Petroleum Refining Design and Applications Handboo k Volume 5

ISBN-13: 9781394206988 / Twarda / 2023 / 800 str.

Coker

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Preface xxivAcknowledgments xxvii23 Pressure Relieving Devices and Emergency Relief System Design 123.0 Introduction 123.1 Types of Positive Pressure Relieving Devices (See Manufacturers' Catalogs for Design Details) 223.2 Types of Valves/Relief Devices 6Conventional Safety Relief Valve 6Balanced Safety Relief Valve 7Special Valves 7Rupture Disk 7Example 23.1 1523.3 Materials of Construction 18Safety and Relief Valves: Pressure-Vacuum Relief Values 18Rupture Disks 1923.4 General Code Requirements [1] 2023.5 Relief Mechanisms 20Reclosing Devices, Spring Loaded 20Non-Reclosing Pressure Relieving Devices 2123.6 Pressure Settings and Design Basis 2123.7 Unfired Pressure Vessels Only, But Not Fired or Unfired Steam Boilers 24Non-Fire Exposure 24External Fire or Heat Exposure Only and Process Relief 2423.8 Relieving Capacity of Combinations of Safety Relief Valves and Rupture Disks or Non-Reclosure Devices (Reference ASME Code, Par. UG-127, U-132) 24Primary Relief 24Rupture Disk Devices, [44] Par UG-127 25Footnotes to ASME Code 2623.9 Establishing Relieving or Set Pressures 27Safety and Safety Relief Valves for Steam Service 2823.10 Selection and Application 28Causes of System Overpressure 2823.11 Capacity Requirements Evaluation for Process Operation (Non-Fire) 29Installation 3423.12 Piping Design 37Pressure Drops 37Line Sizing 3723.13 Selection Features: Safety, Safety-Relief Valves, and Rupture Disks 4423.14 Calculations of Relieving Areas: Safety and Relief Valves 4623.15 Standard Pressure Relief Valves Relief Area Discharge Openings 4623.16 Sizing Safety Relief Type Devices for Required Flow Area at Time of Relief 4723.17 Effects of Two-Phase Vapor-Liquid Mixture on Relief Valve Capacity 4723.18 Sizing for Gases or Vapors or Liquids for Conventional Valves with Constant Backpressure Only 47Procedure 48Establish Critical Flow for Gases and Vapors 48Example 23.2: Flow through Sharp Edged Vent Orifice (Adapted after [41]) 5423.19 Orifice Area Calculations [42] 5423.20 Sizing Valves for Liquid Relief: Pressure-Relief Valves Requiring Capacity Certification [5D] 6023.21 Sizing Valves For Liquid Relief: Pressure Relief Valves Not Requiring Capacity Certification [5D] 6123.22 Reaction Forces 66Example 23.3 67Solution 67Example 23.4 69Solution 7023.23 Calculations of Orifice Flow Area using Pressure Relieving Balanced Bellows Valves, with Variable or Constant Backpressure 7223.24 Sizing Valves for Liquid Expansion (Hydraulic Expansion of Liquid Filled Systems/ Equipment/Piping) 8023.25 Sizing Valves for Subcritical Flow: Gas or Vapor But Not Steam [5d] 8123.26 Emergency Pressure Relief: Fires and Explosions Rupture Disks 8423.27 External Fires 8423.28 Set Pressures for External Fires 8523.29 Heat Absorbed 85The Severe Case 8523.30 Surface Area Exposed to Fire 8623.31 Relief Capacity for Fire Exposure 8723.32 Code Requirements for External Fire Conditions 8723.33 Design Procedure 88Example 23.5 88Solution 8823.34 Pressure Relief Valve Orifice Areas on Vessels Containing Only Gas, Unwetted Surface 9223.35 Rupture Disk Sizing Design and Specification 9323.36 Specifications to Manufacturer 9323.37 Size Selection 9423.38 Calculation of Relieving Areas: Rupture Disks for Non-Explosive Service 9423.39 The Manufacturing Range (MR) 9523.40 Selection of Burst Pressure for Disk, P b (Table 23.3) 95Example 23.6: Rupture Disk Selection 9823.41 Effects of Temperature on Disk 9823.42 Rupture Disk Assembly Pressure Drop 10123.43 Gases and Vapors: Rupture Disks [5a, Par, 4.8] 101Volumetric Flow: scfm Standard Conditions (1.4.7 psia and 60°F) 102Steam: Rupture Disk Sonic Flow; Critical Pressure = 0.55 and P 2 /p 1 is Less Than Critical Pressure Ratio of 0.55 10323.44 API for Subsonic Flow: Gas or Vapor (Not Steam) 