX
Important Stream Data – Material Balance Stream Data
Texaco Gasifier with HP Steam Raising Boiler
CHARACTERISTICS OF COAL
Material Balance Considerations
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
Application of Process to Management of Change and ModificationsGerard B. Hawkins
Application of Process to Management of Change and Modifications
Hazard Study Process: GBHE-PGP-006
CONTENTS
1.0 PURPOSE
1.1 THE NEED FOR MODIFICATIONS
1.2 GENERAL DESCRIPTION OF A MODIFICATION
1.3 PRINCIPLES TO BE FOLLOWED
1.4 REPLACEMENT OF ’LIKE WITH LIKE’
1.5 REMOTE / SMALLER SITES
1.6 GENERAL GUIDANCE TO INDIVIDUALS DOING SHE ASSESSMENTS FOR MODIFICATIONS
1.7 MODIFICATIONS HAZARD STUDY DECISION MECHANISM
1.7.1 Purpose
1.7.2 Methodology
FIGURE 1 MODIFICATION FLOWCHART
M1 Title, description, registration and process flowsheet
Gate 1 Preliminary authorization
Table 1 Difference between a Modification and a Project
M2 Risk Assessment
Gate 2 Approval
M3 Detailed design and implementation
Gate 3 Pre-Commissioning check
M4 Commissioning
Gate 4 Commissioned
M5 Final review and file
APPENDIX
APPENDIX A CHECKLIST FOR MODIFICATIONS
APPENDIX B DOCUMENTATION PROMPT LIST
APPENDIX C TYPICAL MODIFICATION FORM
G1 PRELIMINARY AUTHORIZATION
M2 PRELIMINARY SSHE ASSESSMENT
G2 REVIEW PRELIMINARY SSHE ASSESSMENT
M3 DESIGN and ESTIMATION
SSHE ASSESSMENT
G3 APPROVAL
M4 DETAILED DESIGN AND IMPLEMENTATION
G4 PRE-COMMISSIONING CHECK
M5 COMMISSIONING
G5 COMMISSIONED
M6 FINAL REVIEW AND FILE
Reactor Modeling Tools - An Overview
CONTENTS
1 SCOPE
2 OPTIONS IN REACTOR MODELING
2.1 General
2.2 Level of Complexity of Model
2.3 Mode of Operation of Model
2.4 Deterministic versus Empirical Modeling
2.5 Platforms for Model
2.6 Steady State versus Dynamic Model
2.7 Dimensions Modeled in Reactor
2.8 Scale of Modeling for Multiphase Reactors
2.9 Writing and Using the Model
APPENDICES
A CHARACTERISTICS OF DIFFERENT REACTOR MODELS
B NEEDS FOR MODELING AT DIFFERENT SCALES IN
HETEROGENEOUS CATALYTIC REACTORS
C REACTOR MODELS EMPLOYED WITHIN GBHE
DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE
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 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
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
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
Distillation Sequences, Complex Columns and Heat Integration
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 SEQUENCING OF SIMPLE COLUMNS
4.1 Sidestream Columns
4.2 Multi-Feed Columns
5 SIMPLE COLUMN SEQUENCING AND HEAT
INTEGRATION INTERACTIONS
5.1 Energy Quantity and Quality
5.2 Heat Integration within the Total Flowsheet
6 COMPLEX COLUMN ARRANGEMENTS
6.1 Indirect Sequence with Vapor Link
6.2 Sidestream Systems
6.3 Pre-Fractionator Systems
7 COMPLEX COLUMNS AND HEAT INTEGRATION
INTERACTIONS
FIGURES
1 DIRECT AND INDIRECT SEQUENCES
2 A SINGLE SIDESTREAM COLUMN REPLACING 2
SIMPLE COLUMNS
3 A TYPICAL MULTI-FEED COLUMN
4 TYPICAL GRAND COMPOSITION CURVE
5 TYPICAL INDIRECT SEQUENCE WITH VAPOUR LINK
6 SIDESTREAM STRIPPER AND SIDESTREAM
RECTIFIER
7 SIMPLEST PRE-FRACTIONATOR SYSTEM
8 SIMPLEST PRE-FRACTIONATOR SYSTEM
9 PETLYUK COLUMN
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.
