Data Sources For Calculating Chemical Reaction Equilibria

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Data Sources For Calculating Chemical Reaction Equilibria 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 BACKGROUND TO THEORY 5 BIBLIOGRAPHY

Technologie Business

GBH Enterprises, Ltd.

Process Engineering Guide:
GBHE-PEG-FLO-300

Data sources for Calculating
Chemical Reaction Equilibria
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

Process Engineering Guide:

Data sources for Calculating
Chemical Reaction Equilibria

CONTENTS

SECTION

0

INTRODUCTION/PURPOSE

2

1

SCOPE

2

2

FIELD OF APPLICATION

2

3

DEFINITIONS

2

4

BACKGROUND TO THEORY

2

5

BIBLIOGRAPHY

3

TABLE

1

SOURCES OF DATA

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

0

INTRODUCTION/PURPOSE

This Guide is one of a series produced for GBH Enterprises.
The calculation of chemical equilibria for a single notional reaction is rarely
difficult. A typical example is given in GBHE-PEG-RXT-813. The solution of such
cases is well understood; the mass action equation generates a polynomial
relationship between conversion and equilibrium constant (or free energy) which
can be solved (at worst iteratively) and the relevant root selected by inspection.
Extension of this approach to more than one reaction rapidly becomes untenable
for hand calculation due to the highly non-linear nature of the resulting
simultaneous equations. The solution of these multi-reaction equilibrium
problems has been investigated since the early days of the Second World War
when interest in rocket motor design became strategically important. Indeed,
work for the V2 at the "Hermann Göring Air Force Research Institute" provided
some of the earliest papers on the subject.
To this day, combustion/explosion problems remain the mainspring of research
effort in this area and a number of commercially available computer programs
have appeared in the public domain.
1

SCOPE

This Guide provides a comprehensive list of sources of data for calculating
chemical reaction equilibria, for Reactor Modeling.

2

FIELD OF APPLICATION

This Guide applies to process engineers in GBH Enterprises worldwide.

3

DEFINITIONS

No specific definitions apply to this Guide.
With the exception of terms used as proper nouns or titles, those terms with initial
capital letters which appear in this document and are not defined above are
defined in the Glossary of Engineering Terms.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

4

BACKGROUND TO THEORY

For a detailed discussion of the theory the reader is referred to Smith and Missen
(1982).
5

BIBLIOGRAPHY

Note:
The reference numbers in the left hand column correspond to those numbers listed in the footer
to Table 1.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

Note:The reference numbers in the left hand column correspond to those numbers listed in the
footer to Table 1.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

Contenu connexe

Tendances

0 INTRODUCTION The four main sources of Fugitive Emissions on most plants are valves, machine seals, re-makable joints and pressure relief devices. Other possible sources include open-ended lines, sampling connections, drains and vents. Sometimes special precautions are taken to minimize Fugitive Emissions, for example the use of bellows seal valves. However, generally no special precautions are taken and the subsequent Fugitive Emissions to atmosphere represent a significant amount of plant losses. Regulatory requirements covering Fugitive Emissions exist in many countries and therefore a leak reduction program should be implemented. Fugitive Emissions also represent financial losses to the business as well as potential damage to the environment.

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Heating and Cooling of Batch Processes

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How to Use the GBHE Mixing Guides

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Integration of Reciprocating Metering Pumps into a Process Engineering Design Guide 1 SCOPE 2 PRELIMINARY CHOICE OF PUMP SECTION A - TYPE/FLOW/PRESSURE/SPEED RATING Al Pumping Pressure A2 Pump Flowrate and Capacity A3 Guide to Pump Speed & Type A4 Metering Criteria A5 Pressure Pulsation A6 Over Delivery SECTION B - INLET CONDITIONS B1 Calculation of Basic NPSH B2 Correction for Frictional Head B3 Correction for Acceleration Head B4 Calculation of Available NPSH B5 Corrections to NPSH for Fluid Properties B6 Estimation of NPSH Required B7 Priming SECTION C - POWER RATING C1 Pump Efficiency C2 Calculation of Absorbed Power C3 Determination of Driver Power Rating SECTION D - CASING PRESSURE RATING Dl Calculation of Maximum Discharge Pressure D2 Discharge Pressure Relief Rating D3 Calculation of Pump Head Outlet Losses D4 Casing Hydrostatic Test Pressure APPENDICES A RELIABILITY CLASSIFICATION FIGURES A3.1 ESTIMATE OF CRANK SPEED A3.3 SELECTION OF PUMPING HEAD TYPE B5.1 ESTIMATE OF VISCOSITY OF FINE SUSPENSIONS B6 ESTIMATE OF NPSH REQUIRED C1.1 GRAPH - VOLUMETRIC EFFICIENCY VS MEAN DIFFERENTIAL PRESSURE

Integration of Reciprocating Metering Pumps Into A Process

Gerard B. Hawkins

Design and Rating of Trayed Distillation Columns 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 DESIGN PHILOSOPHY 5 PERFORMANCE GUARANTEES 6 TRAY DESCRIPTION 7 DESIGN CALCULATIONS 7.1 Rough Design 7.2 Preliminary Design 7.3 Detailed Design and Rating 8 PROGRAM USE – DESIGN CONSIDERATIONS 8.1 General Considerations 8.2 Effects of Design Variables on Performance Parameters 9 PRACTICAL ASPECTS OF TRAY DESIGN 9.1 Liquid Feeds 9.2 Vapor Feeds 9.3 Two Phase or Flashing Feeds 9.4 Reboiler Returns 9.5 Liquid Drawoffs 9.6 Vapor Drawoffs 9.7 Reboiler Circuits 10 TRAY VIBRATION 10.1 Unstable Flow 10.2 Oscillation Frequencies 10.3 Analysis of Tray Vibration and Action to be Taken 11 REFERENCES APPENDICES A TRAY DEFINITIONS FIGURES 1 TYPICAL TRAY LAYOUT 2 LIQUID RECIRCULATION ON A LARGE ONE-PASS TRAY 3 BASIC CROSS FLOW TRAY LAYOUTS 4 TRAY DESIGN DEFINITIONS 5 LIQUID FEEDS 6 REBOIL RETURN NOZZEL 7 PARTIAL LIQUID DRAWOFF FROM BOTTOM OF DOWNCOMER 8 CHIMMNEY TRAY 9 VAPOR DRAWOFF – INTERMEDIATE TRAY 10 TOWER INTERNALS FOR REBOILER CIRCUITS 11 IDEALIZED PRESSURE DROP CHARACTERISTIC 12 TYPICAL SIEVE TRAY PRESSURE DROP CHARACTERISTIC

Design and Rating of Trayed Distillation Columns

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DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS CONTENTS 1 INTRODUCTION 1.1 Purpose 1.2 Scope of this Guide 1.3 Use of the Guide 2 ENVIRONMENTAL ISSUES 2.1 Principal Concerns 2.2 Mechanisms for Ozone Formation 2.3 Photochemical Ozone Creation Potential 2.4 Health and Environmental Effects 2.5 Air Quality Standards for Ground Level Concentrations of Ozone, Targets for Reduction of VOC Discharges and Statutory Discharge Limits 3 VENTS REDUCTION PHILOSOPHY 3.1 Reduction at Source 3.2 End-of-pipe Treatment 4 METHODOLOGY FOR COLLECTION & ASSESSMENT OF PROCESS FLOW DATA 4.1 General 4.2 Identification of Vent Sources 4.3 Characterization of Vents 4.4 Quantification of Process Vent Flows 4.5 Component Flammability Data Collection 4.6 Identification of Operating Scenarios 4.7 Quantification of Flammability Characteristics for Combined Vents 4.8 Identification, Quantification and Assessment of Possibility of Air Ingress Routes 4.9 Tabulation of Data 4.10 Hazard Study and Risk Assessment 4.11 Note on Aqueous / Organic Wastes 4.12 Complexity of Systems 4.13 Summary 5 SAFE DESIGN OF VENT COLLECTION HEADER SYSTEMS 5.1 General 5.2 Process Design of Vent Headers 5.3 Liquid in Vent Headers 5.4 Materials of Construction 5.5 Static Electricity Hazard 5.6 Diversion Systems 5.7 Snuffing Systems 6 SAFE DESIGN OF THERMAL OXIDISERS 6.1 Introduction 6.2 Design Basis 6.3 Types of High Temperature Thermal Oxidizer 6.4 Refractories 6.5 Flue Gas Treatment 6.6 Control and Safety Systems 6.7 Project Program 6.8 Commissioning 6.9 Operational and Maintenance Management APPENDICES A GLOSSARY B FLAMMABILITY C EXAMPLE PROFORMA D REFERENCES DOCUMENTS REFERRED TO IN THIS PROCESS GUIDE TABLE 1 PHOTOCHEMICAL OZONE CREATION POTENTIAL REFERENCED TO ETHYLENE AS UNITY FIGURES 1 SCHEMATIC OF TYPICAL VENT COLLECTION AND THERMAL OXIDIZER SYSTEM 2 TYPICAL KNOCK-OUT POT WITH LUTED DRAIN 3 SCHEMATIC OF DIVERSION SYSTEM 4 CONVENTIONAL VERTICAL THERMAL OXIDIZER 5 CONVENTIONAL OXIDIZER WITH INTEGRAL WATER SPARGER 6 THERMAL OXIDIZER WITH STAGED AIR INJECTION 7 DOWN-FIRED UNIT WITH WATER BATH QUENCH 8 FLAMELESS THERMAL OXIDATION UNIT 9 THERMAL OXIDIZER WITH REGENERATIVE HEAT RECOVERY 10 TYPICAL PROJECT PROGRAM 11 TYPICAL FLAMMABILITY DIAGRAM 12 EFFECT OF DILUTION WITH AIR 13 EFFECT OF DILUTION WITH AIR ON 100 Rm³ OF FLAMMABLE GAS

DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS

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The Design and Layout of Vertical Thermosyphon Reboilers 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 THE DESIGN PROBLEM 5 COMPUTER PROGRAMS 6 GENERAL CONSIDERATIONS 6.1 Heating Medium Temperature 6.2 Fouling Resistance 7 DESIGN PARAMETERS 7.1 Overall Arrangement and Specifications 7.2 Geometry Elements 8 ANALYSIS OF COMMERCIALLY AVAILABLE PROGRAM RESULTS 8.1 Main Results 8.2 Supplementary Results 8.3 Error Analysis 8.4 Adjustments to Design 9 OPERATING RANGE 10 CONTROL 10.1 Control of Condensing Heating Medium Pressure 10.2 Control of The Condensate Level 10.3 Control of Sensible Fluid Flow Rate 11 LAYOUT 11.1 Factors Influencing Design 11.2 A Standard Layout 12 BIBLIOGRAPHY

The Design and Layout of Vertical Thermosyphon Reboilers

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PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF AQUEOUS ORGANIC EFFLUENT STREAMS CONTENTS 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 3.1 IPU 3.2 AOS 3.3 BODs 3.4 COD 3.5 TOC 3.6 Toxicity 3.7 Refractory Organics/Hard COD 3.8 Heavy Metals 3.9 EA 3.10 Biological Treatment Terms 3.11 BATNEEC 3.12 BPEO 3.13 EQS/LV 3.14 IPC 3.15 VOC 3.16 F/M Ratio 3.17 MLSS 3.18 MLVSS 4 DESIGN/ECONOMIC GUIDELINES 5 EUROPEAN LEGISLATION 5.1 General 5.2 Integrated Pollution Control (IPC) 5.3 Best Available Techniques Not Entailing Excessive Costs (BATNEEC) 5.4 Best Practicable Environmental Option (BPEO) 5.5 Environmental Quality Standards(EQS) 6 IPU EXIT CONCENTRATION 7 SITE/LOCAL REQUIREMENTS 8 PROCESS SELECTION PROCEDURE 8.1 Waste Minimization Techniques (WMT) 8.2 AOS Stream Definition 8.3 Technical Check List 8.4 Preliminary Selection of Suitable Technologies 8.5 Process Sequences 8.6 Economic Evaluation 8.7 Process Selection APPENDICES A DIRECTIVE 76/464/EEC - LIST 1 B DIRECTIVE 76/464/EEC - LIST 2 C THE EUROPEAN COMMISSION PRIORITY CANDIDATE LIST D THE UK RED LIST E CURRENT VALUES FOR EUROPEAN COMMUNITY ENVIRONMENTAL QUALITY STANDARDS AND CORRESPONDING LIMIT VALUES F ESTABLISHED TECHNOLOGIES G EMERGING TECHNOLOGY H PROPRIETARY/LESS COMMON TECHNOLOGIES J COMPARATIVE COST DATA

PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...

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Selection of Heat Exchanger Types

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Control of Continuous Distillation Columns 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 GENERAL DESCRIPTION OF A DISTILLATION COLUMN 5 REGULATORY CONTROL 5.1 Composition Control 5.2 Mass Balance Control 5.3 Design of Feedback Control Systems 5.4 Pressure and Condensation Control 5.5 Reboiler Control 6 DISTURBANCE COMPENSATION 6.1 Feed-forward Control 6.2 Cascade Control 6.3 Internal Reflux Control 7 CONSTRAINT CONTROL 7.1 Override Controls 7.2 Flooding 7.3 Limiting Control 8 MORE ADVANCED TOPICS 8.1 Temperature Position Control 8.2 Inferential Measurement 8.1 Floating Pressure Control 8.2 Model Based Predictive Control 8.1 Control of Side-streams 8.2 Extractive/Azeotropic Systems 9 REFERENCES TABLES 1 SYMPTOMS OF IMBALANCE AND THE REGULATORY VARIABLES 2 PRACTICAL LINKAGES BETWEEN CONTROL (P, R, B, C) AND REGULATION VARIABLES (h, r, d, b, c, v) 3 COMPOSITION REGULATION 4 COMPOSITION REGULATION - VERY SMALL FLOWS

Control of Continuous Distillation Columns

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Start Up Procedures for Primary Reforming Catalyst

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Thermal Design Margins for Heat Exchangers 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 TERMINOLOGY 5 REASONS FOR SPECIFYING A DESIGN MARGIN 5.1 Instantaneous Rates 5.2 Future Uprating 5.3 Plant Upsets 5.4 Process Control 5.5 Uncertainties in Properties 5.6 Uncertainties in Design Methods 5.7 Fouling 6 COMBINATION OF DESIGN MARGINS 7 CRITICAL AND NON-CRITICAL DUTIES 7.1 General 7.2 Penalties of Over-design 8 OPTIMIZATION OF EXCHANGER DUTY 9 WAYS OF PROVIDING DESIGN MARGINS 9.1 The Provision of Excess Surface 9.2 Decreasing the Design Temperature Difference 9.3 Increasing the Design Process Throughput 9.4 Increasing the Design Fouling Resistance 9.5 Reducing the Design Process Outlet Temperature Approach 9.6 Adjusting the Physical Properties 10 ACCURACY OF THE DESIGN METHODS FOR SHELL AND TUBE EXCHANGERS 10.1 Pressure Drop 10.2 Heat Transfer 11 SUGGESTED DESIGN MARGINS 11.1 No Phase Change Duties 11.2 Condensers 11.3 Boilers 12 EFFECT OF UNDER- OR OVER-SURFACE ON PERFORMANCE FIGURES 1 EFFECT OF LENGTH ON EXCHANGER DUTY COUNTERCURRENT FLOW, C* = 1.0 2 EFFECT OF NUMBER OF TUBES ON EXCHANGER PERFORMANCE COUNTERCURRENT FLOW, C* = 1.0, ALL RESISTANCE IN TUBES 3 EFFECT OF TUBE LENGTH ON NUMBER OF TUBES, AREA AND PRESSURE DROP

Thermal Design Margins for Heat Exchangers

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0 INTRODUCTION / PURPOSE 1 SCOPE SECTION ONE - INTEGRATING.THE PUMP INTO THE SYSTEM 2 AVAILABILITY CONSIDERATIONS 3 CHOICE OF NUMBER OF PUMPS 4 CHOICE OF PUMP TYPE 4.1 Barske Type 4.2 Peripheral Type 4.3 Multistage Centrifugal Type 4.4 Inlet Booster Pumps 5 DRIVERS 5.1 Steam Turbines 5.2 Electric Motors 5.3 Dual Drivers 6 DUTY 6.1 Differential Head 6.2 Capacity 6.3 NPSH 7 MINIMUM FLOW THROUGH PUMP 7.1 Limit due to Instability in Head/Flow Characteristic 7.2 Minimum Flow Arrangements 7.3 Variable Speed Control 8 TRANSIENT EFFECTS 8.1 Reverse Flow upon Trip 8.2 Flashing 9 TEMPERATURE GRADIENTS IN CASINGS 10 INLET STRAINERS AND CASING PIPING CONNECTIONS 10.1 Strainers 10.2 Casing Piping Arrangements 11 SEAL COOLING 11.1 Packed Glands for Category 1 Pumps 11.2 Mechanical Seals SECTION TWO - PUMP CONSTRUCTION FEATURES 12 MINIMUM FLOW THROUGH PUMP 12.1 Limit Due to First Stage Cavitation Damage 12.2 Limit Due to Instability in Head/Flow Characteristic 13 IMPELLER/DIFFUSER STAGE 13 .1 Local Cavitation 13.2 Labyrinth or Bushing Clearances 13.3 Clearances Affecting Hydraulic Forces 14 ROTOR 14. 1 Rotor Dynamics 14.2 Rotor Mechanical Balance 14.3 Torsional Critical Speeds 14.4 Rotor Assembly 15 GLAND ARRANGEMENTS 15.1 Guarding 15.2 Soft-Packed Glands 15.3 Mechanical Seals for Category 1 Pumps 15.4 Mechanical Seals for Category 2 Pumps 16 AXIAL HYDRAULIC THRUST BALANCE METHODS 16. 1 Opposed Impeller Configuration 16.2 Balance Disc 16.3 Balance Piston 17 CASING 17.1 Casing Type 17.2 Casing Connections 18 MATERIALS 19 DRIVER CONSIDERATIONS

Boiler Feedwater Pumps

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Estimation of Pressure Drop in Pipe Systems 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 3.1 units 4 SOURCES OF DATA 5 BASIC CONCEPTS 5.1 Equation for Pressure Change in a Flowing Fluid 5.2 Static and Stagnation Pressures 5.3 Sonic Flow 6 INCOMPRESSIBLE FLOW IN PIPES OF CONSTANT CROSS-SECTION 6.1 Straight Circular Pipes 6.2 Ducts of Non-circular Cross-section 6.3 Coils 6.4 General Equation for Incompressible Flow in Pipes of Constant Cross-section 7 COMPRESSIBLE FLOW IN PIPES OF CONSTANT CROSS-SECTION 7.1 Isothermal Flow 7.2 Adiabatic Flow 7.3 Estimation of Pressure Drop for Adiabatic Flow in Pipes of Constant Cross-section 7.4 Ratio of Isothermal to Adiabatic Pressure Drop 8 FLOW IN PIPE FITTINGS 8.1 Incompressible Flow 8.2 Compressible Flow 9 FLOW IN BENDS 9.1 Incompressible Flow in Bends 9.2 Compressible Flow in Bends 10 CHANGES IN CROSS-SECTIONAL AREA 9.1 Incompressible Flow 9.2 Compressible Flow 11 ORIFICES, NOZZLES AND VENTURIS 11.1 Incompressible Flow through an Orifice 11.2 Compressible Flow through an Orifice or Nozzle 11.3 Venturi Choke Tubes 12 VALVES 12.1 General 12.2 Incompressible Flow in Valves 12.2 Compressible Flow in Valves 13 COMBINING AND DIVIDING FLOW 9.1 Incompressible Flow 9.2 Compressible Flow 14 COMPUTER PROGRAMS FOR FLUID FLOW 15 NOMENCLATURE 16 REFERENCES APPENDICES A BASIC THERMODYNAMICS B COMPRESSIBLE FLOW THROUGH ORIFICES C THE ‘TWO-K’ METHOD FOR FITTING PRESSURE LOSS

