Hydroprocessing for Clean Energy: Design, Operation, and Optimization

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 INDICE: 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

• ISBN: 978-1-118-92135-7
• Editorial: Wiley–Blackwell
• Encuadernacion: Cartoné
• Páginas: 576
• Fecha Publicación: 07/03/2017
• Nº Volúmenes: 1
• Idioma: Inglés