Shortcut Methods of Distillation Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 ESTIMATIONOF PLATEAGE AND REFLUX
REQUIREMENTS
2.1 Generalized Procedure for Nmin and Rmin
2.2 Equation based Procedure for Nmin and Rmin
3 PREDICTION OF OVERALL PLATE EFFICIENCY
4 SIZING OF MAIN PLANT ITEMS
4.1 Column Diameter
4.2 Surface Area of Condensers and Reboilers
FIGURES
1 NON-IDEAL EQUILIBRIUM CURVE
2 AT A GLANCE CHART BASED ON FENSKE,
UNDERWOOD
3 PLATE EFFICIENCY CORRELATION OF O’CONNEL
Introduction to Hazard Studies
CONTENTS
1 INTRODUCTION
2 HAZARD EVALUATION TECHNIQUES
2.1 Hazard Identification and Control
2.2 Selection of Technique
2.3 GBHE Hazard Study Procedure
2.3.1 Study One – Concept stage hazard review
2.3.2 Study two - Front-end engineering design
and project definition
2.3.3 Study three – detailed design hazard study
2.3.4 Study four – construction/ design verification
2.3.5 Study five – pre-commissioning safety review
2.3.6 Study six – project close-out/ post start-up review
2.4 Application of Hazard Study Procedure
2.5 Outcomes from the Process
2.6 the Hazard Study Toolkit
2.7 Change Management/Modifications
3 HAZARD STUDY LEADER CAPABILITY AND APPOINTMENT
REFERENCES
APPENDICES
A THE PROJECT PROCESS
B GBHE HAZARD STUDY TOOLKIT
Carbon Formation in Mixed Feed Preheat Coils:
Maximum Mixed Feed Pre-heat Temperature
What follows is a crude but effective routine, which evaluates the maximum possible temperature allowable to prevent excessive carbon laydown in the mixed feed pre-heat coils.
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
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.
How to use the GBHE Reactor Technology Guides
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 THE DECISION TREE
6 GBHE REACTION ENGINEERING
7 GENERAL ASPECTS OF REACTOR TECHNOLOGY
7.1 Criteria of Reactor Performance
7.2 Factors of Economic Importance
7.3 Physicochemical Mechanisms
8 GENERAL GUIDE TO SELECTION OF REACTOR TYPE AND OPERATION
8.1 Choice of Reactor Type
8.2 Reaction Mechanism and Kinetics
8.3 Thermodynamics
8.4 Other Factors
9 GENERAL REFERENCES AND SOURCES OF
INFORMATION
APPENDICES
A RELATIONSHIP BEWTEEN DEFINED TERMS
FIGURES
1 DECISION TREE
2 RELATIVE YIELDS OF B FOR BATCH (OR PLUG FLOW) AND CST REACTORS
3 REACTOR SURVEY FORM
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainl...Gerard B. Hawkins
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainless Steels in Chloride and Caustic Environments
SYNOPSIS
This Maintenance Best Practice Guide is concerned with the performance of carbon and low alloy steels, and austenitic stainless steels, in chloride and caustic containing fluids. Those factors which are known to promote stress corrosion cracking are outlined, and service charts defining environmental boundaries for stress corrosion cracking in caustic and chloride containing fluids are presented.
General guidance on the avoidance of stress corrosion cracking is provided.
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:
Application of Process to Management of Change and ModificationsGerard B. Hawkins
Application of Process to Management of Change and Modifications
Hazard Study Process: GBHE-PGP-006
CONTENTS
1.0 PURPOSE
1.1 THE NEED FOR MODIFICATIONS
1.2 GENERAL DESCRIPTION OF A MODIFICATION
1.3 PRINCIPLES TO BE FOLLOWED
1.4 REPLACEMENT OF ’LIKE WITH LIKE’
1.5 REMOTE / SMALLER SITES
1.6 GENERAL GUIDANCE TO INDIVIDUALS DOING SHE ASSESSMENTS FOR MODIFICATIONS
1.7 MODIFICATIONS HAZARD STUDY DECISION MECHANISM
1.7.1 Purpose
1.7.2 Methodology
FIGURE 1 MODIFICATION FLOWCHART
M1 Title, description, registration and process flowsheet
Gate 1 Preliminary authorization
Table 1 Difference between a Modification and a Project
M2 Risk Assessment
Gate 2 Approval
M3 Detailed design and implementation
Gate 3 Pre-Commissioning check