Estimation of Pressure Drop in Pipe Systems

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Study 2: Front-End Engineering Design and Project Definition CONTENTS 2.0 PURPOSE 2.0.1 Team 2.0.2 Timing 2.0.3 Documentation HAZARD STUDY 2: APPLICATION 2.1 Study of Process and Non-Process Activities 2.2 Study of Programmable Electronic Systems (PES) 2.3 Risk Assessment 2.4 Defining the Basis for Safe Operation 2.5 Review of Hazard Study 2 APPENDICES Appendix A Hazard Study 2 Method A.1 Significant Hazards Flowsheet A.2 Event Guide Diagram A.3 Consequence Guide Diagram A.4 Typical Measures to Reduce Consequences Appendix B Programmable Electronic Systems (PES) Guide Diagram Appendix C Risk Assessment C.1 Risk Assessment Procedure C.2 Risk Matrix C.3 Risk Matrix Guidance for Consequence Categories – Safety and Health Incidents C.4 Risk Matrix Guidance for Consequence Categories – Environmental Incidents Appendix D Key Hazards and Control Measures Appendix E Content of Hazard Study 2 Report Package.

Study 2: Front-End Engineering Design and Project Definition

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Gas Solid Mixing 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 GAS-SOLID FLUIDIZED BED 5 MIXING IN FLUIDIZED BEDS 5.1 Group A Powders 5.2 Group B Powders 5.3 Group C Powders 5.4 Group D Powders 6 MECHANISMS OF MIXING AND SEGREGATION 6.1 Particle Segregation 6.2 Rate of Mixing 6.3 Solids Circulation 7 GRID DESIGN 7.1 Choice of Configuration 8 PLENUM CHAMBER DESIGN 9 SPOUTED BED 10 NOMENCLATURE 11 BIBLIOGRAPHY FIGURES 1 POWDER CLASSIFICATION DIAGRAM FOR FLUIDIZATION BY AIR 2 DIAGRAMMATIC REPRESENTATION OF MIXING BY A SINGLE RISING BUBBLE IN A BED OF SMALL PARTICLES 3 SEGREGATION PATTERNS WITH 'PRACTICAL' MATERIALS 4 SPOUTED BED – DIAGRAMMATIC

Gas Solid Mixing

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Examination of Critical Centrifugal Fans and Blowers 0 INTRODUCTION/PURPOSE 0.1 Reasons for Critical Classification of Arduous Duty Fans < 500 kW 0.2 Reasons for Critical Classification of Arduous Duty Fans > 500 kW 0.3 Critical Classification for High Substance Hazard Reasons 0.4 Centrifugal Blowers 0.5 General Purpose Fans 1 SCOPE 3 2 FIELD OF APPLICATION 3 3 DEFINITIONS 3 4 PRINCIPLES 4 5 CONDITION MONITORING 4 6 EXAMINATION 4 6.1 Impeller 5 6.2 Shaft and Sleeves 5 6.3 Bearings 5 7 ADDITIONAL EXAMINATION REQUIREMENTS FOR ALL FANS DEEMED CRITICAL FOR HIGH PROCESS SUBSTANCE HAZARD REASONS 7 7.1 Casing 7 7.2 Dynamic Seals 7 APPENDICES A EXAMINATION LOGIC DIAGRAM

Examination of Critical Centrifugal Fans and Blowers

Gerard B. Hawkins

General Water Treatment For Cooling Water 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 CHOICE OF COOLING SYSTEM 4.1 ‘Once through' Cooling Systems 4.2 Open Evaporative Recirculating Systems 4.3 Closed Recirculating Systems 4.4 Comparison of Cooling Systems 5 MAKE-UP WATER QUALITY 6 FOULING PROCESSES 6.1 Deposition 6.2 Scaling 6.3 Corrosion 6.4 Biological Growth 7 CONTROL OF THE COOLING SYSTEM 7.1 ‘Once through' Cooling Systems 7.2 Closed Recirculating Systems 7.3 Open Evaporative Cooling Systems TABLES 1 RELATIVE IMPORTANCE OF FOULING PROCESSES AND INSTALLED COSTS 2 WATER QUALITY PARAMETERS FIGURES 1 PREDICTION OF CALCIUM CARBONATE SCALING 2 CALCIUM SULFATE SOLUBILITY 3 CALCIUM PHOSPHATE SCALING INDEX

General Water Treatment For Cooling Water

Gerard B. Hawkins

Centrifugal Pump Operation and Maintenance Code of Practice 1 SCOPE 2 SETTING UP A MAINTENANCE INSPECTION SYSTEM 2.1 Design and Purchase 2.2 Maintenance Data 2.2.1 Data File 2.2.2 Maintenance Data Card 2.2.3 Plant Pump Schedule 2.2.4 Maintenance Record Card 2.2.5 Pump Maintenance Report 2.2.6 Lubrication Schedule 3 CONTROL OF MODIFICATIONS 4 PUMP COMPONENT FAILURE MODES 4.1 Bearings 4.4.1 Adequacy of oil or grease supply 4.1.2 Mechanical Breakdown 4.1.3 External Factors 4.2 Seals 4.2.1 Seat Wear 4.2.2 Shaft or Sleeve Fretting 4.2.3 Multiple Spring or Bellows Breakages 4.2.4 Double Seal Arrangements (Back-to-Back) 4.2.5 O-Rings 4.3 Couplings 4.3.1 Gear Type Coupling (grease lubricated) 4.3.2 Flexible (Elastomer) Element 4.3.3 Multi-Disc Pack or Membrane Coupling 5 HAZARDOUS AND CRITICAL DUTY PUMPS 5.1 Quench Systems 5.2 Cooling Systems 5.2.1 Bearing Cooling 5.2.2 Pedestal Cooling 5.2.3 Stuffing Box Cooling 5.2.4 Throttle Bushes 6 PROCESS PRIORITIES 6.1 Immediate Attention (Priority 1) 6.2 Daily Attention (Priority 2) 6.3 Weekly Attention (Priority 3) 7 PROCESS OPERATION AND FAILURE DIAGNOSIS 7.1 Process Changes 7.2 Failure Diagnosis 8 B I BLI OGRAPHY

Code of Practice - Centrifugal Pump Operation and Maintenance

Gerard B. Hawkins

Solids Mixing 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 BACKGROUND 5 MIXING QUALITY 5.1 Qualitative Mixture Quality 5.2 Quantitative Mixture Quality 5.3 Sampling of Mixtures 6 THE MIXING PROCESS 6.1 Powder Mobility 6.2 Mixing Free-Flowing Powders 6.3 Mixing Cohesive Powders 7 MIXER SELECTION 7.1 Available Equipment 7.2 A Selection Procedure 8 LATERAL THINKING 9 BIBLIOGRAPHY FIGURES 1 DIVISION BETWEEN FREE FLOWING SOLIDS AND COHESIVE POWDERS 2 REPRESENTATION OF TYPICAL BINARY POWDER MIXTURE STATES 3 POSSIBLE STRUCTURES FOR BINARY COHESIVE POWDERS 4 TUMBLER MIXERS 5 CONVECTIVE MIXERS 6 HIGH SHEAR MIXERS 7 HIGH IMPACTION MIXERS 8 MIXER SELECTION DECISION CHART

Solids Mixing

Gerard B. Hawkins

Tendances (20)

Fugitive Emissions

Heating and Cooling of Batch Processes

How to Use the GBHE Mixing Guides

Integration of Reciprocating Metering Pumps Into A Process

Design and Rating of Trayed Distillation Columns

DESIGN OF VENT GAS COLLECTION AND DESTRUCTION SYSTEMS

The Design and Layout of Vertical Thermosyphon Reboilers

PRACTICAL GUIDE ON THE SELECTION OF PROCESS TECHNOLOGY FOR THE TREATMENT OF A...