10323.45 Liquids: Rupture Disk 10423.46 Sizing for Combination of Rupture Disk and Pressure Relief Valve in Series Combination 105Example 23.7: Safety Relief Valve for Process Overpressure 106Example 23.8: Rupture Disk External Fire Condition 106Solution 107Heat Input 107Total Heat Input (from Figure 23.30a) 107Quantity of Vapor Released 107Critical Flow Pressure 107Disk Area 108Example 23.9: Rupture Disk for Vapors or Gases; Non-Fire Condition 108Solution 108Example 23.10: Liquids Rupture Disk 109Example 23.11: Liquid Overpressure, Figure 23.34 11023.47 Pressure-Vacuum Relief for Low-Pressure Storage Tanks 11023.48 Basic Venting For Low-Pressure Storage Vessels 11123.49 Non-Refrigerated Above Ground Tanks; API-Std. 2000 11223.50 Boiling Liquid Expanding Vapor Explosions (BLEVEs) 113Ignition of Flammable Mixtures 11623.51 Managing Runaway Reactions 116Hydroprocessing Units 117Acid/Base Reactions 118Methanation 118Alkylation Unit Acid Runaway 11823.51.1 Runaway Reactions: DIERS 11823.52 Hazard Evaluation in the Chemical Process Industries 12023.53 Hazard Assessment Procedures 121Exotherms 122Accumulation 12223.54 Thermal Runaway Chemical Reaction Hazards 122Heat Consumed Heating the Vessel. The x-Factor 123Onset Temperature 124Time-To-Maximum Rate 125Maximum Reaction Temperature 125Vent Sizing Package (VSP) 126Vent Sizing Package 2 (TM) (VSP2 (TM)) 127Advanced Reactive System Screening Tool (ARSST) 12823.55 Two-Phase Flow Relief Sizing for Runaway Reaction 128Runaway Reactions 131Vapor Pressure Systems 132Gassy Systems 132Hybrid Systems 132Simplified Nomograph Method 134Vent Sizing Methods 138Vapor Pressure Systems 138Fauske's Method 140Gassy Systems 142Homogeneous Two-Phase Venting Until Disengagement 143Two-Phase Flow Through an Orifice 144Conditions of Use 14523.56 Discharge System 145Design of The Vent Pipe 145Safe Discharge 146Direct Discharge to The Atmosphere 147Example 23.12 147Tempered Reaction 147Solution 147Example 23.13 149Solution 149Example 23.14 150Solution 151Example 23.15 152Solution 152DIERS Final Reports 15523.57 Sizing for Two-Phase Fluids 155Example 23.16 161Solution 162Example 23.17 164Solution 164Example 23.18 172Example 23.19 177Solution 178Type 3 Integral Method [5] 179Example 23.20 [76] 180Solution 18123.58 Flares/Flare Stacks 182Flares 184Sizing 184Flame Length [5c] 186Flame Distortion [5c] Caused by Wind Velocity 187Flare Stack Height 189Flaring Toxic Gases 194Purging of Flare Stacks and Vessels/Piping 195Pressure Purging 195Example 23.21: Purge Vessel by Pressurization Following the Method of [41] 19523.59 Compressible Flow for Discharge Piping 197Design Equations for Compressible Fluid Flow for Discharge Piping 197Critical Pressure, P crit 200Compressibility Factor Z 201Friction factor, f 202Discharge Line Sizing 20323.60 Vent Piping 204Discharge Reactive Force 204Example 23.22 205Solution 206Example 23.23: Flare and Relief Blowdon System 208Solution 208A Rapid Solution for Sizing Depressuring Lines [5c] 208Codes and Standards 212Discharge Locations 213Process Safety Incidents with Relief Valve Failures and Flarestacks 214A Case Study on Williams Geismar Olefins Plant, Geismar, Louisiana [95] 214Process Flow of the Olefins 214The Incident 216Technical Analysis 219Key Lessons 222Explosions in Flarestacks 225Relief Valves 227Location 228Relief Valve Registers 228Relief Valve Faults [92] 229Tailpipes [92] 230GLOSSARY 230Acronyms and Abbreviations 239Nomenclature 240Subscripts 244Greek Symbols 244References 245World Wide Web on Two-Phase Relief Systems 24724 Process Safety and Energy Management in Petroleum Refinery 24924.1 Introduction 24924.2 Process Safety 25024.2.1 Process Safety Information 25324.2.2 Conduct of Operations (COO) and Operational Discipline (OD) 254Process Safety Culture: BP Refinery Explosion, Texas City, 2005 257Detailed Description 257Causes 258Key Lessons 260Process Safety Culture 260Selected CSB Findings 