M4 Commissioning
Gate 4 Commissioned
M5 Final review and file
APPENDIX
APPENDIX A CHECKLIST FOR MODIFICATIONS
APPENDIX B DOCUMENTATION PROMPT LIST
APPENDIX C TYPICAL MODIFICATION FORM
G1 PRELIMINARY AUTHORIZATION
M2 PRELIMINARY SSHE ASSESSMENT
G2 REVIEW PRELIMINARY SSHE ASSESSMENT
M3 DESIGN and ESTIMATION
SSHE ASSESSMENT
G3 APPROVAL
M4 DETAILED DESIGN AND IMPLEMENTATION
G4 PRE-COMMISSIONING CHECK
M5 COMMISSIONING
G5 COMMISSIONED
M6 FINAL REVIEW AND FILE
Reactor Modeling Tools - An Overview
CONTENTS
1 SCOPE
2 OPTIONS IN REACTOR MODELING
2.1 General
2.2 Level of Complexity of Model
2.3 Mode of Operation of Model
2.4 Deterministic versus Empirical Modeling
2.5 Platforms for Model
2.6 Steady State versus Dynamic Model
2.7 Dimensions Modeled in Reactor
2.8 Scale of Modeling for Multiphase Reactors
2.9 Writing and Using the Model
APPENDICES
A CHARACTERISTICS OF DIFFERENT REACTOR MODELS
B NEEDS FOR MODELING AT DIFFERENT SCALES IN
HETEROGENEOUS CATALYTIC REACTORS
C REACTOR MODELS EMPLOYED WITHIN GBHE
DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE
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 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
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
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
Distillation Sequences, Complex Columns and Heat Integration
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 SEQUENCING OF SIMPLE COLUMNS
4.1 Sidestream Columns
4.2 Multi-Feed Columns
5 SIMPLE COLUMN SEQUENCING AND HEAT
INTEGRATION INTERACTIONS
5.1 Energy Quantity and Quality
5.2 Heat Integration within the Total Flowsheet
6 COMPLEX COLUMN ARRANGEMENTS
6.1 Indirect Sequence with Vapor Link
6.2 Sidestream Systems
6.3 Pre-Fractionator Systems
7 COMPLEX COLUMNS AND HEAT INTEGRATION
INTERACTIONS
FIGURES
1 DIRECT AND INDIRECT SEQUENCES
2 A SINGLE SIDESTREAM COLUMN REPLACING 2
SIMPLE COLUMNS
3 A TYPICAL MULTI-FEED COLUMN
4 TYPICAL GRAND COMPOSITION CURVE
5 TYPICAL INDIRECT SEQUENCE WITH VAPOUR LINK
6 SIDESTREAM STRIPPER AND SIDESTREAM
RECTIFIER
7 SIMPLEST PRE-FRACTIONATOR SYSTEM
8 SIMPLEST PRE-FRACTIONATOR SYSTEM
9 PETLYUK COLUMN
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.
Shortcut Methods of Distillation Design
0 INTRODUCTION/PURPOSE
1 SCOPE
2 ESTIMATIONOF PLATEAGE AND REFLUX
REQUIREMENTS
2.1 Generalized Procedure for Nmin and Rmin
2.2 Equation based Procedure for Nmin and Rmin
3 PREDICTION OF OVERALL PLATE EFFICIENCY
4 SIZING OF MAIN PLANT ITEMS
4.1 Column Diameter
4.2 Surface Area of Condensers and Reboilers
FIGURES
1 NON-IDEAL EQUILIBRIUM CURVE
2 AT A GLANCE CHART BASED ON FENSKE,
UNDERWOOD
3 PLATE EFFICIENCY CORRELATION OF O’CONNEL
Introduction to Hazard Studies
CONTENTS
1 INTRODUCTION
2 HAZARD EVALUATION TECHNIQUES
2.1 Hazard Identification and Control
2.2 Selection of Technique
2.3 GBHE Hazard Study Procedure
2.3.1 Study One – Concept stage hazard review
2.3.2 Study two - Front-end engineering design
and project definition
2.3.3 Study three – detailed design hazard study
2.3.4 Study four – construction/ design verification
2.3.5 Study five – pre-commissioning safety review
2.3.6 Study six – project close-out/ post start-up review
2.4 Application of Hazard Study Procedure
2.5 Outcomes from the Process
2.6 the Hazard Study Toolkit
2.7 Change Management/Modifications
3 HAZARD STUDY LEADER CAPABILITY AND APPOINTMENT
REFERENCES
APPENDICES
A THE PROJECT PROCESS
B GBHE HAZARD STUDY TOOLKIT
Carbon Formation in Mixed Feed Preheat Coils:
Maximum Mixed Feed Pre-heat Temperature
What follows is a crude but effective routine, which evaluates the maximum possible temperature allowable to prevent excessive carbon laydown in the mixed feed pre-heat coils.
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
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.