Selection of Heat Exchanger Types

Control of Continuous Distillation Columns

Start Up Procedures for Primary Reforming Catalyst

Thermal Design Margins for Heat Exchangers

Boiler Feedwater Pumps

Estimation of Pressure Drop in Pipe Systems

Study 2: Front-End Engineering Design and Project Definition

Gas Solid Mixing

Examination of Critical Centrifugal Fans and Blowers

General Water Treatment For Cooling Water

Code of Practice - Centrifugal Pump Operation and Maintenance

Solids Mixing

En vedette

Gas Mixing

Gerard B. Hawkins

Graphite Heat Exchangers 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 TYPES OF GRAPHITE 4.1 Phenolic Resin Impregnation 4.2 Furane Resin Impregnation 4.3 PTFE Impregnation 4.4 Carbon Impregnation 5 TYPES OF EXCHANGER 5.1 Shell and Tube 5.2 Cubic Block Exchangers 5.3 Cylindrical Graphite Block Exchangers 6 LIMITATIONS ON USE 7 COSTS OF GRAPHITE EXCHANGERS 8 RATING OF GRAPHITE EXCHANGERS 8.1 Rating Cylindrical Block Exchangers 8.2 Rating Cubic Block Exchangers 9 MANUFACTURERS OF GRAPHITE EXCHANGERS 10 REFERENCES FIGURES 1 SPLIT VIEW OF A CUBIC BLOCK HEAT EXCHANGER 2 TYPICAL BLOCK FROM A CYLINDRICAL GRAPHITE BLOCK HEAT EXCHANGER 3 GENERAL ARRANGEMENT OF A CYLINDRICAL BLOCK GRAPHITE HEAT EXCHANGER 4 APPROXIMATE COSTS FOR GRAPHITE HEAT EXCHANGERS

Graphite Heat Exchangers

Gerard B. Hawkins

Fixed Bed Reactor Scale-up Checklist The purpose of this checklist is to identify the stages and potential problems associated with the scale up of fixed bed reactors from the drawing board to the full scale plant, and to determine how they should be checked. The checking can be done using various methods. These are: • Literature data. • Lab testing. • Calculation. • Modeling. • Semi-tech testing. • Piloting or Sidestream testing. Identifying the stages that need to be addressed for a particular catalyst/reactor development will help in estimating the time needed for the development of the reactor

Fixed Bed Reactor Scale-up Checklist

Gerard B. Hawkins

Physical Properties for Heat Exchanger Design 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 COMPONENT PROPERTIES 4.1 General 4.2 Use of Component Properties for Mixtures 5 INPUT OF MIXTURE CURVES 5.1 General 5.2 Generation of the Mixture Curves 5.3 Selection of Temperature Points 5.4 Extrapolation 6 IMMISCIBLE CONDENSATES FIGURES 1 TEMPERATURE POINTS SELECTED FOR EQUAL ENTHALPY CHANGE 2 TEMPERATURE POINTS SELECTED FOR GOOD FIT TO CURVE

Physical Properties for Heat Exchanger Design

Gerard B. Hawkins

Homogeneous Reactors 0 INTRODUCTION / PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 DESIGN STEPS 4.1 Residence Time and Flow Pattern 4.2 Modeling of Ideal Reactor Types 4.3 Costing 5 EQUIPMENT SELECTION SUMMARY 6 EQUIPMENT EXAMPLES 6.1 Gas Reactors - Plug Flow 6.2 Gas Reactors - Backmixed or Batch 6.3 Liquid Reactors - Low Viscosity 6.4 Liquid Reactors - High Viscosity 7 MEASUREMENT OF HOMOGENEOUS REACTION KINETICS 7.1 Gas Phase Reactions 7.2 Liquid Phase Reactions 8 NOMENCLATURE TABLES 1 EQUIPMENT SUMMARY FIGURES 1 LOOP REACTOR 2 BACKMIXED GAS REACTOR 3 IN-LINE FLOW MIXERS 4 SPINNING CONE THIN-FILM REACTOR 5 STIRRED VESSEL REACTOR 6 JET-MIXED REACTOR VESSEL 7 EXTRUDER 8 SCRAPED-FILM REACTOR 9 Z-BLADE MIXER 10 CONTINUOUS FLOW 11 STOPPED FLOW

Homogeneous Reactors

Gerard B. Hawkins

Columns and their hydraulic limits

Gautham Sankaraselvam

Shortcut Methods of Distillation Design 0 INTRODUCTION/PURPOSE 1 SCOPE 2 ESTIMATIONOF PLATEAGE AND REFLUX REQUIREMENTS 2.1 Generalized Procedure for Nmin and Rmin 2.2 Equation based Procedure for Nmin and Rmin 3 PREDICTION OF OVERALL PLATE EFFICIENCY 4 SIZING OF MAIN PLANT ITEMS 4.1 Column Diameter 4.2 Surface Area of Condensers and Reboilers FIGURES 1 NON-IDEAL EQUILIBRIUM CURVE 2 AT A GLANCE CHART BASED ON FENSKE, UNDERWOOD 3 PLATE EFFICIENCY CORRELATION OF O’CONNEL

Shortcut Methods of Distillation Design

Gerard B. Hawkins

The use of chemical additives, such as flocculants, is a common step in solid-liquid separation operations. The correct selection of agent is an essential part of the design of such processes. Many excellent reviews and guides deal with this topic, and the interested reader is referred to works such as [l-4]. In particular the Harwell-Warren Spring Report “The Use and Selection of Flocculants" provides a good overview on the application of coagulants and flocculants. This section does not attempt to reproduce a detailed treatment of that kind; instead it is our intention to state a few general rules and principles concerning methods of choosing an additive, and to illustrate briefly their application in practice. The types of agents employed in solid-liquid separation fall into three principal classes:

The Selection of Flocculants and other Solid-Liquid Separation Aids

Gerard B. Hawkins

Tube Wall Temperature Measurement On Steam Reformers - Best Practices

Gerard B. Hawkins

Reactor Modeling Tools - An Overview CONTENTS 1 SCOPE 2 OPTIONS IN REACTOR MODELING 2.1 General 2.2 Level of Complexity of Model 2.3 Mode of Operation of Model 2.4 Deterministic versus Empirical Modeling 2.5 Platforms for Model 2.6 Steady State versus Dynamic Model 2.7 Dimensions Modeled in Reactor 2.8 Scale of Modeling for Multiphase Reactors 2.9 Writing and Using the Model APPENDICES A CHARACTERISTICS OF DIFFERENT REACTOR MODELS B NEEDS FOR MODELING AT DIFFERENT SCALES IN HETEROGENEOUS CATALYTIC REACTORS C REACTOR MODELS EMPLOYED WITHIN GBHE DOCUMENTS REFERRED TO IN THIS PROCESS ENGINEERING GUIDE

Reactor Modeling Tools - An Overview

Gerard B. Hawkins

GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases This Process Safety Guide has been written with the aim of assisting process engineers, hazard analysts and environmental advisers in carrying out gas dispersion calculations. The Guide aims to provide assistance by: • Improving awareness of the range of dispersion models available within GBHE, and providing guidance in choosing the most appropriate model for a particular application. • Providing guidance to ensure that source terms and other model inputs are correctly specified, and the models are used within their range of applicability. • Providing guidance to deal with particular topics in gas dispersion such as dense gas dispersion, complex terrain, and modeling the chemistry of oxides of nitrogen. • Providing general background on air quality and dispersion modeling issues such as meteorology and air quality standards. • Providing example calculations for real practical problems. SCOPE The gas dispersion guide contains the following Parts: 1 Fundamentals of meteorology. 2 Overview of air quality standards. 3 Comparison between different air quality models. 4 Designing a stack. 5 Dense gas dispersion. 6 Calculation of source terms. 7 Building wake effects. 8 Overview of the chemistry of the oxides of nitrogen. 9 Overview of the ADMS complex terrain module. 10 Overview of the ADMS deposition module. 11 ADMS examples. 12 Modeling odorous releases. 13 Bibliography of useful gas dispersion books and reports. 14 Glossary of gas dispersion modeling terms. Appendix A : Modeling Wind Generation of Particulates. APPENDIX B TABLE OF PROPERTY VALUES FOR SPECIFIC CHEMICALS

GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases

Gerard B. Hawkins

Pressure Relief Systems BACKGROUND TO RELIEF SYSTEM DESIGN Vol.1 of 6 The Guide has been written to advise those involved in the design and engineering of pressure relief systems. It takes the user from the initial identification of potential causes of overpressure or under pressure through the process design of relief systems to the detailed mechanical design. "Hazard Studies" and quantitative hazards analysis are not described; these are seen as complementary activities. Typical users of the Guide will use some Parts in detail and others in overview.

Pressure Relief Systems

Gerard B. Hawkins

Liquid Liquid Extraction - Basic Principles 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 LIQUID-LIQUID EXTRACTION PROCESS 4.1 General 4.2 Choice of Solvent 4.3 Principles of Extraction 4.4 Liquid-Liquid Extraction Equipment 4.5 Operating Modes 4.6 Operating And Design Pitfalls 5 BIBLIOGRAPHY FIGURES 1 SCHEMATIC OUTLINE OF LIQUID-LIQUID EXTRACTION PROCESS: COUNTERCURRENT FLOW IN ROTATING DISC CONTACTOR 2 COUNTERCURRENT EXTRACTION WITH REFLUX

Liquid Liquid Extraction - Basic Principles

Gerard B. Hawkins

PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGANIC COMPOUNDS (VOCs) FOREWORD CONTENTS 1 INTRODUCTION 2 THE NEED FOR VOC CONTROL 3 CONTROL AT SOURCE 3.1 Choice or Solvent 3.2 Venting Arrangements 3.3 Nitrogen Blanketing 3.4 Pump Versus Pneumatic Transfer 3.5 Batch Charging 3.6 Reduction of Volumetric Flow 3.7 Stock Tank Design 4 DISCHARGE MEASUREMENT 4.1 By Inference or Calculation 4.2 Flow Monitoring Equipment 4.3 Analytical Instruments 4.4 Vent Emissions Database 5 ABATEMENT TECHNOLOGY 5.1 Available Options 5.2 Selection of Preferred Option 5.3 Condensation 5.4 Adsorption 5.5 Absorption 5.6 Thermal Incineration 5.7 Catalytic Oxidation 5.8 Biological Filtration 5.9 Combinations of Process technologies 5.10 Processes Under Development 6 GLOSSARY OF TERMS 7 REFERENCES Appendix 1. Photochemical Ozone Creation Potentials Appendix 2. Examples of Adsorption Preliminary Calculations Appendix 3. Example of Thermal Incineration Heat and Mass Balance Appendix 4. Cost Correlations

PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...

