Carbon Formation in Mixed Feed Preheat Coils

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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.

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GBH Enterprises, Ltd.

Engineering Design Guide
Carbon Formation in Mixed Feed Preheat
Coils

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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 coil.
The method assumes that 100% CH4 mixed with steam (S/C =3) could in theory
be heated-up with steam to 645oC. As heavier hydrocarbons are added, this
temperature will fall. As hydrogen is added, or S/C increased, the temperature
can increase. A table of indices for the calculation is as follows:

Component
C1
C2
C3
C4
C5
C6
C7
C8
H2
N2, CO, CO2 etc
S/C (molar)

Index
[X]
0.05
1.2
1.5
1.7
1.55
1.65
1.75
1.8
-0.5
0
10

Each component composition in the feed (mol %) is then multiplied by the
respective index number [X] and totalled. The S/C ratio correction is then
calculated by subtracting the S/C ratio from 3 and multiplied by the index number
[X = 10]. The total summation of these numbers is then subtracted from 650oC to
yield the maximum allowable pre-heat temperature.

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Web Site: www.GBHEnterprises.com

Example 1 (NG)
NG composition......
C1
86.0 mol %
C2
6.6 mol %
C3
3.6 mol %
C4
1.5 mol %
C5
0.4 mol %
H2
2.0 mol %
N2
1.0 mol %
S/C ratio

3.3

So maximum pre-heat temperature
= 650 - [(86 x 0.05) + (5.5 x 1.2) + (3.6 x 1.5) + (1.5 x 1.7) + (0.4 x 1.55) +
(2 x -0.5) + (3 - 3.3)x10]
= 632oC
Example 2 (LPG)
LPG composition......
C3
0.47 mol %
C4
83.52 mol %
C5
0.35 mol %
H2
15.66 mol %
S/C ratio

3.3

So maximum pre-heat temperature
= 650 - [(0.47 x 1.5) + (83.52 x 1.7) + (0.35 x 1.55) + (15.66 x -0.5) +
(3 - 3.3)x10]
= 518oC

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
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Note: This approach takes no account of pre-heat coil positioning, size,
counter/co-current etc. notwithstanding the other approximations.
However, even a crude approach may help in recommending maximum pre-heat
temperatures.

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
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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

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Fugitive Emissions

Gerard B. Hawkins

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

Biological Systems - A Special Case

Gerard B. Hawkins

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

Reactor Modeling Tools – Multiple Regressions

Gerard B. Hawkins

Quality of Life Correlates to Oil Consumption - Infographic

Gerard 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

Integration of Special Purpose Centrifugal Pumps into a Process

Gerard B. Hawkins

Capital Projects Assessment [Infographic]

Gerard B. Hawkins

The Most Popular Free Lance Tools

Gerard B. Hawkins

BENFIELD LIQUOR - DETERMINATION OF IRON

Gerard 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.

BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto Titrator

Gerard B. Hawkins

Determination of Residue and Oil in Anhydrous Ammonia

Gerard B. Hawkins

Determination of Anions by Ion Chromatography 1 SCOPE AND FIELD OF APPLICATION This method is suitable for the determination of inorganic anions in Ammonia Solution in the range 100 ppb to 50 ppm m/v. 2 PRINCIPLE The sample is passed through a column of anion exchange resin, on which the anions are absorbed and separated. They are then eluted with dilute sodium carbonate/sodium hydrogen carbonate solution and passed through a suppressor. This replaces the cations with hydrogen ions and thus reduces the background conductivity of the eluent. Final measurement is by conductivity

Determination of Anions by Ion Chromatography

Gerard B. Hawkins

OLEFIN HYDROGENATION - VULCAN Series VHT-S101/S103

Gerard 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.

Integration of Rotary Positive Displacement Pumps into a Process

Gerard 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

Application of Process to Management of Change and Modifications

Gerard B. Hawkins

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

Study 1: Concept Hazard Review

Gerard B. Hawkins

Hydrogen Plant Flowsheet - Effects of Low Steam Ratio

Gerard B. Hawkins

Tools for Reactor Modeling: THE ELEMENT POTENTIAL METHOD FOR CHEMICAL EQUILIBRIUM ANALYSIS: STANJAN CONTENTS 1 SCOPE 2 SUMMARY 3 INTRODUCTION 4 EXAMPLES 4.1 CARBON-RICH C-0 SYSTEM 4.2 EXAMPLE WITH TWO COMPLEX PHASES 4.3 GAS TURBINE ENGINE EXAMPLE 4.4 OTHER APPLICATIONS APPENDIX FIGURES 5.1 EXAMPLE RUN LOG FOR CARBON-RICH C-O SYSTEM 5.2 OUTPUT FOR EXAMPLE WITH TWO COMPLEX PHASES 5.3 FIRST STEP IN THE TURBINE EXAMPLE: CALCULATION OF THE ENTHALPY OF THE REACTANTS 5.4 SECOND STEP IN THE TURBINE EXAMPLE: CALCULATION OF THE ADIABATIC FLAME TEMPERATURE 5.5 THIRD STEP IN THE TURBINE EXAMPLE: CALCULATION OF THE NOZZLE EXIT STATE AVAILABILITY AND IMPLEMENTATION OF STANJAN REFERENCES