260Selected Baker Panel Finding 261Process Knowledge Management 261Training and Performance Assurance 261Management of Change (MOC) 261Asset Integrity and Reliability 26124.2.3 Process Hazard Analysis 262Safe Operating Limits 263Impact on Other Process Safety Elements 26424.3 General Process Safety Hazards in a Refinery 265Desalters 266Critical Operating Parameters Impacting Process Safety 266The Quality of Aqueous Effluent from Desalters 267Desalter Water Supply 267Vibration within Relief Valve (RV) Pipework 267Example of Process Safety Incidents and Hazards 267Hydrotreating [2] 26724.4 Example of Process Safety Incidents and Hazards 267Catalytic Cracking [2] 27024.5 Process Safety Hazards 270Reforming 271Alkylation [2] 271Hydrotreating Units 27124.5.1 Examples of Process Safety Incidents and Hazards 272HF release, Texas City, TX, 1987 [2] 272HF release, Corpus Christi, TX, 2009 272HF release at Philadelphia Energy Solutions Refining and Marketing LLC (PES), Philadelphia 2019 273Post-Incident Activities 276Coking [2] 277Equilon Anacortes Refinery Coking Plant Accident, 1998 277Design Considerations 27824.6 Hazards Relating to Equipment Failure 27824.7 Columns and Other Process Pressure Vessels and Piping 279Corrosion 279Corrosion Inhibitors 28024.8 Inadequate Design and Construction 290Corrosion within "dead legs" 29024.9 Inadequate Material of Construction Specification 29024.10 Material Failures and Process Safety Prevention Programs 291Piping Repair Incident at Tosco Avon Refinery, CA, USA 291Lessons Learned from this accident 29724.11 Hazard and Operability Studies (HAZOP) 297Study Co-ordination 30324.11.1 HAZOP Documentation Requirements 30324.11.2 The Basic Concept of HAZOP 30424.11.3 Division into Sections 304Use of Guidewords 30424.11.4 Conducting a HAZOP Study 305Define Objective and Scope 306Prepare for the Study 307Record the Results 30724.11.5 Hazop Case Study [8] 30724.11.6 HAZOP of a Batch Process 308Limitations of HAZOP Studies 315Conclusions 31524.12 Hazan 31524.13 Fault Tree Analysis 31724.14 Failure Mode and Effect Analysis (FMEA) 318Methodology of FMEA 318Definition of System to be Evaluated 318Level of Analysis 318Analysis of Failures 31824.15 The Swiss Cheese Model 31924.16 Bowtie Analysis 320Validity Rules for Barriers 320Example 322Process Safety Isolation Practices in Petroleum Refinery and Chemical Process Industries 32224.17 Inherently Safer Plant Design 325Inherently Safer Plant Design in Reactor Systems 32724.18 Energy Management in Petroleum Refinery 330Total cost of energy 331Energy Policy 331Crude Distillation Unit 332Heat Exchangers 332Steam Traps 333Optimization of Refinery Steam/Power System 333Reducing fouling/surface cleaning/surface coating in heat exchanger/furnace 333Pumping System 333Electric Drives 334Furnace System 334Compressed Air 335Flare System 33524.18.1 Environmental Impact of Flaring 33624.18.2 Environmental Impact of Petroleum Industry 33724.18.3 Environmental Impact Assessment (EIA) 33924.18.4 Pollution Control Strategies in Petroleum Refinery 34024.18.5 Energy Management and Co2 Emissions in Refinery 34524.19 Benchmarking in Refinery 345Glossary 346Acronyms and Abbreviations 354References 35425 Product Blending 35725.0 Introduction 35725.1 Blending Processes 36025.1.1 Gasoline Blending 36125.2 Ternary Diagram of Crude Oils 36125.2.1 Elemental Analysis and Ternary Classification of Crude Oils 36125.2.2 Reading a Ternary Diagram 363Solution 364Example 25.1 364References 464Bibliography 46626 Cost Estimation and Economic Evaluation 46726.1 Introduction 46726.2 Refinery Operating Cost 46826.2.1 Theoretical Sales Realization Valuation Method 470Example 26.14 538Solution 538Product Quality 539Standard Density 539Blending Components 539Constraining Properties 539Quality Premiums/Discounts 539A Case Study [44] 540Problem Statement 540Process Description 542Catalytic Reformer 542Naphtha Desulfurizer 544Summary of