How to Reuse, Re-Purpose, and Retrofit Existing Process Equipment
Buch, Englisch, 304 Seiten, Format (B × H): 161 mm x 240 mm, Gewicht: 607 g
ISBN: 978-0-470-58794-2
Verlag: Wiley
Methods for more planet-friendly process engineering
Our earth is just one big, complex Process Facility with limited air, water, and mineral resources. It responds to a number of process variables—among them, humanity and the environmental effects of our carbon consumption. What can professionals in the Hydrocarbon Process Industry do to retard environmental degradation? Rather than looking to exotic technology for solutions, Process Engineering for a Small Planet details ready-at-hand methods that the process engineer can employ to help combat the environmental crisis.
Drawing from the author's professional experience working with petroleum refineries petroleum refineries, petrochemical plants, and natural gas wells, this handbook explains how to operate and retrofit process facilities to:
- Reuse existing process equipment
- Save energy
- Reduce greenhouse gas emissions
- Expand plant capacity without installing new equipment
- Reduce corrosion and equipment failures
Covering topics from expanding fractionator and compressor capacity and vacuum tower heater expansion to minimizing process water consumption and increasing centrifugal pump capacity, Process Engineering for a Small Planet offers big ideas for saving our small planet.
Autoren/Hrsg.
Fachgebiete
- Technische Wissenschaften Verfahrenstechnik | Chemieingenieurwesen | Biotechnologie Chemische Verfahrenstechnik
- Geowissenschaften Umweltwissenschaften Umwelttechnik
- Geowissenschaften Umweltwissenschaften Umweltschutz, Umwelterhaltung
- Technische Wissenschaften Verfahrenstechnik | Chemieingenieurwesen | Biotechnologie Chemische Anlagen
- Geowissenschaften Umweltwissenschaften Soziale & wirtschaftliche Auswirkungen von Umweltfaktoren
Weitere Infos & Material
Foreword xv
Preface xvii
Introduction: Turning of the Tide 1
1. Expanding Fractionator and Compressor Capacity 3
Reuse of Existing Fractionator
Changing Tray Deck Panels
Alternates to New Compressor
Keeping Compressor Rotor Clean
Calculating Liquid Injection Rates to Compressor
2. Vacuum Tower Heater Expansion 17 Entrainment Velocity Limitations Missing Tray Deck Manways Heater Draft Limitation Improving Ejector Performance Velocity Steam in Heater Passes
3. Natural-Draft-Fired Heaters 27 Control Excess Air O2 and Combustible Analyzers Improving Air–Fuel Mixing Convective Section Air Leaks Air Preheater Leaks Indirect Air Preheat
4. Crude Pre-Flash Towers 37 Pre-Flash Tower Flooding Energy Saving with Pre-Flash Towers Capacity Benefits Pre-Flash Tower External Reflux
5. Amine Regeneration and Sulfur Recovery 47 Amine Capacity Expansion Sulfur Plant Capacity Expansion Rich Amine Flash Drum Design Cascaded Seal Legs Sulfur Recovery from Sour Water Stripper Off-Gas Acid Gas of High CO2 Content Sulfur Plant Oxygen Enrichment
6. Treating and Drying Hydrocarbons 59 Jet Fuel Treating Salt Dryer Operation Water-Washing Sodium Naphthanates from Jet Fuel Pipe Distributor Design Treating Sour Naphtha Converting Mercaptans to Disulfides
7. Minimizing Process Water Consumption 71 Two-Stage Wastewater Stripper Steam Condensate Recovery Condensate Drum Balance Line Location Water Hammer Measuring Condensate Recovery Cooling Tower Cycles of Concentration
8. Incremental Expansion Design Concept: Reprocessing Waste Lube Oil 79 Reprocessing Waste Lube Oil Vacuum Tower Design Wash Oil Grid Coking Vapor Horn Design in Vacuum Towers Stripping Tray Efficiency Precondenser Fouling Pump NPSH Limit in Vacuum Service Exchanger Fouling in Waste Oil Service Transfer-Line Sonic Velocity
9. Improving Fractionation Efficiency in Complex Fractionators 91 Pre-Flash Tower Concept Intermediate Reflux Stripping Tray Efficiency Maximizing Diesel Recovery from Crude Picket Weirs Adjusting Pump-arounds Pressure Optimization