How to use the GBHE Reactor Technology Guides
0 INTRODUCTION / PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND
5 THE DECISION TREE
6 GBHE REACTION ENGINEERING
7 GENERAL ASPECTS OF REACTOR TECHNOLOGY
7.1 Criteria of Reactor Performance
7.2 Factors of Economic Importance
7.3 Physicochemical Mechanisms
8 GENERAL GUIDE TO SELECTION OF REACTOR TYPE AND OPERATION
8.1 Choice of Reactor Type
8.2 Reaction Mechanism and Kinetics
8.3 Thermodynamics
8.4 Other Factors
9 GENERAL REFERENCES AND SOURCES OF
INFORMATION
APPENDICES
A RELATIONSHIP BEWTEEN DEFINED TERMS
FIGURES
1 DECISION TREE
2 RELATIVE YIELDS OF B FOR BATCH (OR PLUG FLOW) AND CST REACTORS
3 REACTOR SURVEY FORM
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainl...Gerard B. Hawkins
Avoiding Stress Corrosion Cracking of Carbon Low Alloy and Austenitic Stainless Steels in Chloride and Caustic Environments
SYNOPSIS
This Maintenance Best Practice Guide is concerned with the performance of carbon and low alloy steels, and austenitic stainless steels, in chloride and caustic containing fluids. Those factors which are known to promote stress corrosion cracking are outlined, and service charts defining environmental boundaries for stress corrosion cracking in caustic and chloride containing fluids are presented.
General guidance on the avoidance of stress corrosion cracking is provided.
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:
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
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
A Kinetic Model of Methanol Formation Over LTS CatalystsGerard B. Hawkins
Impact of by-product methanol
Catalyst chemistry and methanol formation
Factors affecting by-product methanol formation
Development process for the kinetic model
Conclusions
Nichols is the editor/associate publisher of Hydrocarbon Processing magazine. At present, he manages all content and business development for Hydrocarbon Processing, as well as data/content for Gulf Publishing Company’s Data Division. This includes all data content for Hydrocarbon Processing’s Construction Boxscore Database, annual Market Data Book and US Gas Plant Directory.
Study 1: Concept Hazard Review
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZARD STUDY 1: APPLICATION
1.1 Project Definition
1.2 Process Description
1.3 Materials Hazards
1.4 External Authorities
1.5 Organization and Human Factors
1.6 Additional Activities to be Completed
1.7 Review of Hazard Study 1
APPENDICES
A Chemical Hazard Guide Diagram
B Safety Risk Criteria - Limit Values for Tolerable Risk
C List of Additional Assessments
HAZCON / HAZDEM
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZCON / HAZDEM: APPLICATION
1.1 SPECIFICATION OF THE WORK
a) HAZCON
b) HAZDEM
1.2 METHOD STATEMENT
1.3 HAZCON STUDY
1.4 HAZDEM STUDY
1.5 MONITORING OF ACTIVITIES
1.6 REVIEW OF HAZARD STUDY
Fixed Bed Reactor Scale-up Checklist
The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked.
The checking can be done using various methods. These are:
• Literature data.
• Lab testing.
• Calculation.
• Modeling.
• Semi-tech testing.
• Piloting or Sidestream testing.
Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor
Pressure Systems
CONTENTS
0 INTRODUCTION
1 SCOPE
2 DEFINITIONS ADDITIONAL TO THOSE IN THE EP GLOSSARY
2.1 PRESSURE VESSEL
2.2 ATMOSPHERIC PRESSURE STORAGE TANK
2.3 VESSEL
2.4 PIPING SYSTEM
2.5 NON-PRESSURE PROTECTIVE DEVICE
2.6 ASSOCIATED RELIEF EQUIPMENT
3 APPLICATION OF PRINCIPLES
3.1 IMPLEMENTATION OF PEG 4
3.2 DESIGN, MANUFACTURE, REPAIR AND MODIFICATION
3.3 VERIFICATION OF DESIGN
3.4 GBHE REGISTRATION AND RECORDS
3.5 PERIODIC EXAMINATION
4 AUDITING
4.1 General
4.2 Scope of Audit
APPENDICES
A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION
C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT
D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT
E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES
F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS
G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION
TABLES
1 REGISTERED VESSELS AND PIPING SYSTEMS: MAXIMUM EXAMINATION INTERVALS
2 EQUIPMENT TO BE CONSIDERED FOR CATEGORY LLT
FIGURES
1 SIMPLE PRESSURE RELIEF ARRANGEMENT
2 COMPLEX PRESSURE RELIEF ARRANGEMENT
DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS DOCUMENT
SYNOPSIS
The principles underlying centrifugal separation of particulate species are briefly considered, and the main types of separator available are noted. The procedures available for scale-up from laboratory or semi-technical data are then discussed in detail with particular reference to perhaps the most important class of machine for fine particle processing: the disc-nozzle centrifuge.
