Details

Efficient Petrochemical Processes


Efficient Petrochemical Processes

Technology, Design and Operation
1. Aufl.

von: Frank (Xin X.) Zhu, James A. Johnson, David W. Ablin, Gregory A. Ernst

144,99 €

Verlag: Wiley
Format: EPUB
Veröffentl.: 17.10.2019
ISBN/EAN: 9781119487883
Sprache: englisch
Anzahl Seiten: 432

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Beschreibungen

<p><b>A GUIDE TO THE DESIGN, OPERATION, CONTROL, TROUBLESHOOTING, OPTIMIZATION AS WELL AS THE RECENT ADVANCES IN THE FIELD OF PETROCHEMICAL PROCESSES</b></p> <p><i>Efficient Petrochemical Processes: Technology, Design and Operation</i> is a guide to the tools and methods for energy optimization and process design. Written by a panel of experts on the topic, the book highlights the application of these methods on petrochemical technology such as the aromatics process unit. The authors describe practical approaches and tools that focus on improving industrial energy efficiency, reducing capital investment, and optimizing yields through better design, operation, and optimization.</p> <p>The text is divided into sections that cover the range of essential topics: petrochemical technology description; process design considerations; reaction and separation design; process integration; process system optimization; types of revamps; equipment assessment; common operating issues; and troubleshooting case analysis. This important book:</p> <ul> <li>Provides the basic knowledge related to fundamentals, design, and operation for petrochemical processes</li> <li>Applies process integration techniques and optimization techniques that improve process design and operations in the petrochemical process</li> <li>Provides practical methods and tools for industrial practitioners</li> <li>Puts the focus on improving industrial energy efficiency, reducing capital investment, and optimizing yields</li> <li>Contains information on the most recent advances in the field.</li> </ul> <p>Written for managers, engineers, and operators working in process industries as well as university students, <i>Efficient Petrochemical Processes: Technology, Design and Operation</i> explains the most recent advances in the field of petrochemical processes and discusses in detail catalytic and adsorbent materials, reaction and separation mechanisms.</p>
<p>Preface xix</p> <p>Acknowledgments xxi</p> <p><b>Part I Market, Design and Technology Overview 1</b></p> <p>1 Overview of This Book 3</p> <p>1.1 Why Petrochemical Products are Important for the Economy 3</p> <p>1.2 Overall Petrochemical Configurations 8</p> <p>1.3 Context of Process Designs and Operation for Petrochemical Production 11</p> <p>1.4 Who is This Book Written For? 11</p> <p><b>2 Market and Technology Overview 13</b></p> <p>2.1 Overview of Aromatic Petrochemicals 13</p> <p>2.2 Introduction and Market Information 13</p> <p>2.3 Technologies in Aromatics Synthesis 21</p> <p>2.4 Alternative Feeds for Aromatics 27</p> <p>2.5 Technologies in Aromatic Transformation 28</p> <p>2.6 Technologies in Aromatic Separations 35</p> <p>2.7 Separations by Molecular Weight 39</p> <p>2.8 Separations by Isomer Type: <i>para</i>‐Xylene 39</p> <p>2.9 Separations by Isomer Type: <i>meta</i>‐Xylene 44</p> <p>2.10 Separations by Isomer Type: <i>ortho</i>‐Xylene and Ethylbenzene 45</p> <p>2.11 Other Related Aromatics Technologies 46</p> <p>2.12 Integrated Refining and Petrochemicals 57</p> <p>References 61</p> <p><b>3 Aromatics Process Description 63</b></p> <p>3.1 Overall Aromatics Flow Scheme 63</p> <p>3.2 Adsorptive Separations for <i>para</i>‐Xylene 64</p> <p>3.3 Technologies for Treating Feeds for Aromatics