Norman P. Lieberman

Process Engineering for a Small Planet (eBook, PDF)

How to Reuse, Re-Purpose, and Retrofit Existing Process Equipment

• Format: PDF

Produktbeschreibung

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.

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Produktdetails

• Verlag: John Wiley & Sons
• Seitenzahl: 304
• Erscheinungstermin: 29. Januar 2010
• Englisch
• ISBN-13: 9780470637043
• Artikelnr.: 37298155

Autorenporträt

NORMAN P. LIEBERMAN is an independent process design engineer and field troubleshooter. His clients are refineries and petrochemical plants. He is well known in the process industry for his seminar "Troubleshooting Process Operations," which has been presented to over 16,000 engineers and plant operators.

Inhaltsangabe

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