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Efficient Petrochemical Technology for Growth - Design Integration and Operation Optimization

Efficient Petrochemical Technology for Growth - Design Integration and Operation Optimization

Autorzy
Wydawnictwo John Wiley and Sons Ltd
Data wydania 2019
Liczba stron 432
Forma publikacji książka w twardej oprawie
Poziom zaawansowania Dla profesjonalistów, specjalistów i badaczy naukowych
Język angielski
ISBN 9781119487869
Kategorie Chemia
786.45 PLN (z VAT)
$176.91 / €168.61 / £146.37 /
Produkt na zamówienie
Dostawa 5-6 tygodni
Ilość
Do schowka

Opis książki

A GUIDE TO THE DESIGN, OPERATION, CONTROL, TROUBLESHOOTING, OPTIMIZATION AS WELL AS THE RECENT ADVANCES IN THE FIELD OF PETROCHEMICAL PROCESSES


Efficient Petrochemical Processes: Technology, Design and Operation 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.


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:





Provides the basic knowledge related to fundamentals, design, and operation for petrochemical processes

Applies process integration techniques and optimization techniques that improve process design and operations in the petrochemical process

Provides practical methods and tools for industrial practitioners

Puts the focus on improving industrial energy efficiency, reducing capital investment, and optimizing yields

Contains information on the most recent advances in the field.



Written for managers, engineers, and operators working in process industries as well as university students, Efficient Petrochemical Processes: Technology, Design and Operation explains the most recent advances in the field of petrochemical processes and discusses in detail catalytic and adsorbent materials, reaction and separation mechanisms.

Efficient Petrochemical Technology for Growth - Design Integration and Operation Optimization