Gerard B. Hawkins

Pressure Relief Systems Vol 2

Gerard B. Hawkins

Ammonia Plant Technology Pre-Commissioning Best Practices Piping and Vessels Flushing and Cleaning Procedure CONTENTS 1 Scope 2 Aim/purpose 3 Responsibilities 4 Procedure 4.1 Main cleaning methods 4.1.1 Mechanical cleaning 4.1.2 Cleaning with air 4.1.3 Cleaning with steam (for steam networks only) 4.1.4 Cleaning with water 4.2 Choice of the cleaning method 4.3 Cleaning preparation 4.4 Protection of the devices included in the network 4.5 Protection of devices in the vicinity of the network 4.6 Water flushing procedure 4.6.1 Specific problems of water flushing 4.6.2 Preparation for water flushing 4.6.3 Performing a water flush 4.6.4 Cleanliness criteria 4.7 Air blowing procedure 4.7.1 Specific problems of air blowing 4.7.2 Preparation for air blowing 4.7.3 Performing air blowing 4.7.4 Cleanliness checks 4.8 Steam blowing procedure 4.8.1 Specific problems of steam blowing 4.8.2 Preparation for steam blowing 4.8.3 Performing steam blowing 4.8.4 Cleanliness checks 4.9 Chemical cleaning procedure 4.9.1 Specific problems of cleaning with a chemical solution 4.9.2 Preparation for chemical cleaning 4.9.3 Performing a chemical cleaning 4.9.4 Cleanliness criteria 4.10 Re-assembly - general guideline 4.11 Preservation of flushed piping

Piping and Vessels Flushing and Cleaning Procedure

Gerard B. Hawkins

En vedette (16)

Gas Mixing

Graphite Heat Exchangers

Fixed Bed Reactor Scale-up Checklist

Physical Properties for Heat Exchanger Design

Homogeneous Reactors

Columns and their hydraulic limits

Shortcut Methods of Distillation Design

The Selection of Flocculants and other Solid-Liquid Separation Aids

Tube Wall Temperature Measurement On Steam Reformers - Best Practices

Reactor Modeling Tools - An Overview

GAS DISPERSION - A Definitive Guide to Accidental Releases of Heavy Gases

Pressure Relief Systems

Liquid Liquid Extraction - Basic Principles

PRACTICAL GUIDE ON THE REDUCTION OF DISCHARGES TO ATMOSPHERE OF VOLATILE ORGA...

Pressure Relief Systems Vol 2

Piping and Vessels Flushing and Cleaning Procedure

Similaire à Data Sources For Calculating Chemical Reaction Equilibria

Mixing of Gas Liquid Systems 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 FLUID INTERFACE AND REACTION EFFECTS 5 EQUIPMENT SELECTION 6 DESIGN OF BUBBLE COLUMNS 6.1 Recommendations 6.2 Design Procedure 6.3 Mass Transfer and Voidage 6.4 Heat Transfer 6.5 Mixing Patterns 7 DESIGN OF GAS-LIQUID STIRRED VESSELS (Re > 104 ONLY) 7.1 Recommendations 7.2 Design Procedure 7.3 Mass Transfer 8 DESIGN OF GAS-LIQUID STATIC MIXERS 8.1 Recommendations 8.2 Design Procedure 9 NOMENCLATURE TABLE 1 COMPARISON OF DIFFERENT GAS-LIQUID CONTACTING DEVICES FIGURES 1 BUBBLE COLUMN 2 STIRRED VESSEL 3 JET-MIXED VESSEL 4 STATIC MIXER 5 JET EJECTORS 6 THIN FILM 7 THIN FILM 8 DOUGH MIXER 9 IN-LINE DYNAMIC MIXER 10 MULTI-PIPE GAS SPARGER 11 VESSEL GEOMETRY 12 AGITATORS

Mixing of Gas Liquid Systems

Gerard B. Hawkins

Distillation Sequences, Complex Columns and Heat Integration 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 SEQUENCING OF SIMPLE COLUMNS 4.1 Sidestream Columns 4.2 Multi-Feed Columns 5 SIMPLE COLUMN SEQUENCING AND HEAT INTEGRATION INTERACTIONS 5.1 Energy Quantity and Quality 5.2 Heat Integration within the Total Flowsheet 6 COMPLEX COLUMN ARRANGEMENTS 6.1 Indirect Sequence with Vapor Link 6.2 Sidestream Systems 6.3 Pre-Fractionator Systems 7 COMPLEX COLUMNS AND HEAT INTEGRATION INTERACTIONS FIGURES 1 DIRECT AND INDIRECT SEQUENCES 2 A SINGLE SIDESTREAM COLUMN REPLACING 2 SIMPLE COLUMNS 3 A TYPICAL MULTI-FEED COLUMN 4 TYPICAL GRAND COMPOSITION CURVE 5 TYPICAL INDIRECT SEQUENCE WITH VAPOUR LINK 6 SIDESTREAM STRIPPER AND SIDESTREAM RECTIFIER 7 SIMPLEST PRE-FRACTIONATOR SYSTEM 8 SIMPLEST PRE-FRACTIONATOR SYSTEM 9 PETLYUK COLUMN

Distillation Sequences, Complex Columns and Heat Integration

Gerard B. Hawkins

Solid Catalyzed Reactions 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 GENERAL BACKGROUND 4.1 General Considerations 5 SOLID CATALYZED GAS REACTIONS 5.1 Reaction Kinetics 5.2 Tests for Transport Limitations 5.3 Building a Reaction Kinetic Equation 6 INTRAPARTICLE 6.1 Types of Pore System 6.2 The Catalyst Effectiveness Factor 6.3 The Measurement of Effective Diffusivity 7 ENHANCEMENT OF INTRAPARTICLE 8 NOMENCLATURE 8.1 Dimensionless Parameters 8.2 Greek Letters 8.3 Subscripts 9 BIBLIOGRAPHY 9.1 Further Reading APPENDICES A LANGMUIR - HINSHELWOOD KINETICS FIGURES 1 EFFECTIVE RATE CONSTANT 2 ITERATIVE APPROACH TO REACTOR MODEL DEVELOPMENT 3 COMMON LABORATORY MICROREACTORS (FLOW TYPE) 4 THE BERTY REACTOR 5 STEPS IN BUILDING A REACTION RATE EQUATION 6 A CENTRAL-COMPOSITE DESIGN FOR TWO FACTORS 7 FIRST ORDER ISOTHERMAL IRREVERSIBLE REACTION WITHIN A CATALYST SPHERE 8 INTEGRAL YIELD vs CONVERSION SHOWING EFFECT OF PELLET DIFFUSION 9 PREDICTED AND EXPERIMENTAL EFFECTIVENESS FACTORS 10 STRUCTURAL PERMEABILITY vs PRESSURE PARAMETER Z FOR BI-MODAL SUPPORTS 11 EFFECTIVENESS FACTOR vs THIELE MODULUS AND INTRAPARTICLE PECLET NUMBER 12 RELATIVE INCREASE IN CATALYST PERFORMANCE

Solid Catalyzed Reactions

Gerard B. Hawkins

Pressure Systems CONTENTS 0 INTRODUCTION 1 SCOPE 2 DEFINITIONS ADDITIONAL TO THOSE IN THE EP GLOSSARY 2.1 PRESSURE VESSEL 2.2 ATMOSPHERIC PRESSURE STORAGE TANK 2.3 VESSEL 2.4 PIPING SYSTEM 2.5 NON-PRESSURE PROTECTIVE DEVICE 2.6 ASSOCIATED RELIEF EQUIPMENT 3 APPLICATION OF PRINCIPLES 3.1 IMPLEMENTATION OF PEG 4 3.2 DESIGN, MANUFACTURE, REPAIR AND MODIFICATION 3.3 VERIFICATION OF DESIGN 3.4 GBHE REGISTRATION AND RECORDS 3.5 PERIODIC EXAMINATION 4 AUDITING 4.1 General 4.2 Scope of Audit APPENDICES A EQUIPMENT WHICH MAY BE EXEMPTED FROM GBHE REGISTRATION C DOCUMENTATION FOR INCLUSION IN FILES OF REGISTERED EQUIPMENT D ADDITIONAL REQUIREMENTS FOR THE PERIODIC EXAMINATION OF SPECIAL CATEGORIES OF EQUIPMENT E DIAGRAMMATIC REPRESENTATION OF PRESSURE SYSTEMS PROCEDURES F DECISION TREE FOR REGISTRATION OF PIPING SYSTEMS G REGISTERED EQUIPMENT WHICH MAY BE EXEMPTED FROM DESIGN VERIFICATION TABLES 1 REGISTERED VESSELS AND PIPING SYSTEMS: MAXIMUM EXAMINATION INTERVALS 2 EQUIPMENT TO BE CONSIDERED FOR CATEGORY LLT FIGURES 1 SIMPLE PRESSURE RELIEF ARRANGEMENT 2 COMPLEX PRESSURE RELIEF ARRANGEMENT DOCUMENTS REFERRED TO IN THIS INFORMATION FOR ENGINEERS DOCUMENT

