Zhu, Richard Hoehn, Vasant Thakkar, Edwin Yuh

Hydroprocessing for Clean Energy

Design, Operation, and Optimization

• Gebundenes Buch

Produktbeschreibung

Provides a holistic approach that looks at changing process conditions, possible process design changes, and process technology upgrades * Includes process integration techniques for improving process designs and for applying optimization techniques for improving operations focusing on hydroprocessing units. * Discusses in details all important aspects of hydroprocessing - including catalytic materials, reaction mechanism, as well as process design, operation and control, troubleshooting and optimization * Methods and tools are introduced that have a successful application track record at UOP and many industrial plants in recent years * Includes relevant calculations/software/technologies hosted online for purchasers of the book

Produktdetails

• Verlag: John Wiley & Sons / Wiley
• Seitenzahl: 576
• Erscheinungstermin: 4. Januar 2017
• Englisch
• Abmessung: 236mm x 160mm x 33mm
• Gewicht: 930g
• ISBN-13: 9781118921357
• ISBN-10: 1118921356
• Artikelnr.: 42835865

Autorenporträt

Frank Zhu, PhD, is Senior Fellow at Honeywell UOP, Des Plaines. He is a leading expert in industrial process design, modeling and energy optimization with more than 80 publications and 30 patents. He is the co-founder of the ECI International Conference: CO2 Summit, the recipient of AIChE Energy and Sustainability Award, and the author of Energy and Process Optimization for the Process Industries by Wiley/AICHE. Richard Hoehn is a Senior Fellow at Honeywell UOP, Des Plaines where he has been employed for 42 years, 31 of which have been in the field of hydroprocessing. He received a BS in chemical engineering from Purdue University. He currently holds 36 US patents and has received the Ernest W. Thiele Award from the Chicago Section of the AIChE. Dr. Vasant Thakkar, PhD, was a Senior Fellow at Honeywell UOP, Des Plaines, before retiring in 2015. Vasant worked in Refining R&D Group for over 36 years. Vasant received Honeywell Distinguished Technologist award in 2014. Vasant holds 38 US patents. He received Ph. D. in chemical Engineering from Colorado school of Mine. He held membership in AIChE and ASTM D2 committee. Edwin Yuh is a Fellow at Honeywell UOP, Des Plaines where he has been employed for 37 years, 35 of which have been in the field of hydroprocessing. He received a BS in chemical engineering from Columbia University and a MS in chemical engineering from Northwestern University. Most of his UOP career is in technical service.