Reactor Modeling Tools - STANJAN

Gerard B. Hawkins

Destaque (20)

Determination of Carbon Dioxide, Ethane And Nitrogen in Natural Gas by Gas C...

Determination of Hydrocarbons in Anhydrous Ammonia By Gas Chromatography

Other Separations Techniques for Suspensions

Fugitive Emissions

Biological Systems - A Special Case

Reactor Modeling Tools – Multiple Regressions

Quality of Life Correlates to Oil Consumption - Infographic

Integration of Special Purpose Centrifugal Pumps into a Process

Capital Projects Assessment [Infographic]

The Most Popular Free Lance Tools

BENFIELD LIQUOR - DETERMINATION OF IRON

BENFIELD LIQUOR:Determination of Diethanolamine Using an Auto Titrator

Determination of Residue and Oil in Anhydrous Ammonia

Determination of Anions by Ion Chromatography

OLEFIN HYDROGENATION - VULCAN Series VHT-S101/S103

Integration of Rotary Positive Displacement Pumps into a Process

Application of Process to Management of Change and Modifications

Study 1: Concept Hazard Review

Hydrogen Plant Flowsheet - Effects of Low Steam Ratio

Reactor Modeling Tools - STANJAN

Semelhante a Carbon Formation in Mixed Feed Preheat Coils

Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...

Gerard B. Hawkins

H - Acid Caustic Fusion Stage CONTENTS 0 INTRODUCTION 1 DESIGN INFORMATION 1.1 Reactor Type 1.2 Temperature Range 1.3 Pressure Range 1.4 Chemical System 2 BACKGROUND 3 KINETICS AND MECHANISM 4 MAXIMUM YIELD AND IMPLICATIONS FOR REACTOR DESIGN 5 USE OF DESIGN MODEL FOR START-UP AND MANUFACTURING MONITORING 6 BIBLIOGRAPHY FIGURES 1 FUSION MODEL OUTLINE MECHANISM AND KINETIC SCHEME 2 TEST RUN OPTIMIZATION OF HEATING TIME 3600 kg/h STEAM

H - Acid Caustic Fusion Stage

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

Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...

Gerard 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

Integration of Special Purpose Reciprocating Compressors into a Process

Gerard 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

Design and Simulation of Continuous Distillation Columns

Gerard B. Hawkins

STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS

Gerard B. Hawkins

Methanation Catalyst Start Up Procedures

Gerard 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

Reactor Arrangement for Continuous Vapor Phase Chlorination

Gerard B. Hawkins

Start Up Procedures for Primary Reforming Catalyst

Gerard B. Hawkins

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

Batch Distillation

Gerard B. Hawkins

Heating and Cooling of Batch Processes 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 3.1 units 4 STATEMENT OF THE PROBLEM 5 DEVELOPMENT OF THE METHOD 5.1 Assumptions 5.2 Basic Equations 6 APPLICATION OF THE METHOD 6.1 Determining the Behavior of an Existing System 6.2 Specifying the Heat Transfer Duty for a New System APPENDICES A DERIVATION OF THE EQUATIONS B WORKED EXAMPLES FIGURES 1 CASES CONSIDERED

Heating and Cooling of Batch Processes

Gerard 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

Distillation Sequences, Complex Columns and Heat Integration

Gerard 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.

Isothermal Methanol Converter (IMC) UA Distribution Analysis

Gerard B. Hawkins

The Selective Oxidation of n-Butane to Maleic Anhydride in a Catalyst Packed ...