Spis treści

Preface xix





Acknowledgments xxi





Part I Market, Design and Technology Overview 1





1 Overview of This Book 3





1.1 Why Petrochemical Products are Important for the Economy 3





1.2 Overall Petrochemical Configurations 8





1.3 Context of Process Designs and Operation for Petrochemical Production 11





1.4 Who is This Book Written For? 11





2 Market and Technology Overview 13





2.1 Overview of Aromatic Petrochemicals 13





2.2 Introduction and Market Information 13





2.3 Technologies in Aromatics Synthesis 21





2.4 Alternative Feeds for Aromatics 27





2.5 Technologies in Aromatic Transformation 28





2.6 Technologies in Aromatic Separations 35





2.7 Separations by Molecular Weight 39





2.8 Separations by Isomer Type: para?Xylene 39





2.9 Separations by Isomer Type: meta?Xylene 44





2.10 Separations by Isomer Type: ortho?Xylene and Ethylbenzene 45





2.11 Other Related Aromatics Technologies 46





2.12 Integrated Refining and Petrochemicals 57





References 61





3 Aromatics Process Description 63





3.1 Overall Aromatics Flow Scheme 63





3.2 Adsorptive Separations for para?Xylene 64





3.3 Technologies for Treating Feeds for Aromatics Production 68





3.4 para?Xylene Purification and Recovery by Crystallization 68





3.5 Transalkylation Processes 71





3.6 Xylene Isomerization 72





3.7 Adsorptive Separation of Pure meta?Xylene 76





3.8 para?Selective Catalytic Technologies for para?Xylene 78





References 81





Part II Process Design 83





4 Aromatics Process Unit Design 85





4.1 Introduction 85





4.2 Aromatics Fractionation 85





4.3 Aromatics Extraction 88





4.4 Transalkylation 96





4.5 Xylene Isomerization 101





4.6 para?Xylene Separation 105





4.7 Process Design Considerations: Design Margin Philosophy 106





4.8 Process Design Considerations: Operational Flexibility 108





4.9 Process Design Considerations: Fractionation Optimization 109





4.10 Safety Considerations 110





4.10.1 Reducing Exposure to Hazardous Materials 110





4.10.2 Process Hazard Analysis (PHA) 110





4.10.3 Hazard and Operability (HAZOP) Study 110





Further Reading 111





5 Aromatics Process Revamp Design 113





5.1 Introduction 113





5.2 Stages of Revamp Assessment and Types of Revamp Studies 113





5.3 Revamp Project Approach 115





5.4 Revamp Study Methodology and Strategies 116





5.5 Setting the Design Basis for Revamp Projects 118





5.6 Process Design for Revamp Projects 121





5.7 Revamp Impact on Utilities 123





5.8 Equipment Evaluation for Revamps 124





5.9 Economic Evaluation 147





5.10 Example Revamp Cases 152





Further Reading 154





Part III Process Equipment Assessment 155





6 Distillation Column Assessment 157





6.1 Introduction 157





6.2 Define a Base Case 157





6.3 Calculations for Missing and Incomplete Data 159





6.4 Building Process Simulation 161





6.5 Heat and Material Balance Assessment 162





6.6 Tower Efficiency Assessment 164





6.7 Operating Profile Assessment 166





6.8 Tower Rating Assessment 168





6.9 Guidelines for Existing Columns 169





Nomenclature 170





Greek Letters 170





References 170





7 Heat Exchanger Assessment 171





7.1 Introduction 171





7.2 Basic Calculations 171





7.3 Understand Performance Criterion: U?Values 173





7.4 Understand Fouling 176





7.5 Understand Pressure Drop 178





7.6 Effects of Velocity on Heat Transfer, Pressure Drop, and Fouling 178





7.7 Improving Heat Exchanger Performance 185





7.A TEMA Types of Heat Exchangers 186





References 188





8 Fired Heater Assessment 189





8.1 Introduction 189





8.2 Fired Heater Design for High Reliability 189





8.3 Fired Heater Operation for High Reliability 194





8.4 Efficient Fired Heater Operation 197





8.5 Fired Heater Revamp 201





References 202





9 Compressor Assessment 203





9.1 Introduction 203





9.2 Types of Compressors 203





9.3 Impeller Configurations 205





9.4 Type of Blades 207





9.5 How a Compressor Works 207





9.6 Fundamentals of Centrifugal Compressors 208





9.7 Performance Curves 209





9.8 Partial Load Control 210





9.9 Inlet Throttle Valve 212





9.10 Process Context for a Centrifugal Compressor 212





9.11 Compressor Selection 213





References 213





10 Pump Assessment 215





10.1 Introduction 215





10.2 Understanding Pump Head 215





10.3 Define Pump Head: Bernoulli Equation 216





10.4 Calculate Pump Head 218





10.5 Total Head Calculation Examples 219





10.6 Pump System Characteristics: System Curve 221





10.7 Pump Characteristics: Pump Curve 222





10.8 Best Efficiency Point (BEP) 224





10.9 Pump Curves for Different Pump Arrangement 225





10.10 NPSH 226





10.11 Spillback 229





10.12 Reliability Operating Envelope (ROE) 230





10.13 Pump Control 230





10.14 Pump Selection and Sizing 231





Nomenclature 233





Greek Letters 233





References 233





Part IV Energy and Process Integration 235





11 Process Integration for Higher Efficiency and Low Cost 237





11.1 Introduction 237





11.2 Definition of Process Integration 237





11.3 Composite Curves and Heat Integration 238





11.4 Grand Composite Curves (GCC) 244





11.5 Appropriate Placement Principle for Process Changes 244





11.6 Systematic Approach for Process Integration 249





11.7 Applications of the Process Integration Methodology 251





References 261





12 Energy Benchmarking 263





12.1 Introduction 263





12.2 Definition of Energy Intensity for a Process 263





12.3 The Concept of Fuel Equivalent (FE) for Steam and Power 264





12.4 Calculate Energy Intensity for a Process 265





12.5 Fuel Equivalent for Steam and Power 267





12.6 Energy Performance Index (EPI) Method for Energy Benchmarking 271





12.7 Concluding Remarks 272





References 273





13 Key Indicators and Targets 275





13.1 Introduction 275





13.2 Key Indicators Represent Operation Opportunities 275





13.3 Defining Key Indicators 277





13.4 Set Up Targets for Key Indicators 280





13.5 Economic Evaluation for Key Indicators 283





13.6 Application 1: Implementing Key Indicators into an "Energy Dashboard" 285





13.7 Application 2: Implementing Key Indicators to Controllers 287





13.8 It is Worth the Effort 287





References 288





14 Distillation System Optimization 289





14.1 Introduction 289





14.2 Tower Optimization Basics 289





14.3 Energy Optimization for Distillation System 293





14.4 Overall Process Optimization 296





14.5 Concluding Remarks 302





References 302





15 Fractionation and Separation Theory and Practices 303





15.1 Introduction 303





15.2 Separation Technology Overview 303





15.3 Distillation Basics 305





15.4 Advanced Distillation Topics 311





15.5 Adsorption 316





15.6 Simulated Moving Bed (SMB) 317





15.7 Crystallization 320





15.8 Liquid-Liquid Extraction 320





15.9 Extractive Distillation 321





15.10 Membranes 322





15.11 Selecting a Separation Method 323





References 324





16 Reaction Engineering Overview 325





16.1 Introduction 325





16.2 Reaction Basics 325





16.3 Reaction Kinetic Modeling Basics 326





16.4 Rate Equation Based on Surface Kinetics 328





16.5 Limitations in Catalytic Reaction 330





16.6 Reactor Types 333





16.7 Reactor Design 335





16.8 Hybrid Reaction and Separation 340





16.9 Catalyst Deactivation Root Causes and Modeling 341





References 343





Part V Operational Guidelines and Troubleshooting 345





17 Common Operating Issues 347





17.1 Introduction 347





17.2 Start?up Considerations 348





17.3 Methyl Group and Phenyl Ring Losses 349





17.4 Limiting Aromatics Losses 350





17.5 Fouling 356





17.6 Aromatics Extraction Unit Solvent Degradation 360





17.7 Selective Adsorption of para?Xylene by Simulated Moving Bed 363





17.8 Common Issues with Sampling and Laboratory Analysis 371





17.9 Measures of Operating Efficiency in Aromatics Complex Process Units 374





17.10 The Future of Plant Troubleshooting and Optimization 377





References 377





18 Troubleshooting Case Studies 379





18.1 Introduction 379





18.2 Transalkylation Unit: Low Catalyst Activity During Normal Operation 379





18.3 Xylene Isomerization Unit: Low Catalyst Activity Following Start?up 381





18.4 para?Xylene Selective Adsorption Unit: Low Recovery After Turnaround 384





18.5 Aromatics Extraction Unit: Low Extract Purity/Recovery 385





18.6 Aromatics Complex: Low para?Xylene Production 386





18.7 Closing Remarks 388





Reference 389





Index 391

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