Pressure Systems

Gerard B. Hawkins

Batch Distillation 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 BACKGROUND TO THE DESIGN 4.1 General 4.2 Choice of batch/continuous operation 4.3 Boiling point curve and cut policy 4.4 Method of design 4.5 Scope of calculations required for design 5 SIMPLE BATCH DISTILLATION 6 FRACTIONAL BATCH DISTILLATION 6.1 General 6.2 Approximate methods 6.3 Rigorous design - use of a computer model 6.4 Other factors influencing the design 6.4.1 Occupation 6.4.2 Choice of Batch Rectification or Stripping 6.4.3 Batch size 6.4.4 Initial estimate of cut policy 6.4.5 Liquid Holdup 6.4.6 Total reflux operation and heating-up time 6.4.7 Column operating pressure 6.5 Optimum Design of the Batch Still 6.6 Special design problems 7 GENERAL ASPECTS OF EQUIPMENT DESIGN 7.1 Kettle reboilers 7.2 Column Internals 7.3 Condensers and reflux split boxes 8 PROCESS CONTROL AND INSTRUMENTATION IN BATCH DISTILLATION 9 MECHANICAL DESIGN FEATURES 10 BIBLIOGRAPHY APPENDICES A McCABE - THIELE METHOD - TYPICAL EXAMPLE

Batch Distillation

Gerard B. Hawkins

Physical Properties and Thermochemistry for Reactor Technology 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 PHYSICAL PROPERTIES 4.1 Form of Equations 4.2 The Physical Property System: “The VAULT” 4.3 Physical Property Programs 4.4 Physical Property Estimation 4.5 Sources of Expertise 5 INTERFACING COMPUTER PROGRAMS TO THE GBHE VAULT PHYSICAL PROPERTIES PACKAGE 5.1 Preparation of the Physical Property Data 6 THERMOCHEMISTRY 6.1 Hess's Law 6.2 Standard States 6.3 Heats of Formation 6.4 Determination of Heats of Reaction 7 CALCULATION OF HEATS OF REACTION 7.1 Analogous Reactions 7.2 Heat of Formation Data Compilations 7.3 Estimation of Standard Heats of Formation 7.4 Heats of Neutralization 7.5 Temperature Effect on Heat of Reaction 8 HEATS OF SOLUTION, DILUTION AND MIXING 8.1 Calculation of Heats of Solution / Dilution from Literature Data 8.2 Estimation of Heats of Solution and Mixing 8.3 Integral and Differential Heats 9 EXPERIMENTAL DETERMINATION OF THERMOCHEMICAL PARAMETERS 9.1 Isoperibol Calorimetry for Heats of Reaction and Solution 9.2 Heat Flow Calorimetry 9.3 Adiabatic Calorimeter 9.4 Differential Scanning Calorimetry 10 COMPUTER CALCULATION OF ENTHALPY OR TEMPERATURE 11 BIBLIOGRAPHY

Physical properties and thermochemistry for reactor technology

Gerard B. Hawkins

Cost Estimating: Turbo Blowers

Gerard B. Hawkins

The Preliminary Choice of Fan or Compressor 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 METHOD FOR PRELIMINARY SELECTION OF COMPRESSOR 5 PROCESS DATA SHEET 5.1 Essential Data for the Completion of a Process Data Sheet 5.2 Gas Properties 5.3 Discharge Requirements 6 PRELIMINARY CHOICE OF FAN AND COMPRESSOR TYPE 6.1 Essential Data for Preliminary Selection 7 FAN AND COMPRESSOR APPLICATIONS 7.1 Fans 7.2 Centrifugal Compressors 7.3 Axial Compressors 7.4 Reciprocating Compressors 7.5 Screw Compressors 7.6 Positive Displacement Blowers 7.7 Sliding Vane Compressors 7.8 Liquid Ring Compressors 8 PROVISION OF INSTALLED SPARES 9 PRELIMINARY ESTIMATE OF COSTS

The Preliminary Choice of Fan or Compressor

Gerard B. Hawkins

Hydrogen Plant Monitoring & Methane Steam Reformer Troubleshooting

Gerard B. Hawkins

Mixing of Immiscible Liquids 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 EQUIPMENT 4.1 Agitated Tanks 4.2 Flow Mixers 4.3 'High Shear' Mixers 5 SYSTEM PHYSICAL PROPERTIES 5.1 Density 5.2 Viscosity 5.3 Interfacial Tension 6 STIRRED VESSELS 6.1 Design for Complete Dispersion 6.2 Prediction of Phase Inversion 6.3 Design for Mass Transfer 6.4 Design for Dispersed Phase Mixing 6.5 Hold-Up in Continuous Vessels 7 FLOW MIXERS 7.1 Design for Turbulent Conditions 7.2 Design for Laminar Conditions TABLES 1 REYNOLDS NUMBER RANGES FIGURES 1 STANDARD TANK CONFIGURATION 2 EXPERIMENTAL RELATIONSHIP BETWEEN MASS TRANSFER COEFFICIENT AND POWER DENSITY

Mixing of Immiscible Liquids

Gerard B. Hawkins

Centrifugal Compressors SECTION ONE - ANTI-SURGE PROTECTION AND THROUGHPUT REGULATION 0 INTRODUCTION 1 SCOPE 2 MACHINE CHARACTERISTICS 2.1 Characteristics of a Single Compressor Stage 2.2 Characteristic of a Multiple Stage Having More Than One Impeller 2.3 Use of Compressor Characteristics in Throughput Regulation Schemes 3 MECHANISM AND EFFECTS OF SURGE 3.1 Basic Flow Instabilities 3.2 Occurrence of Surge 3.3 Intensity of Surge 3.4 Effects of Surge 3.5 Avoidance of Surge 3.6 Recovery from Surge 4 CONTROL SCHEMES INCLUDING SURGE PROTECTION 4.1 Output Control 4.2 Surge Protection 4.3 Surge Detection and Recovery 5 DYNAMIC CONSIDERATIONS 5.1 Interaction 5.2 Speed of Response of Antisurge Control System 6 SYSTEM EQUIPMENT SPECIFICATIONS 6.1 The Antisurge Control Valve 6.2 Non-return Valve 6.3 Pressure and flow measurement 6.4 Signal transmission 6.5 Controllers 7 TESTING 7.1 Determination of the Surge Line 7.2 Records 8 INLET GUIDE VANE UNITS 8.1 Application 8.2 Effect on Power Consumption of the Compressor 8.3 Effect of Gas Conditions, Properties and Contaminants 8.4 Aerodynamic Considerations 8.5 Control System Linearity 8.6 Actuator Specification 8.7 Avoidance of Surge 8.8 Features of Link Mechanisms 8.9 Limit Stops and Shear Links APPENDICES A LIST OF SYMBOLS AND PREFERRED UNITS B WORKED EXAMPLE 1 COMPRESSOR WITH VARIABLE INLET PRESSURE AND VARIABLE GAS COMPOSITION C WORKED EXAMPLE 2 A CONSTANT SPEED ~ STAGE COMPRESSOR WITH INTER-COOLING D WORKED EXAMPLE 3 DYNAMIC RESPONSE OF THE ANTISURGE PROTECTION SYSTEM FOR A SERVICE AIR COMPRESSOR RUNNING AT CONSTANT SPEED E EXAMPLE OF INLET GUIDE VANE REGULATION FIGURES 2.1 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT DISCHARGE CONDITIONS 2.2 TYPICAL COMPRESSOR STAGE CHARACTERISTIC PLOTTED WITH FLOW AT INLET CONDITIONS 2.3 PERFORMANCE CHARACTERISTICS OF A COMPRESSOR STAGE AT VARYING SPEEDS 2.4 SYSTEM WORKING POINT DEFINED BY INTERSECTION OF PROCESS AND COMPRESSOR CHARACTERISTICS 2.5 DISCHARGE THROTTLE REGULATION 2.6 BYPASS REGULATION 2.7 INLET THROTTLE REGULATION 2.8 INLET GUIDE VANE REGULATION 2.9 VARIABLE SPEED REGULATION 3.1 GAS PULSATION LEVELS FOR A CENTRIFUGAL COMPRESSOR 3.2 REPRESENTATION OF CYCLIC FLOW DURING SURGE OF LONG PERIOD 3.3 TYPICAL WAVEFORM OF DISCHARGE PRESSURE DURING SURGE 3.4 MULTIPLE SURGE LINE FOR A MULTISTAGE CENTRIFUGAL COMPRESSOR 3.5 TYPICAL MULTIPLE SURGE LINES FOR SINGLE STAGE AXIAL-FLOW COMPRESSOR 4.1 GENERAL SCHEMATIC FOR COMPRESSORS OPERATING IN PARALLEL TO FEED MULTIPLE USER PLANTS 4.2 ILLUSTRATION OF SAFETY MARGIN BETWEEN SURGE POINT AND SURGE PROTECTION POINT AT WHICH ANTISURGE SYSTEM IS ACTIVATED 4.3 ANTISURGE SYSTEM FOR COMPRESSOR WITH FLAT PERFO ..........