Gerard B. Hawkins

Physical Properties for Heat Exchanger Design 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 COMPONENT PROPERTIES 4.1 General 4.2 Use of Component Properties for Mixtures 5 INPUT OF MIXTURE CURVES 5.1 General 5.2 Generation of the Mixture Curves 5.3 Selection of Temperature Points 5.4 Extrapolation 6 IMMISCIBLE CONDENSATES FIGURES 1 TEMPERATURE POINTS SELECTED FOR EQUAL ENTHALPY CHANGE 2 TEMPERATURE POINTS SELECTED FOR GOOD FIT TO CURVE

Physical Properties for Heat Exchanger Design

Spray Drying

Psychrometry

Gas Mixing

Reciprocating Compressors - Protection against Crank Case Explosions

Gerard B. Hawkins

Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 THE INTEGRATION OF THE ENERGY EQUATION 5 THE EDDY VISCOSITY FOR NON-NEWTONIAN AND DRAG REDUCING FLUIDS 6 THE CALCULATION OF HEAT TRANSFER COEFFICIENTS FOR NON-NEWTONIAN AND DRAG REDUCING FLUIDS IN TURBULENT PIPE FLOW 6.1 General 6.2 Drag Reducing Fibre Suspensions 6.3 Transition Delay 7 NOMENCLATURE 8 BIBLIOGRAPHY

Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes

Gerard B. Hawkins

Semelhante a Carbon Formation in Mixed Feed Preheat Coils (20)

Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...

H - Acid Caustic Fusion Stage

Debottlenecking Claus Sulfur Recovery Units: An Investigation of the applicat...

Integration of Special Purpose Reciprocating Compressors into a Process

Design and Simulation of Continuous Distillation Columns

STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS

Methanation Catalyst Start Up Procedures

Reactor Arrangement for Continuous Vapor Phase Chlorination

Start Up Procedures for Primary Reforming Catalyst

Batch Distillation

Heating and Cooling of Batch Processes

Distillation Sequences, Complex Columns and Heat Integration

Isothermal Methanol Converter (IMC) UA Distribution Analysis

The Selective Oxidation of n-Butane to Maleic Anhydride in a Catalyst Packed ...

Physical Properties for Heat Exchanger Design

Spray Drying

Psychrometry

Gas Mixing

Reciprocating Compressors - Protection against Crank Case Explosions

Turbulent Heat Transfer to Non Newtonian Fluids in Circular Tubes

Mais de Gerard B. Hawkins

Pressure Relief Systems Vol 2

Gerard B. Hawkins

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.

Pressure Relief Systems

Gerard B. Hawkins

101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide

Gerard B. Hawkins

El impacto en el rendimiento del catalizador por envenenamiento y ensuciamien...

Gerard B. Hawkins

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

Theory of Carbon Formation in Steam Reforming

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

Calculation of an Ammonia Plant Energy Consumption:

Gerard B. Hawkins

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

Piping and Vessels Flushing and Cleaning Procedure

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

DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS

Gerard B. Hawkins

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Carbon Formation in Mixed Feed Preheat Coils

1. GBH Enterprises, Ltd. Engineering Design Guide Carbon Formation in Mixed Feed Preheat Coils 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. 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 coil. The method assumes that 100% CH4 mixed with steam (S/C =3) could in theory be heated-up with steam to 645oC. As heavier hydrocarbons are added, this temperature will fall. As hydrogen is added, or S/C increased, the temperature can increase. A table of indices for the calculation is as follows: Component C1 C2 C3 C4 C5 C6 C7 C8 H2 N2, CO, CO2 etc S/C (molar) Index [X] 0.05 1.2 1.5 1.7 1.55 1.65 1.75 1.8 -0.5 0 10 Each component composition in the feed (mol %) is then multiplied by the respective index number [X] and totalled. The S/C ratio correction is then calculated by subtracting the S/C ratio from 3 and multiplied by the index number [X = 10]. The total summation of these numbers is then subtracted from 650oC to yield the maximum allowable pre-heat 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

3. Example 1 (NG) NG composition...... C1 86.0 mol % C2 6.6 mol % C3 3.6 mol % C4 1.5 mol % C5 0.4 mol % H2 2.0 mol % N2 1.0 mol % S/C ratio 3.3 So maximum pre-heat temperature = 650 - [(86 x 0.05) + (5.5 x 1.2) + (3.6 x 1.5) + (1.5 x 1.7) + (0.4 x 1.55) + (2 x -0.5) + (3 - 3.3)x10] = 632oC Example 2 (LPG) LPG composition...... C3 0.47 mol % C4 83.52 mol % C5 0.35 mol % H2 15.66 mol % S/C ratio 3.3 So maximum pre-heat temperature = 650 - [(0.47 x 1.5) + (83.52 x 1.7) + (0.35 x 1.55) + (15.66 x -0.5) + (3 - 3.3)x10] = 518oC 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. Note: This approach takes no account of pre-heat coil positioning, size, counter/co-current etc. notwithstanding the other approximations. However, even a crude approach may help in recommending maximum pre-heat temperatures. 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

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