Production 68</p> <p>3.4 <i>para</i>‐Xylene Purification and Recovery by Crystallization 68</p> <p>3.5 Transalkylation Processes 71</p> <p>3.6 Xylene Isomerization 72</p> <p>3.7 Adsorptive Separation of Pure <i>meta</i>‐Xylene 76</p> <p>3.8 <i>para</i>‐Selective Catalytic Technologies for <i>para</i>‐Xylene 78</p> <p>References 81</p> <p><b>Part II Process Design 83</b></p> <p><b>4 Aromatics Process Unit Design 85</b></p> <p>4.1 Introduction 85</p> <p>4.2 Aromatics Fractionation 85</p> <p>4.3 Aromatics Extraction 88</p> <p>4.4 Transalkylation 96</p> <p>4.5 Xylene Isomerization 101</p> <p>4.6 <i>para</i>‐Xylene Separation 105</p> <p>4.7 Process Design Considerations: Design Margin Philosophy 106</p> <p>4.8 Process Design Considerations: Operational Flexibility 108</p> <p>4.9 Process Design Considerations: Fractionation Optimization 109</p> <p>4.10 Safety Considerations 110</p> <p>4.10.1 Reducing Exposure to Hazardous Materials 110</p> <p>4.10.2 Process Hazard Analysis (PHA) 110</p> <p>4.10.3 Hazard and Operability (HAZOP) Study 110</p> <p>Further Reading 111</p> <p><b>5 Aromatics Process Revamp Design 113</b></p> <p>5.1 Introduction 113</p> <p>5.2 Stages of Revamp Assessment and Types of Revamp Studies 113</p> <p>5.3 Revamp Project Approach 115</p> <p>5.4 Revamp Study Methodology and Strategies 116</p> <p>5.5 Setting the Design Basis for Revamp Projects 118</p> <p>5.6 Process Design for Revamp Projects 121</p> <p>5.7 Revamp Impact on Utilities 123</p> <p>5.8 Equipment Evaluation for Revamps 124</p> <p>5.9 Economic Evaluation 147</p> <p>5.10 Example Revamp Cases 152</p> <p>Further Reading 154</p> <p><b>Part III Process Equipment Assessment 155</b></p> <p><b>6 Distillation Column Assessment 157</b></p> <p>6.1 Introduction 157</p> <p>6.2 Define a Base Case 157</p> <p>6.3 Calculations for Missing and Incomplete Data 159</p> <p>6.4 Building Process Simulation 161</p> <p>6.5 Heat and Material Balance Assessment 162</p> <p>6.6 Tower Efficiency Assessment 164</p> <p>6.7 Operating Profile Assessment 166</p> <p>6.8 Tower Rating Assessment 168</p> <p>6.9 Guidelines for Existing Columns 169</p> <p>Nomenclature 170</p> <p>Greek Letters 170</p> <p>References 170</p> <p><b>7 Heat Exchanger Assessment 171</b></p> <p>7.1 Introduction 171</p> <p>7.2 Basic Calculations 171</p> <p>7.3 Understand Performance Criterion: U‐Values 173</p> <p>7.4 Understand Fouling 176</p> <p>7.5 Understand Pressure Drop 178</p> <p>7.6 Effects of Velocity on Heat Transfer, Pressure Drop, and Fouling 178</p> <p>7.7 Improving Heat Exchanger Performance 185</p> <p>7.A TEMA Types of Heat Exchangers 186</p> <p>References 188</p> <p><b>8 Fired Heater Assessment 189</b></p> <p>8.1 Introduction 189</p> <p>8.2 Fired Heater Design for High Reliability 189</p> <p>8.3 Fired Heater Operation for High Reliability 194</p> <p>8.4 Efficient Fired Heater Operation 197</p> <p>8.5 Fired Heater Revamp 201</p> <p>References 202</p> <p><b>9 Compressor Assessment 203</b></p> <p>9.1 Introduction 203</p> <p>9.2 Types of Compressors 203</p> <p>9.3 Impeller Configurations 205</p> <p>9.4 Type of Blades 207</p> <p>9.5 How a Compressor Works 207</p> <p>9.6 Fundamentals of Centrifugal Compressors 208</p> <p>9.7 Performance Curves 209</p> <p>9.8 Partial Load Control 210</p> <p>9.9 Inlet Throttle Valve 212</p> <p>9.10 Process Context for a Centrifugal Compressor 212</p> <p>9.11 Compressor Selection 213</p> <p>References 213</p> <p><b>10 Pump Assessment 215</b></p> <p>10.1 Introduction 215</p> <p>10.2 Understanding Pump Head 215</p> <p>10.3 Define Pump Head: Bernoulli Equation 216</p> <p>10.4 Calculate Pump Head 218</p> <p>10.5 Total Head Calculation Examples 