Centrifugal Compressors

Gerard B. Hawkins

Reactor Modeling Tools – Multiple Regressions CONTENTS 0 INTRODUCTION 1 SCOPE 2 THEORY 3 EXCEL 2007: MULTIPLE REGRESSIONS 3.1 Overview 3.2 Multiple Regression Using the Data Analysis ADD-IN 3.3 Interpret Regression Statistics Table 3.4 Interpret ANOVA Table 3.5 Interpret Regression Coefficients Table 3.6 Confidence Intervals for Slope Coefficients 3.7 Test Hypothesis of Zero Slope Coefficients ("Test of Statistical Significance") 3.8 Test Hypothesis on a Regression Parameter 3.8.1 Using the p-value approach 3.8.2 Using the critical value approach 3.9 Overall Test of Significance of the Regression Parameters 3.10 Predicted Value of Y Given Regressors 3.11 Excel Limitations 4 SPECIAL FEATURES REQUIRING MORE SOPHISTICATED TECHNIQUES 5 USER INFORMATION SUPPLIED A SUBROUTINE B DATA C RESULTS 6 EXAMPLE

Reactor Modeling Tools – Multiple Regressions

Gerard B. Hawkins

H - Acid Caustic Fusion Stage CONTENTS 0 INTRODUCTION 1 DESIGN INFORMATION 1.1 Reactor Type 1.2 Temperature Range 1.3 Pressure Range 1.4 Chemical System 2 BACKGROUND 3 KINETICS AND MECHANISM 4 MAXIMUM YIELD AND IMPLICATIONS FOR REACTOR DESIGN 5 USE OF DESIGN MODEL FOR START-UP AND MANUFACTURING MONITORING 6 BIBLIOGRAPHY FIGURES 1 FUSION MODEL OUTLINE MECHANISM AND KINETIC SCHEME 2 TEST RUN OPTIMIZATION OF HEATING TIME 3600 kg/h STEAM

H - Acid Caustic Fusion Stage

Gerard B. Hawkins

Reciprocating Compressors - Protection against Crank Case Explosions

Gerard B. Hawkins

OVERVIEW - FIXED BED ADSORBER DESIGN GUIDELINES Fixed-bed adsorber design is based upon the following considerations: • Adsorbent bed profile and media loading capacity characteristics for the specific application and adsorbent material used. • Pressure drop characteristics across the adsorbent bed. • Reaction kinetics. Typically, adsorber design entails use of the following methodology: • Adsorbent selection based upon performance and application information. • Bed sizing based upon adsorbent loading data and service life requirements. • Bed sizing adjustment based upon pressure drop criteria. • Bed sizing adjustment based upon reaction kinetics criteria. A discussion of each design consideration follows.

Fixed Bed Adsorber Design Guidelines

Gerard B. Hawkins

VLE Data - Selection and Use 0 INTRODUCTION/PURPOSE 1 SCOPE 2 FIELD OF APPLICATION 3 DEFINITIONS 4 DIAGRAMMATIC REPRESENTATION OF IDEAL AND NON-IDEAL SYSTEMS 4.1 Ideal Mixtures 4.2 Non-Ideal Mixtures 5 REVIEW OF VLE MODELS 5.1 Ideal Behavior in Both Phases 5.2 Liquid Phase Non-Idealities 5.3 High Pressure Systems 5.4 Special Models 6 SETTING UP A VLE MODEL 6.1 Define Problem 6.2 Select Data 6.3 Select Correlation(s) 6.4 Produce Model 7 AVOIDING PITFALLS 7.1 Experimental Data is Better than Estimates 7.2 Check Validity of Fitted Model 7.3 Check Limitations of Estimation Methods 7.4 Know Your System 7.5 Appreciate Errors and Effects 7.6 If in Doubt – Ask 8 A CASE STUDY 8.1 The Problem 8.2 The System 8.3 Data Available 8.4 Selected Correlation 8.5 Simulation 8.6 Selection of Model 9 RECOMMENDED READING 10 VLE EXPERTS IN GBHE APPENDICES A USE OF EXTENDED ANTOINE EQUATION B USE OF WILSON EQUATION C USEFUL METHODS OF ESTIMATING D EQUATIONS OF STATE FOR VLE CALCULATIONS TABLES 1 SUMMARY OF VLE METHODS 2 LIST OF USEFUL REFERENCES FIGURES 1 VAPOR-LIQUID EQUILIBRIUM - IDEAL SOLUTION BEHAVIOR 2 VAPOR-LIQUID EQUILIBRIUM - A GENERALISED Y-X DIAGRAM 3 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING AZEOTROPE 4 VAPOR-LIQUID EQUILIBRIUM - MAXIMUM BOILING AZEOTROPE 5 VAPOR-LIQUID EQUILIBRIUM - MINIMUM BOILING AZEOTROPE -TWO LIQUID PHASES 6 SENSITIVITY TO ERROR IN VLE DATA (BASED ON FENSKE EQUATION) 7(a) FITTING WILSON 'A' VALUES TO VLE DATA - CASE A 7(b) FITTING WILSON 'A' VALUES TO VLE DATA - CASE B 7(c) FITTING WILSON 'A' VALUES TO VLE DATA - CASE C

VLE Data - Selection and Use

Gerard B. Hawkins

SMR PRE-REFORMER DESIGN Case Study #0618416GB/H Contents 1. SMR Pre-Reformer Design 2. Inlet Baffle Design 3. Outlet Collector 4. Hold Down Grating 5. Floating Hold Down Screen 6. Catalyst Drop Out Nozzle 7. Thermowell Detail 8. Technical Performance requirements 9. SMR Pre-Reformer Isolation Technical Review and Commentary on Proposed Design APPENDIX A. Operating / Mechanical Data B. Materials Specifications C. Fabrication and Inspection Requirements D. Weights E. Nozzle Data F. Instrument Connections G. Manholes

SMR PRE-REFORMER DESIGN: Case Study

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Critical Variables in Catalytic Reforming and Unit Monitoring Best Practices

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METHANOL PLANT - SHALE GAS FEED PRETREATMENT CASE STUDY #091406 Case Background A Methanol plant operator would like to examine the technical feasibility of using Shale Gas as a feedstock to their Methanol plant. The first step in the Methanol production process is gas pretreatment. The purpose of gas pretreatment is to make the gas suitable for the downstream processes. There are two groups of compounds that are usually present in natural gas and that should be removed during pretreatment—the associate NGL and the sulfur-containing compounds. Some natural gas reservoirs may also have other trace components that must be removed, but these are not discussed here. This case study examines the impact of CO2 (Carbon Dioxide) on the pre-treatment section design, performance and efficiency of ACME Methanol Plant’ feed gas pre-treatment section. Case 1: Normal Shale Gas Case 2: “Bad Gas” Case 3: Low CO2 Case 4: High CO2

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(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENT; Case Study: #0978766GB/H CASE STUDY OVERVIEW Syn Gas Sour Shift: Process Flow Diagram AGR: Acid Gas to VULCAN SYSTEMS Sour Gas Shift DESIGN BASIS: ACID GAS REACTOR CATALYST SPECIFICATION SOUR SHIFT CASE SHIFT REACTOR CATALYST SPECIFICATIONS COS REACTOR CATALYST SPECIFICATIONS SWEET SHIFT CASE SHIFT REACTOR CATALYST SPECIFICATIONS PERFORMANCE SIMULATION RESULTS SOUR SHIFT SECTION 1 Cases Considered 2 Catalyst Used 3 Client Requirements 4 Oxygen and Olefins 5 HCN 6 NH3 7 Arsine 8 Input Data Sour Shift Unit 9 Activity (PROPRIETARY) 10 Results ADIABATIC SWEET SHIFT SECTION: HTS Reactor followed by LTS Reactor 1 Catalyst Used 2 Inlet Operating Temperature HTS Reactor 3 Feed Flow Rate, Inlet Operating Pressure and Feed Composition HTS Reactor 4 Inlet Operating Conditions LTS Reactor 5 Client Requirements 6 Results: Standard Case as Presented to the Client 7 Results: Inlet Operating Pressure HTS Reactor = 25.2 bara 8 Results: Addition of 100 kmol/h N2 COS HYDROLYSIS SECTION FOR SWEET SHIFT CASE 1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure 2 Inlet H2S and COS Levels 3 Equilibrium H2S and COS Levels (COS Hydrolysis Reaction) 4 Client Requirements 5 Results H2S REMOVAL SECTION AFTER AGR UNIT (2 Absorbent Beds (VULCAN VSG-EZ200) in Lead/Lag Arrangement) 1 Total Feed Flow Rate, Feed Composition, Direction of Flow, Inlet Operating Temperature, Inlet Operating Pressure 2 Inlet H2S and COS Levels 3 Client Requirements (All Cases) 4 Results ISOTHERMAL SWEET SHIFT SECTION: Alternative Approach VULCAN Simulation Input Data 1 Enthalpy method 2 Cases considered 3 Feed stream data 4 Kinetics 5 Catalyst 6 Catalyst Activity relative to standard 7 Catalyst size and packing details 8 Catalyst pressure drop parameters 9 Catalyst Volume 10 Standard die-off rate 11 BFW Rate 12 Vapor fraction 13 Steam Temperature 14 Steam Pressure 15 Boiling Model 16 Volumetric UA Isothermal Shift Simulations Results APPENDIX Characteristics of Acid Gas Removal Technologies

(AGRU) ACID GAS SOUR SHIFT: CASE STUDY IN REFINERY GAS TREATMENT

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Theory of Carbon Formation in Steam Reforming Contents 1 Introduction 2 Underpinning Theory 2.1 Conceptualization 2.2 Reforming Reactions 2.3 Carbon Formation Chemistry 2.3.1 Natural Gas 2.3.2 Carbon Formation for Naphtha Feeds 2.3.3 Carbon Gasification 2.4 Heat Transfer 3 Causes 3.1 Effects of Carbon Formation 3.2 Types of Carbon 4 What are the Effects of Carbon Formation? 4.1 Why does Carbon Formation Get Worse? 4.1.1 So what is the Next Step? 4.2 Consequences of Carbon Formation 4.3 Why does Carbon Form where it does? 4.3.1 Effect on Process Gas Temperature 4.4 Why does Carbon Formation Propagate Down the Tube? 4.4.1 Effect on Radiation on the Fluegas Side 4.5 Why does Carbon Formation propagate Up the Tube? 5 How do we Prevent Carbon Formation 5.1 The Role of Potash 5.2 Inclusion of Pre-reformer 5.3 Primary Reformer Catalyst Parameters 5.3.1 Activity 5.3.2 Heat Transfer 5.3.3 Increased Steam to Carbon Ratio 6 Steam Out 6.1 Why does increasing the Steam to Carbon Ratio Not Work? 6.2 Why does reducing the Feed Rate not help? 6.3 Fundamental Principles of Steam Outs TABLES 1 Heat Transfer Coefficients in a Typical Reformer 2 Typical Catalyst Loading Options FIGURES 1 Hot Bands 2 Conceptual Pellet 3 Naphtha Carbon Formation 4 Heat Transfer within an Reformer 5 Types of Carbon Formation 6 Effect of Carbon on Nickel Crystallites 7 Absorption of Heat 8 Comparison of "Base Case" v Carbon Forming Tube 9 Carbon Formation Vicious Circle 10 Temperature Profiles 11 Carbon Pinch Point 12 Carbon Formation 13 Effect on Process Gas Temperature 14 How does Carbon Propagate into an Unaffected Zone? 15 Movement of the Carbon Forming Region 16 Effect of Hot Bands on Radiative Heat Transfer 17 Effect of Potash on Carbon Formation 18 Application of a Pre-reformer 19 Effect of Activity on Carbon Formation