Investment and Utilities Costs 545Calculation of Direct Annual Operating Costs 545On-Stream Time 546Water Makeup 546Power 546Fuel 546Royalties 547Catalyst Consumption 548Insurance 548Local Taxes 548Maintenance 548Miscellaneous Supplies 548Plant Staff and Operators 548Calculations of Income before Income Tax 549Summary of Direct Annual Operating Costs 549Calculation of ROI 550Carbon footprint 558Global Warming Potential (GWP) 558An Improved Method of Using GWPs 560Solution 562Carbon Dioxide Equivalent 565Carbon Credit 566Carbon Offset 566Carbon Price 567Nomenclature 567References 568Bibliography 56927 Sustainability in Engineering, Petroleum Refining and Alternative Fuels 57127.0 Introduction 57127.1 Impacts on the Overall Greenhouse Effect 57627.2 Carbon Capture and Storage in Refineries 57827.3 Sustainability in the Refinery Industries 58027.4 Sustainability in Engineering Design Principles 58227.5 Alternative Fuels (Biofuels) 58727.6 Process Intensification (PI) in Biodiesel 58927.7 Biofuel from Green Diesel 592Analysis 592Processing of Biodiesel 59227.7.1 Specifications of Biodiesel 596Advantages 597Disadvantages 59727.7.2 Bioethanol 59727.7.3 Biodiesel Production 601Application 601Process 602Reaction Chemistry 603Economics 60327.7.4 An Alternative Process of Manufacturing Biodiesel 604Reaction Chemistry 60727.7.5 Biofuel from Algae 60727.7.6 Economic Viability of Algae 60827.8 Fast Pyrolysis 60927.8.1 Fast Pyrolysis Principle 60927.8.2 Fast Pyrolysis Technologies 61027.8.3 Minerals of Biomass 61127.8.4 Applications of Fast Pyrolysis Liquid 611Heat and Power 61127.8.5 Chemicals and Materials 61327.8.6 Bio-Fuels-Fast Pyrolysis Bio-Oil (FPBO) from Biomass Residues 613Feedstocks 61427.8.7 Properties of Pyrolysis Oil 615Main advantages 61627.9 Acid Gas Removal 617Chemical Solvent Processes 617Physical Solvent Processes 61727.9.1 Process Description of Amine Gas Treating 618Chemical Reactions 618For hydrogen sulfide H2 S removal: 618For carbon dioxide (CO2) removal 618Amines Used [48] 62127.9.2 Equilibrium Data for Amine-Sour Gas Systems 62527.9.3 Emerging Technologies [48] 625Chemistry 62727.9.4 Advanced Amine Based Solvents 627Chemistry 628Disadvantages of Amine Solvents 62827.10 Alkaline Salt Process (Hot Carbonate) 629Split Flow Process of Potassium Carbonate Process 630Two Stage Process 63027.11 Ionic Liquids 632Disadvantages 632Viscosity 633Tunability 633Design Suite R470 Technology) 634Learning Objectives 634Building the Simulation 636Defining the Simulation Basis 636Amines Property Package 636Column Overview 636Contactor 636Adding the Basics 636Adding the feed streams 636Physical Unit Operations 638Separator Operation 638Contactor Operation 639Valve Operation 641Separator Operation 641Heat Exchanger Operation 642Regenerator Operation 643Mixer Operation 644Cooler Operation 646Pump Operation 646Adding Logical Unit Operations 647Set Operation 647Recycle Operation 648Save your case 649Analyzing the Results 649Systems Thinking 657Global Mechanisms 657Best Available Techniques 657Innovation 65727.29 Conclusions 722Glossary 723References 729Bibliography 732Appendix D 733Glossary of Petroleum and Petrochemical Technical Terminologies 809About the Author 937Index 939

O autorze

A. Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company (SASREF) and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. (C. Eng., FIChemE), and a senior member of the American Institute of Chemical Engineers (AIChE). He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K., and a Teacher's Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of 10 books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train - the mentor trainer. A Technical Report Assessor and Interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, U.K. (IBC) as Leading Engineers of the World for 2008. Also, he is a member of International Who's Who of ProfessionalsTM and Madison Who's Who in the U.S.