219</p> <p>10.6 Pump System Characteristics: System Curve 221</p> <p>10.7 Pump Characteristics: Pump Curve 222</p> <p>10.8 Best Efficiency Point (BEP) 224</p> <p>10.9 Pump Curves for Different Pump Arrangement 225</p> <p>10.10 NPSH 226</p> <p>10.11 Spillback 229</p> <p>10.12 Reliability Operating Envelope (ROE) 230</p> <p>10.13 Pump Control 230</p> <p>10.14 Pump Selection and Sizing 231</p> <p>Nomenclature 233</p> <p>Greek Letters 233</p> <p>References 233</p> <p><b>Part IV Energy and Process Integration 235</b></p> <p><b>11 Process Integration for Higher Efficiency and Low Cost 237</b></p> <p>11.1 Introduction 237</p> <p>11.2 Definition of Process Integration 237</p> <p>11.3 Composite Curves and Heat Integration 238</p> <p>11.4 Grand Composite Curves (GCC) 244</p> <p>11.5 Appropriate Placement Principle for Process Changes 244</p> <p>11.6 Systematic Approach for Process Integration 249</p> <p>11.7 Applications of the Process Integration Methodology 251</p> <p>References 261</p> <p><b>12 Energy Benchmarking 263</b></p> <p>12.1 Introduction 263</p> <p>12.2 Definition of Energy Intensity for a Process 263</p> <p>12.3 The Concept of Fuel Equivalent (FE) for Steam and Power 264</p> <p>12.4 Calculate Energy Intensity for a Process 265</p> <p>12.5 Fuel Equivalent for Steam and Power 267</p> <p>12.6 Energy Performance Index (EPI) Method for Energy Benchmarking 271</p> <p>12.7 Concluding Remarks 272</p> <p>References 273</p> <p><b>13 Key Indicators and Targets 275</b></p> <p>13.1 Introduction 275</p> <p>13.2 Key Indicators Represent Operation Opportunities 275</p> <p>13.3 Defining Key Indicators 277</p> <p>13.4 Set Up Targets for Key Indicators 280</p> <p>13.5 Economic Evaluation for Key Indicators 283</p> <p>13.6 Application 1: Implementing Key Indicators into an “Energy Dashboard” 285</p> <p>13.7 Application 2: Implementing Key Indicators to Controllers 287</p> <p>13.8 It is Worth the Effort 287</p> <p>References 288</p> <p><b>14 Distillation System Optimization 289</b></p> <p>14.1 Introduction 289</p> <p>14.2 Tower Optimization Basics 289</p> <p>14.3 Energy Optimization for Distillation System 293</p> <p>14.4 Overall Process Optimization 296</p> <p>14.5 Concluding Remarks 302</p> <p>References 302</p> <p><b>15 Fractionation and Separation Theory and Practices 303</b></p> <p>15.1 Introduction 303</p> <p>15.2 Separation Technology Overview 303</p> <p>15.3 Distillation Basics 305</p> <p>15.4 Advanced Distillation Topics 311</p> <p>15.5 Adsorption 316</p> <p>15.6 Simulated Moving Bed (SMB) 317</p> <p>15.7 Crystallization 320</p> <p>15.8 Liquid–Liquid Extraction 320</p> <p>15.9 Extractive Distillation 321</p> <p>15.10 Membranes 322</p> <p>15.11 Selecting a Separation Method 323</p> <p>References 324</p> <p><b>16 Reaction Engineering Overview 325</b></p> <p>16.1 Introduction 325</p> <p>16.2 Reaction Basics 325</p> <p>16.3 Reaction Kinetic Modeling Basics 326</p> <p>16.4 Rate Equation Based on Surface Kinetics 328</p> <p>16.5 Limitations in Catalytic Reaction 330</p> <p>16.6 Reactor Types 333</p> <p>16.7 Reactor Design 335</p> <p>16.8 Hybrid Reaction and Separation 340</p> <p>16.9 Catalyst Deactivation Root Causes and Modeling 341</p> <p>References 343</p> <p><b>Part V Operational Guidelines and Troubleshooting 345</b></p> <p><b>17 Common Operating Issues 347</b></p> <p>17.1 Introduction 347</p> <p>17.2 Start‐up Considerations 348</p> <p>17.3 Methyl Group and Phenyl Ring Losses 349</p> <p>17.4 Limiting Aromatics Losses 350</p> <p>17.5 Fouling 356</p> <p>17.6 Aromatics Extraction Unit Solvent Degradation 360</p> <p>17.7 Selective Adsorption of <i>para</i>‐Xylene by Simulated Moving Bed 363</p> <p>17.8 Common