Inhaltsangabe

PREFACE xiii PART 1 FUNDAMENTALS 1 1 Overview of This Book 3 1.1 Energy Sustainability
3 1.2 ULSD - Important Part of the Energy Mix
4 1.3 Technical Challenges for Making ULSD
7 1.4 What is the Book Written for
8 References
8 2 Refinery Feeds
Products
and Processes 9 2.1 Introduction
9 2.2 ASTM Standard for Crude Characterization
10 2.3 Important Terminologies in Crude Characterization
12 2.4 Refining Processes
13 2.5 Products and Properties
15 2.6 Biofuel
20 3 Diesel Hydrotreating Process 23 3.1 Why Diesel Hydrotreating?
23 3.2 Basic Process Flowsheeting
25 3.3 Feeds
28 3.4 Products
30 3.5 Reaction Mechanisms
36 3.6 Hydrotreating Catalysts
40 3.7 Key Process Conditions
44 3.8 Different Types of Process Designs
47 References
48 4 Description of Hydrocracking Process 51 4.1 Why Hydrocracking
51 4.2 Basic Processing Blocks
53 4.3 Feeds
58 4.4 Products
59 4.5 Reaction Mechanism and Catalysts
61 4.6 Catalysts
67 4.7 Key Process Conditions
70 4.8 Typical Process Designs
75 References
78 PART 2 HYDROPROCESSING DESIGN 79 5 Process Design Considerations 81 5.1 Introduction
81 5.2 Reactor Design
81 5.3 Recycle Gas Purity
98 5.4 Wash Water
102 5.5 Separator Design
107 5.6 Makeup Gas Compression
115 References
121 6 Distillate Hydrotreating Unit Design 123 6.1 Introduction
123 6.2 Number of Separators
123 6.3 Stripper Design
127 6.4 Debutanizer Design
135 6.5 Integrated Design
136 References
147 7 Hydrocracking Unit Design 149 7.1 Introduction
149 7.2 Single-stage Hydrocracking Reactor Section
150 7.3 Two-stage Hydrocracking Reactor Section
155 7.4 Use of a Hot Separator in Hydrocracking Unit Design
158 7.5 Use of Flash Drums
160 7.6 Hydrocracking Unit Fractionation Section Design
161 7.7 Fractionator First Flow Scheme
161 7.8 Debutanizer First Flow Scheme
163 7.9 Stripper First Fractionation Flow Scheme
166 7.10 Dual Zone Stripper Fractionation Flow Scheme
168 7.11 Dual Zone Stripper - Dual Fractionator Flow Scheme
170 7.12 Hot Separator Operating Temperature
171 7.13 Hydrogen Recovery
174 7.14 LPG Recovery
175 7.15 HPNA Rejection
177 7.16 Hydrocracking Unit Integrated Design
181 References
187 PART 3 ENERGY AND PROCESS INTEGRATION 189 8 Heat Integration for Better Energy Efficiency 191 8.1 Introduction
191 8.2 Energy Targeting
191 8.3 Grassroots Heat Exchanger Network (Hen) Design
202 8.4 Network Pinch for Energy Retrofit
206 Nomenclature
213 References
213 9 Process Integration for Low-Cost Design 215 9.1 Introduction
215 9.2 Definition of Process Integration
216 9.3 Grand Composite Curves (GCC)
218 9.4 Appropriate Placement Principle for Process Changes
219 9.5 Dividing Wall Distillation Column
225 9.6 Systematic Approach for Process Integration
228 9.7 Applications of the Process Integration Methodology
230 9.8 Summary of Potential Energy Efficiency Improvements
246 References
247 10 Distillation Column Operating Window 249 10.1 Introduction
249 10.2 What is Distillation?
249 10.3 Why Distillation is the Most Widely Used?
251 10.4 Distillation Efficiency
253 10.5 Definition of Feasible Operating Window
255 10.6 Understanding Operating Window
256 10.7 Typical Capacity Limits
275 10.8 Effects of Design Parameters
275 10.9 Design Checklist
278 10.10 Example Calculations for Developing Operating Window
281 10.11 Concluding Remarks
296 Nomenclature
297 References
299 PART 4 PROCESS EQUIPMENT ASSESSMENT 301 11 Fired Heater Assessment 303 11.1 Introduction
303 11.2 Fired Heater Design for High Reliability
304 11.3 Fired Heater Operation for High Reliability
310 11.4 Efficient Fired Heater Operation
315 11.5 Fired Heater Revamp
321 Nomenclature
322 References
322 12 Pump Assessment 323 12.1 Introduction
323 12.2 Understanding Pump Head
324 12.3 Define Pump Head - Bernoulli Equation
325 12.4 Calculate Pump Head
329 12.5 Total Head Calculation Examples
330 12.6 Pump System Characteristics - System Curve
332 12.7 Pump Characteristics - Pump Curve
333 12.8 Best Efficiency Point (Bep)
338 12.9 Pump Curves for Different Pump Arrangement
338 12.10 NPSH
340 12.11 Spillback
345 12.12 Reliability Operating Envelope (ROE)
346 12.13 Pump Control
347 12.14 Pump Selection and Sizing
347 Nomenclature
351 References
351 13 Compressor Assessment 353 13.1 Introduction
353 13.2 Types of Compressors
354 13.3 Impeller Configurations
357 13.4 Type of Blades
358 13.5 How a Compressor Works
358 13.6 Fundamentals of Centrifugal Compressors
360 13.7 Performance Curves
362 13.8 Partial Load Control
364 13.9 Inlet Throttle Valve
366 13.10 Process Context for a Centrifugal Compressor
367 13.11 Compressor Selection
368 Nomenclature
369 References
369 14 Heat Exchanger Assessment 371 14.1 Introduction
371 14.2 Basic Concepts and Calculations
371 14.3 Understand Performance Criterion - U Values
374 14.4 Understand Fouling
380 14.5 Understand Pressure Drop
382 14.6 Effects of Velocity on Heat Transfer
Pressure Drop
and Fouling
384 14.7 Heat Exchanger Rating Assessment
385 14.8 Improving Heat Exchanger Performance
396 Nomenclature
399 References
400 15 Distillation Column Assessment 401 15.1 Introduction
401 15.2 Define a Base Case
401 15.3 Calculations for Missing and Incomplete Data
403 15.4 Building Process Simulation
406 15.5 Heat and Material Balance Assessment
408 15.6 Tower Efficiency Assessment
411 15.7 Operating Profile Assessment
414 15.8 Tower Rating Assessment
417 15.9 Guidelines
419 Nomenclature
420 References
420 PART 5 PROCESS SYSTEM EVALUATION 423 16 Energy Benchmarking 425 16.1 Introduction
425 16.2 Definition of Energy Intensity for a Process
426 16.3 The Concept of Fuel Equivalent for Steam and Power (FE)
427 16.4 Data Extraction
429 16.5 Convert All Energy Usage to Fuel Equivalent
432 16.6 Energy Balance
432 16.7 Fuel Equivalent for Steam and Power
435 16.8 Energy Performance Index (EPI) Method for Energy Benchmarking
441 16.9 Concluding Remarks
444 16.10 Nomenclature
445 References
446 17 Key Indicators and Targets 447 17.1 Introduction
447 17.2 Key Indicators Represent Operation Opportunities
448 17.3 Define Key Indicators
451 17.4 Set Up Targets for Key Indicators
456 17.5 Economic Evaluation for Key Indicators
460 17.6 Application 1: Implementing Key Indicators into an "Energy Dashboard"
463 17.7 Application 2: Implementing Key Indicators to Controllers
465 17.8 It is Worth the Effort
466 Nomenclature
467 References
467 18 Distillation System Optimization 469 18.1 Introduction
469 18.2 Tower Optimization Basics
470 18.3 Energy Optimization for Distillation System
475 18.4 Overall Process Optimization
481 18.5 Concluding Remarks
489 References
490 PART 6 OPERATIONAL GUIDELINES AND TROUBLESHOOTING 491 19 Common Operating Issues 493 19.1 Introduction
493 19.2 Catalyst Activation Problems
494 19.3 Feedstock Variations and Contaminants
495 19.4 Operation Upsets
496 19.5 Treating/Cracking Catalyst Deactivation Imbalance
497 19.6 Flow Maldistribution
500 19.7 Temperature Excursion
501 19.8 Reactor Pressure Drop
504 19.9 Corrosion
506 19.10 HPNA
509 19.11 Conclusion
511 20 Troubleshooting Case Analysis 513 20.1 Introduction
513 20.2 Case Study I - Product Selectivity Changes
514 20.3 Case Study II - Feedstock Changes
516 20.4 Case Study III - Catalyst Deactivation Balance
523 20.5 Case Study IV - Catalyst Migration
526 20.6 Conclusion
536 INDEX 537