Starting with the basic concepts behind their design, discussion follows to explain the factors which may limit centrifuge performance. It is shown how a few simple; laboratory scale tests can give a valuable insight into the design and operation of full-scale industrial machines.
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.
VLE Data - Selection and Use
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 DIAGRAMMATIC REPRESENTATION OF IDEAL
AND NON-IDEAL SYSTEMS
4.1 Ideal Mixtures
4.2 Non-Ideal Mixtures
5 REVIEW OF VLE MODELS
5.1 Ideal Behavior in Both Phases
5.2 Liquid Phase Non-Idealities
5.3 High Pressure Systems
5.4 Special Models
6 SETTING UP A VLE MODEL
6.1 Define Problem
6.2 Select Data
6.3 Select Correlation(s)
6.4 Produce Model
7 AVOIDING PITFALLS
7.1 Experimental Data is Better than Estimates
7.2 Check Validity of Fitted Model
7.3 Check Limitations of Estimation Methods
7.4 Know Your System
7.5 Appreciate Errors and Effects
7.6 If in Doubt – Ask
8 A CASE STUDY
8.1 The Problem
8.2 The System
8.3 Data Available
8.4 Selected Correlation
8.5 Simulation
8.6 Selection of Model
9 RECOMMENDED READING
10 VLE EXPERTS IN GBHE
APPENDICES
A USE OF EXTENDED ANTOINE EQUATION
B USE OF WILSON EQUATION
C USEFUL METHODS OF ESTIMATING
D EQUATIONS OF STATE FOR VLE CALCULATIONS
TABLES
1 SUMMARY OF VLE METHODS
2 LIST OF USEFUL REFERENCES
FIGURES
1 VAPOR-LIQUID EQUILIBRIUM - IDEAL SOLUTION
BEHAVIOR
2 VAPOR-LIQUID EQUILIBRIUM - A GENERALISED
Y-X DIAGRAM
3 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE
4 VAPOR-LIQUID EQUILIBRIUM - MAXIMUM BOILING
AZEOTROPE
5 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING
AZEOTROPE -TWO LIQUID PHASES
6 SENSITIVITY TO ERROR IN VLE DATA (BASED ON FENSKE EQUATION)
7(a) FITTING WILSON 'A' VALUES TO VLE DATA - CASE A
7(b) FITTING WILSON 'A' VALUES TO VLE DATA - CASE B
7(c) FITTING WILSON 'A' VALUES TO VLE DATA - CASE C
The Preliminary Choice of Fan or Compressor
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 METHOD FOR PRELIMINARY SELECTION
OF COMPRESSOR
5 PROCESS DATA SHEET
5.1 Essential Data for the Completion of a
Process Data Sheet
5.2 Gas Properties
5.3 Discharge Requirements
6 PRELIMINARY CHOICE OF FAN AND
COMPRESSOR TYPE
6.1 Essential Data for Preliminary Selection
7 FAN AND COMPRESSOR APPLICATIONS
7.1 Fans
7.2 Centrifugal Compressors
7.3 Axial Compressors
7.4 Reciprocating Compressors
7.5 Screw Compressors
7.6 Positive Displacement Blowers
7.7 Sliding Vane Compressors
7.8 Liquid Ring Compressors
8 PROVISION OF INSTALLED SPARES
9 PRELIMINARY ESTIMATE OF COSTS
Design and Simulation of Continuous Distillation ColumnsGerard B. Hawkins
Design and Simulation of Continuous Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FRACTIONAL DISTILLATION
5 ROUGH METHOD OF COLUMN DESIGN
5.1 Sharp Separations
5.2 Sloppy Separations
6 DETAIL DESIGN USING THE CHEMCAD DISTILLATION PROGRAM
6.1 Sharp Separations
6.2 Sloppy Separations
7 COMPLEX COLUMNS
7.1 Multiple Feeds
7.2 Sidestream Take-Offs
8 DESIGN USING A LABORATORY COLUMN
SIMULATION
9 DESIGN USING ACTUAL PLANT DATA
9.1 Uprating or Debottlenecking Exercises
10 REFERENCES
APPENDICES
A WORKED EXAMPLE
B SLOPPY SEPARATIONS
C SIMULATION USING PLANT DATA : CASE HISTORIES
TABLES
Fluid Separation
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 A SEPARATION LOGIC TREE
5 METHODS OF DISTILLATION
5.1 Fractional Distillation
5.2 Azeotropic Distillation
5.3 Extractive Distillation
6 LIQUID-LIQUID EXTRACTION
7 OTHER COMMERCIAL METHODS OF SEPARATION
7.1 Adsorption
7.2 Fractional Crystallization
7.3 Ion Exchange
7.4 Membrane Processes
7.4.1 Ultrafiltration
7.4.2 Reverse Osmosis
7.4.3 Pervaporation
7.4.4 Liquid Membranes
7.4.5 Gas Permeation
7.4.6 Dialysis
7.4.7 Electrodialysis
7.5 Supercritical Fluid Extraction
7.6 Dissociation Extraction
7.7 Foam Fractionation
7.8 Clathration
7.9 Chromatography
8. OTHER METHODS OF SEPARATION
8.1 Precipitation
8.2 Paper Chromatography
8.3 Ligand Specific Chromatography
8.4 Electrophoresis