Issues with Sampling and Laboratory Analysis 371</p> <p>17.9 Measures of Operating Efficiency in Aromatics Complex Process Units 374</p> <p>17.10 The Future of Plant Troubleshooting and Optimization 377</p> <p>References 377</p> <p><b>18 Troubleshooting Case Studies 379</b></p> <p>18.1 Introduction 379</p> <p>18.2 Transalkylation Unit: Low Catalyst Activity During Normal Operation 379</p> <p>18.3 Xylene Isomerization Unit: Low Catalyst Activity Following Start‐up 381</p> <p>18.4 <i>para</i>‐Xylene Selective Adsorption Unit: Low Recovery After Turnaround 384</p> <p>18.5 Aromatics Extraction Unit: Low Extract Purity/Recovery 385</p> <p>18.6 Aromatics Complex: Low <i>para</i>‐Xylene Production 386</p> <p>18.7 Closing Remarks 388</p> <p>Reference 389</p> <p>Index 391</p>
<p><b>FRANK (XIN X.) ZHU, P<small>H</small>D</b>, is Senior Fellow at Honeywell UOP, Des Plaines, Illionis. He is a leading expert in industrial process design, modeling, and energy efficiency. He holds 60 US patents; is the co-founder for ECI International Conference: CO2 Summit and the recipient of AIChE Energy Sustainability Award. <p><b>JAMES A. JOHNSON</b> is the Director of Petrochemical Development in the R&D Department of Honeywell UOP. He has authored several publications and holds 36 US patents. <p><b>DAVID W. ABLIN</b> was a Fellow at the Aromatics Technology Center of Honeywell UOP before retiring in 2016. He holds 14 U.S. patents and earned several UOP Engineering awards. <p><b>GREGORY A. ERNST</b> is a Technology Specialist at Honeywell UOP, focusing on aromatics technologies with experience in commissioning, field services, and on-site troubleshooting of operating plants.
<p><b>A GUIDE TO THE DESIGN, OPERATION, CONTROL, TROUBLESHOOTING, OPTIMIZATION AS WELL AS THE RECENT ADVANCES IN THE FIELD OF PETROCHEMICAL PROCESSES</b> <p><i>Efficient Petrochemical Processes: Technology, Design and Operation</i> is a guide to the tools and methods for energy optimization and process design. Written by a panel of experts on the topic, the book highlights the application of these methods on petrochemical technology such as the aromatics process unit. The authors describe practical approaches and tools that focus on improving industrial energy efficiency, reducing capital investment, and optimizing yields through better design, operation, and optimization. <p>The text is divided into sections that cover the range of essential topics: petrochemical technology description; process design considerations; reaction and separation design; process integration; process system optimization; types of revamps; equipment assessment; common operating issues; and troubleshooting case analysis. This important book: <ul> <li>Provides the basic knowledge related to fundamentals, design, and operation for petrochemical processes</li> <li>Applies process integration techniques and optimization techniques that improve process design and operations in the petrochemical process</li> <li>Provides practical methods and tools for industrial practitioners</li> <li>Puts the focus on improving industrial energy efficiency, reducing capital investment, and optimizing yields</li> <li>Contains information on the most recent advances in the field.</li> </ul> <p>Written for managers, engineers, and operators working in process industries as well as university students, <i>Efficient Petrochemical Processes: Technology, Design and Operation</i> explains the most recent advances in the field of petrochemical processes and discusses in detail catalytic and adsorbent materials, reaction and separation mechanisms.

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