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Calculation of an Ammonia Plant Energy Consumption: Case Study: #06023300 Plant Note Book Series: PNBS-0602 CONTENTS 0 SCOPE 1 CALCULATION OF NATURAL GAS PROCESS FEED CONSUMPTION 2 CALCULATION OF NATURAL GAS PROCESS FUEL CONSUMPTION 3 CALCULATION OF NATURAL GAS CONSUMPTION FOR PILOT BURNERS OF FLARES 4 CALCULATION OF DEMIN. WATER FROM DEMIN. UNIT 5 CALCULATION OF DEMIN. WATER TO PACKAGE BOILERS 6 CALCULATION OF MP STEAM EXPORT 7 CALCULATION OF LP STEAM IMPORT 8 DETERMINATION OF ELECTRIC POWER CONSUMPTION 9 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT ISBL 10 ADJUSTMENT OF ELECTRIC POWER CONSUMPTION FOR TEST RUN CONDITIONS 11 CALCULATION OF AMMONIA SHARE IN MP STEAM CONSUMPTION IN UTILITIES 12 CALCULATION OF AMMONIA SHARE IN ELECTRIC POWER CONSUMPTION IN UTILITIES 13 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT OSBL 14 DETERMINATION OF THE TOTAL ENERGY CONSUMPTION OF THE AMMONIA PLANT

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Ammonia Plant Technology Pre-Commissioning Best Practices GBHE-APT-0102 PICKLING & PASSIVATION CONTENTS 1 PURPOSE OF THE WORK 2 CHEMICAL CONCEPT 3 TECHNICAL CONCEPT 4 WASTES & SAFETY CONCEPT 5 TARGET RESULTS 6 THE GENERAL CLEANING SEQUENCE MANAGEMENT 6.6.1 Pre-cleaning or “Physical Cleaning 6.6.2 Pre-rinsing 6.6.3 Chemical Cleaning 6.6.4 Critical Factors in Cleaning Success 6.6.5 Rinsing 6.6.6 Inspection and Re-Cleaning, if Necessary 7 Systems to be treated by Pickling/Passivation

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EMERGENCY ISOLATION OF CHEMICAL PLANTS CONTENTS 1 Introduction 2 When should Emergency Isolation Valves be Installed 3 Emergency Isolation Valves and Associated Equipment 3.1 Installations on existing plant 3.2 Actuators 3.3 Power to close or power to open 3.4 The need for testing 3.5 Hand operated Emergency Valves 3.6 The need to stop pumps in an emergency 3.7 Location of Operating Buttons 3.8 Use of control valves for Isolation 4 Detection of Leaks and Fires 5 Precautions during Maintenance 6 Training Operators to use Emergency Isolation Valves 7 Emergency Isolation when no remotely operated valve is available References Glossary Appendix I Some Fires or Serious Escapes of Flammable Gases or Liquids that could have been controlled by Emergency Isolation Valves Appendix II Some typical Installations

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Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems Contents Process Capabilities for gas treating process Typical Amine Treating Typical Amine System Improvements Primary Equipment Overview Inlet Gas Knockout Absorber Three Phase Flash Tank Lean/Rich Heat Exchanger Regenerator Filtration Amine Reclaimer Operating Difficulties Overview Foaming Failure to Meet Gas Specification Solvent Losses Corrosion Typical Amine System Improvements Degradation of Amines and Alkanolamines during Sour Gas Treating APPENDIX Best Practices - Troubleshooting Guide

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OXIDATIVE COUPLING COMBINED WITH DISTILLATION TO REMOVE MERCAPTAN SULFUR FROM NGLS CONTENTS Background Figure 1. Typical LPG Fractionation line-up and Sulfur Compound Distribution Potential Market for low Sulfur LPGs Sulfur removal from LPGs Oxidative coupling combined with distillation Figure 2. Debutanizer with Catalytic Oxidative Coupling Aspen Simulation Results Integration of reaction and distillation Technical Issues Practical Issues Future Considerations Market Issues Technical Issues Additional Technical Requirements References Appendix Kerosene Sweetening

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Debottlenecking Claus Sulfur Recovery Units: An Investigation of the application of Zinc Titanates 1 Executive Summary 2 Claus Process 2.1 Partial Combustion Claus 2.2 Split Flow Claus 2.3 Sulfur Recycle Claus 3 Zinc Titanates 4 Application of Zinc Titanate to Debottleneck Partial Combustion Claus by 10% 4.1 Process 4.2 ASPEN Modeling Results 4.3 Cost of Zinc Titanate Bed Installation 4.3.1 Basis of Costing 4.3.2 Zinc Titanate Beds 4.3.3 Regen Cooler 4.3.4 Blowers 4.3.5 Results 4.4 Alternative Debottlenecking Technology for Partial Combustion Claus 4.5 Cost of 10% Debottlenecking Using COPE Process 5 Debottlenecking Claus Split Flow System by 10% with Zinc Titanates 6 Debottlenecking Claus Sulfur Recycle System With Zinc Titanate 7 Effect of Zinc Titanate Debottlenecking on Existing Tail; Gas Treatment Systems 7.1 Selectox 7.2 SuperClaus99 7.3 Superclaus 99.5 7.4 SCOT Process 7.5 Zinc Titanate as a Claus Tail Gas Treatment 7.6 H2S Removal Efficiency With Zinc Titanate 8 Effects on COS and CS2 Formation 9 Questions for further Investigation FIGURES Figure 1 Claus Unit and TGCU Figure 2 Claus Process Figure 3 Typical Claus Sulfur Recovery Unit Figure 4 Two-Stage Claus SRU Figure 5 The Super Claus Process Figure 6 SCOT Figure 7 SCOT/BSR-MDEA (or clone) TGCU REFERENCES: PATENTS US4333855_PROMOTED_ZINC_TITANATE_CATALYTIC_AGENT US4394297_ZINC_TITANATE_CATALYST US6338794B1_DESULFURIZATION_ZINC_TITANATE_SORBENTS

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Data Sources For Calculating Chemical Reaction Equilibria

1. GBH Enterprises, Ltd. Process Engineering Guide: GBHE-PEG-FLO-300 Data sources for Calculating Chemical Reaction Equilibria Information contained in this publication or as otherwise supplied to Users is believed to be accurate and correct at time of going to press, and is given in good faith, but it is for the User to satisfy itself of the suitability of the information for its own particular purpose. GBHE gives no warranty as to the fitness of this information for any particular purpose and any implied warranty or condition (statutory or otherwise) is excluded except to the extent that exclusion is prevented by law. GBHE accepts no liability resulting from reliance on this information. Freedom under Patent, Copyright and Designs cannot be assumed. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

2. Process Engineering Guide: Data sources for Calculating Chemical Reaction Equilibria CONTENTS SECTION 0 INTRODUCTION/PURPOSE 2 1 SCOPE 2 2 FIELD OF APPLICATION 2 3 DEFINITIONS 2 4 BACKGROUND TO THEORY 2 5 BIBLIOGRAPHY 3 TABLE 1 SOURCES OF DATA Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

3. 0 INTRODUCTION/PURPOSE This Guide is one of a series produced for GBH Enterprises. The calculation of chemical equilibria for a single notional reaction is rarely difficult. A typical example is given in GBHE-PEG-RXT-813. The solution of such cases is well understood; the mass action equation generates a polynomial relationship between conversion and equilibrium constant (or free energy) which can be solved (at worst iteratively) and the relevant root selected by inspection. Extension of this approach to more than one reaction rapidly becomes untenable for hand calculation due to the highly non-linear nature of the resulting simultaneous equations. The solution of these multi-reaction equilibrium problems has been investigated since the early days of the Second World War when interest in rocket motor design became strategically important. Indeed, work for the V2 at the "Hermann Göring Air Force Research Institute" provided some of the earliest papers on the subject. To this day, combustion/explosion problems remain the mainspring of research effort in this area and a number of commercially available computer programs have appeared in the public domain. 1 SCOPE This Guide provides a comprehensive list of sources of data for calculating chemical reaction equilibria, for Reactor Modeling. 2 FIELD OF APPLICATION This Guide applies to process engineers in GBH Enterprises worldwide. 3 DEFINITIONS No specific definitions apply to this Guide. With the exception of terms used as proper nouns or titles, those terms with initial capital letters which appear in this document and are not defined above are defined in the Glossary of Engineering Terms. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

4. 4 BACKGROUND TO THEORY For a detailed discussion of the theory the reader is referred to Smith and Missen (1982). 5 BIBLIOGRAPHY Note: The reference numbers in the left hand column correspond to those numbers listed in the footer to Table 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

6. Note:The reference numbers in the left hand column correspond to those numbers listed in the footer to Table 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

8. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

9. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

Data Sources For Calculating Chemical Reaction Equilibria

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Data Sources For Calculating Chemical Reaction Equilibria