8.5 Isoelectric Focusing
8.6 Thermal Diffusion
8.7 Sedimentation Ultracentrifugation
8.8 Isopycnic Ultracentrifugation
8.9 Molecular Distillation
8.10 Gel Filtration
APPENDICES
A AT A GLANCE CHART BASED ON FENSKE, UNDERWOOD
B A GENERALIZED y - x DIAGRAM
C TEMPERATURE - COMPOSITION DIAGRAMS FOR
AZEOTROPIC MIXTURES
D A TYPICAL y - x DIAGRAM FOR EXTRACTIVE DISTILLATION (SOLVENT FREE BASIS)
E RAPID ESTIMATION OF LIQUID-LIQUID EXTRACTION REQUIREMENTS
F LIQUID - LIQUID EXTRACTION - THE USE OF EXTRACT REFLUX
G SELECTIVITIES REQUIRED FOR EQUAL PLANT COSTS
FIGURE
1 SEPARATION LOGIC TREE
Troubleshooting in Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FLOW DIAGRAM FOR TROUBLESHOOTING
5 GENERAL APPRAISAL OF PROBLEM
5.1 Is the Problem Real?
5.2 What Is the Magnitude of the Problem?
5.3 Is it the Column or the Associated Equipment which is Causing the Problem?
6 PROBLEMS IN THE COLUMN
6.1 Capacity Problems
6.2 Efficiency Problems
7 PROBLEMS OUTSIDE THE COLUMN
7.1 Effect of Other Units on Column Performance
7.2 Column Control System
7.3 Improper Operating Conditions
7.4 Auxiliary Equipment
8 USEFUL BACKGROUND READING
9 BIBLIOGRAPHY
FIGURES
1 FLOW DIAGRAM FOR TROUBLESHOOTING
2 DETERMINATION OF COLUMN CAPACITY
Filtration
0 INTRODUCTION
1 The Theory Underlying Filtration Processes
1.1 The Mechanism of Simple Filtration Systems
1.1.2 Cake Filtration
1.1.3 Complete Blocking
1.1.4 Standard Blocking
1.1.5 Intermediate Blocking
1.2 Cake Filtration – Models and Mechanisms
1.2.1 Classical Theory for the Permeability of Porous Cakes and Beds
1.2.2 The Rate of Filtration through a Compressible Cake – The Standard Filtration Equation
1.2.3 The Compression or Consolidation of Filter Cakes – Ultimate degree of dewatering
1.2.4 The Rate of Consolidation
1.2.5 Useful Semi-Empirical Relations for Constant Pressure and Constant Rate Cake Filtration
1.2.6 Constant Pressure Filtration
1.2.7 Constant Rate Filtration
1.2.8 Multiphase Theory of Filtration
1.3 Crossflow Filtration
2 The Range and Selection of Filtration Equipment Technology
2.1 Scale
2.2 Solids Recovery, Liquids Clarification or Feed stream Concentration
2.3 Rate of Sedimentation
2.4 Rate of Cake Formation and Drainage
2.5 Batch vs Continuous Operation
2.6 Solids Loading
2.7 Further Processing
2.8 Aseptic or “Hygienic” Operation
2.9 Miscellaneous
2.10 Shear versus Compressional Deformation
2.11 Pressure versus Vacuum
3 Suspension Conditioning Prior to Filtration
3.1 Simple Filtration Aids
3.2 Mechanical Treatments
4 Post-Filtration Treatments and Further Downstream Processing
4.1 Washing
4.1.1 Air-Blowing
4.1.2 Drying
5 Testing and Characterization of Suspensions
5.1 Introduction – Suspension
5.2 Properties relevant to Filtration Performance
5.2.1 Pre-Filtration Properties of Suspension
5.2.2 Properties of Filter Cake
5.2.3 Laboratory Scale Filtration Rigs
5.3 Means of Monitoring Flocculant Dosage
5.4 Filter Cake Testing
5.4.1 Strength Testing (See also piston press described earlier)
5.4.2 Cake Permeability or Resistance
5.4.3 Rate of Cake Formation
6 Examples of the Application of the Forgoing Principles
6.1 Dewatering of Calcium Carbonate Slurries
6.2 Dewatering of Organic Products – Procion Dyestuffs
6.3 Filtration of Biological Systems – Harvesting a Filamentous Organism
References
Tables
Figures
Batch Distillation
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 BACKGROUND TO THE DESIGN
4.1 General
4.2 Choice of batch/continuous operation
4.3 Boiling point curve and cut policy
4.4 Method of design
4.5 Scope of calculations required for design
5 SIMPLE BATCH DISTILLATION
6 FRACTIONAL BATCH DISTILLATION
6.1 General
6.2 Approximate methods
6.3 Rigorous design - use of a computer model
6.4 Other factors influencing the design
6.4.1 Occupation
6.4.2 Choice of Batch Rectification or Stripping
6.4.3 Batch size
6.4.4 Initial estimate of cut policy
6.4.5 Liquid Holdup
6.4.6 Total reflux operation and heating-up time
6.4.7 Column operating pressure