10. Increasing Centrifugal Pump Capacity and Efficiency 103 Hydraulic Limitations Worn Impeller-to-Case Clearances Impeller Wear Ring Upgrading Impeller Size Marginal Cavitation Viscosity Effects on Efficiency NPSH Limited Condition
11. Eliminating Process Control Valves Using Variable-Speed Drivers 113 Frequency Control of Motors Eliminating Control Valves on Pump Discharge Direct Speed Control of Steam Turbine Variable-Speed Compressors Spill-backs Waste Energy Calculating Incentive for Variable-Speed Drivers Floating Tower Pressure Control
12. Expanding Refrigeration Capacity 123 Centrifugal Compressor Head vs. Flow Curve Calculating Compression Work Horsepower vs. Suction Pressure Limited Effect of Increasing Suction Pressure Reducing Refrigerant Condenser Fouling Effect of Noncondensibles Condensate Backup in Condenser
13. Oversizing Equipment Pitfalls 135 Amine H2 S Scrubber Optimizing Number of Trays in Absorbers Consequences of Overdesign Use of Demister in Knockout Drum Low Demister Velocity Promotes Mist Entrainment
14. Optimizing Use of Steam Pressure to Minimize Consumption of Energy 145 Preserving the Potential of Steam to Do Work Power Recovery from Steam to a Reboiler Use of the Mollier Diagram Cogeneration Plants Extracting Work from Reboiler Steam Using Existing Equipment Understanding Thermodynamics of Flowing Steam Steam Turbine Efficiency Checklist
15. Expanding Compressor Capacity and Efficiency 157 Reciprocating Compressors Pulsation Dampener Plates Adjustable Head-End Unloaders Natural Gas Engines Axial Compressor Rotor Fouling of Axial Air Compressor Centrifugal Compressors Cleaning Centrifugal Compressor Rotor
16. Vapor–Liquid Separator Entrainment Problems 171 Effect of Foam on Indicated Liquid Levels Hydrogen-Heavy Gas Oil Separtors Foam Induced Carry-Over Enhancing De-Entrainment Rates Vapor Distribution Aids De-Entrainment
17. Retrofitting Shell-and-Tube Heat Exchangers for Greater Efficiency 179 Running Slops Without Fouling Floating Suction in Charge Tanks Exchanger Online Spalling Effect of Feed Interruptions Tube Velocity and Surface Roughness Shell-Side Seal Strips Cooling High-Viscosity Fluids Expanding Water Cooler Capacity Hydrocarbon Losses to Cooling Towers
18. Reducing Sulfur and Hydrocarbon Emissions 189 Sulfur Plant Waste Heat Boiler Modifications Hydrocarbon Leaks in Seawater Cooling Systems Incinerator Back-Fire in Sulfur Plant Main Reaction Furnace Loss of Draft Due to Air Leaks Global Emissions in Perspective
19. Hydrocarbon Leaks to the Environment 201 Measuring Leaks Through Valves Fixing Leaking Valves On-Stream Detecting Leaking Relief Valves On-Stream Repair of Leaking Relief Valves Measuring Flows in Flare Lines Leaks into Cooling Water Air Cooler Leaks Valve Stem Packing Leaking Pump Mechanical Seal and Improper Use of Seal Flush Fixing Weld Leaks On-Stream
20. Composition-Induced Flooding in Packed Towers: FCU Fractionator Expansion 209 Fluid Cracking Unit Fractionator Expansion Flooding of Slurry Oil P/A Sections FCU Fractionator Vapor Line Quench Multipump Piping Stress Analysis Perception vs. Reality in Process Design
21. Maintenance for Longer Run Lengths 219 Sulfuric Acid Regeneration Importance of Reactor Insulation On-Stream Piping Repairs Preserving Pump Mechanical Seals Concept of Avoiding Unit Shutdowns
22. Instrument Malfunctions 229 Control Valve Loss Due to Instrument Air Pressure Signal Stuck Flow Control Valve Stem Mislocated Liquid-Level Tap Reducing Load to Vacuum System by Correcting False Level Indication
23. Summary Checklist for Reuse of Process Equipment 237 Fired Heaters Heat Exchangers Fin-Fan Air Coolers Distillation Tower Trays Vapor–Liquid Separators Centrifugal Pumps Fixed-Bed Reactors Electric Motors Gas and Steam Turbines Reciprocating and Centrifugal Compressors Air Blowers Water–Hydrocarbon Separators Overcoming Utility System Limits
24. Water–Hydrocarbon Separation: Corrosive Effects of Water 245 Water–Oil Separators Corrosive Elements from Cracking Plants Water Traps in Strippers Current CO2 Levels Environmental Overview Appendix: Solar Power Potential 257 Index 259