6.5 Optimum Design of the Batch Still
6.6 Special design problems
7 GENERAL ASPECTS OF EQUIPMENT DESIGN
7.1 Kettle reboilers
7.2 Column Internals
7.3 Condensers and reflux split boxes
8 PROCESS CONTROL AND INSTRUMENTATION IN
BATCH DISTILLATION
9 MECHANICAL DESIGN FEATURES
10 BIBLIOGRAPHY
APPENDICES
A McCABE - THIELE METHOD - TYPICAL EXAMPLE
Similar to Study 4: Construction / Design Verification (20)
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
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
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
Burner Design, Operation and Maintenance on Ammonia PlantsGerard B. Hawkins
Burner Design, Operation and Maintenance on Ammonia Plants
Brief History
Reformer Burner Types/Design
Types of Reformers
Combustion Characteristics
Excess Air/Heater Efficiency
Maintenance, Good Practice
Low Nox Equipment
Summary
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...Gerard B. Hawkins
Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates
1 Executive Summary
2 Claus Process
2.1 Partial Combustion Claus
2.2 Split Flow Claus
2.3 Sulfur Recycle Claus
3 Zinc Titanates
4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10%
4.1 Process
4.2 ASPEN Modeling Results
4.3 Cost of Zinc Titanate Bed Installation
4.3.1 Basis of Costing
4.3.2 Zinc Titanate Beds
4.3.3 Regen Cooler
4.3.4 Blowers
4.3.5 Results
4.4 Alternative Debottlenecking Technology for Partial Combustion Claus
4.5 Cost of 10% Debottlenecking Using COPE Process
5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates
6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate
7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems
7.1 Selectox
7.2 SuperClaus99
7.3 Superclaus 99.5
7.4 SCOT Process
7.5 Zinc Titanate as a Claus Tail Gas Treatment
7.6 H2S Removal Efficiency With Zinc Titanate
8 Effects on COS and CS2 Formation
9 Questions for further Investigation
FIGURES
Figure 1 Claus Unit and TGCU
Figure 2 Claus Process
Figure 3 Typical Claus Sulfur Recovery Unit
Figure 4 Two-Stage Claus SRU
Figure 5 The Super Claus Process
Figure 6 SCOT
Figure 7 SCOT/BSR-MDEA (or clone) TGCU
REFERENCES: PATENTS
US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT
US4394297_ZINC_TITANATE_CATALYST
US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS
The Art of the Pitch: WordPress Relationships and SalesLaura Byrne
Clients don’t know what they don’t know. What web solutions are right for them? How does WordPress come into the picture? How do you make sure you understand scope and timeline? What do you do if sometime changes?
All these questions and more will be explored as we talk about matching clients’ needs with what your agency offers without pulling teeth or pulling your hair out. Practical tips, and strategies for successful relationship building that leads to closing the deal.
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.
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
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:
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👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
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.
JMeter webinar - integration with InfluxDB and GrafanaRTTS
Watch this recorded webinar about real-time monitoring of application performance. See how to integrate Apache JMeter, the open-source leader in performance testing, with InfluxDB, the open-source time-series database, and Grafana, the open-source analytics and visualization application.
In this webinar, we will review the benefits of leveraging InfluxDB and Grafana when executing load tests and demonstrate how these tools are used to visualize performance metrics.
Length: 30 minutes
Session Overview
-------------------------------------------
During this webinar, we will cover the following topics while demonstrating the integrations of JMeter, InfluxDB and Grafana:
- What out-of-the-box solutions are available for real-time monitoring JMeter tests?
- What are the benefits of integrating InfluxDB and Grafana into the load testing stack?
- Which features are provided by Grafana?
- Demonstration of InfluxDB and Grafana using a practice web application
To view the webinar recording, go to:
https://www.rttsweb.com/jmeter-integration-webinar
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.
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Keynote at DIGIT West Expo, Glasgow on 29 May 2024.
Cheryl Hung, ochery.com
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Learn about:
• The Future of Testing: How AI is shifting testing towards verification, analysis, and higher-level skills, while reducing repetitive tasks.
• Test Automation: How AI-powered test case generation, optimization, and self-healing tests are making testing more efficient and effective.
• Visual Testing: Explore the emerging capabilities of AI in visual testing and how it's set to revolutionize UI verification.
• Inflectra's AI Solutions: See demonstrations of Inflectra's cutting-edge AI tools like the ChatGPT plugin and Azure Open AI platform, designed to streamline your testing process.
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This video focuses on the notifications, alerts, and approval requests using Slack for Bonterra Impact Management. The solutions covered in this webinar can also be deployed for Microsoft Teams.
Interested in deploying notification automations for Bonterra Impact Management? Contact us at sales@sidekicksolutionsllc.com to discuss next steps.
Slack (or Teams) Automation for Bonterra Impact Management (fka Social Soluti...
Study 4: Construction / Design Verification
1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBH Enterprises, Ltd.
Process Safety Guide:
GBHE-PSG-HST-050
Study 4: Construction / Design
Verification
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.
2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Process Safety Guide: Study 4: Construction / Design Verification
CONTENTS
4.0 PURPOSE
4.0.1 Team
4.0.2 Timing
4.0.3 Documentation
HAZARD STUDY 4: APPLICATION
4.1 METHOD
4.1.1 Installation Check
4.1.2 Implementation Check
4.1.3 Modification Check
4.2 REVIEW OF HAZARD STUDY 4
3. 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
4.0 PURPOSE
The purpose of Hazard Study 4 is to check that the project has been constructed
as the design intended, that actions from previous Hazard Studies have been
completed and implemented in the design and installation, that detailed
implementation of the project meets regulatory and company requirements.
This document should be used in conjunction with a process safety publication
such as ’HAZOP: Guide to best practice’ (available from IChemE) or ‘Guidelines
for Hazard Evaluation Procedures’ (available from CCPS).
4.0.1 Team
The Commissioning Manager is responsible for the completion of study 4
with or without the assistance of site or project resources as appropriate.
4.0.2 Timing
Hazard Study 4 should be completed prior to the introduction of process
materials, or the commencement of operations, whichever is the sooner.
4. 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
While study 4 cannot be finished until the plant is mechanically complete,
it can be started almost immediately after the completion of study 3 with
the closing out of Hazard Study Actions. Regular visits to the plant during
construction can surface concerns at a time when they can be addressed
with the least possible impact on the schedule.
4.0.3 Documentation
The Commissioning Manager should arrange for the addition of relevant
documents to the Project SSHE dossier (worksheet j). A list of outstanding
actions should be produced and added to the dossier.
HAZARD STUDY 4: APPLICATION
The following sections 4.1 and 4.2 describe how to conduct Hazard Study 4.
4.1 METHOD
This study will require many actions to be carried out by a number of people, all
coordinated by the Commissioning Manager, and will not normally involve many
formal meetings. Use of the Hazard Study 4 worksheet (worksheet r) will help the
Commissioning Manager ensure that a thorough check of the installation is
achieved.
5. 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
4.1.1 Installation Check
Check that the hardware is as the design intended and that the software
requirements are completed.
4.1.2 Implementation Check
Check that what was called for in earlier hazard studies and engineering
change orders has been implemented.
4.1.3 Modification Check
Check that modifications made during construction/commissioning have
been formally reviewed and documented.
4.2 REVIEW OF HAZARD STUDY 4
At the completion of Hazard Study 4 the following key activities should have been
completed:
• Actions from earlier hazard studies have been completed either as agreed
or that any changes to the actions are justified.
• All actions and changes have been documented.
• Changes made following Hazard Study 3 have been studied and
recorded.
• Operating instructions are available for normal operation, start-up, planned
and emergency shutdowns and, where appropriate, for maintenance and
decontamination of plant.
• Emergency procedures are available.
• A review of the arrangements for the protection of employee health,
covering the facilities provided and the arrangements for workplace
monitoring.
6. 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
• A review of the arrangements, including emergency systems, for
employee safety.
• A review of the equipment and systems provided to protect the
environment and for monitoring environmental performance.