Chemical Process Retrofitting and Revamping E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 739

Veröffentlichungsjahr: 2016

Beschreibung

The proposed book will be divided into three parts. The chapters in Part I provide an overview of certain aspect of process retrofitting. The focus of Part II is on computational techniques for solving process retrofit problems. Finally, Part III addresses  retrofit applications from diverse process industries.

Some chapters in the book are contributed by practitioners whereas others are from academia. Hence, the book includes both new developments from research and also practical considerations. Many chapters include examples with realistic data. All these feature make the book useful to industrial engineers, researchers and students.

Leseprobe

Dedication

In memory of my late parents: Gade Sakuntala Devi and Gade Gopala Swami, who nurtured and educated me

and

To my dearest wife: Puvvada Krishna Kumari, for her selfless support and devotion to our family

Chemical Process Retrofitting and Revamping

Techniques and Applications

Edited by

GADE PANDU RANGAIAH

Department of Chemical & Biomolecular Engineering National University of Singapore Singapore

This edition first published 2016 © 2016 John Wiley & Sons, Ltd

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Library of Congress Cataloging-in-Publication Data

Chemical process retrofitting and revamping : techniques and applications / edited by G.P. Rangaiah.   pages cm  Includes bibliographical references and index.  ISBN 978-1-119-01633-5 (cloth)  1. Chemical plants–Remodeling. 2. Chemical plants–Maintenance and repair. 3. Chemical plants–Equipment and supplies. I. Rangaiah, Gade Pandu, editor.  TP155.5.C5128 2016  660–dc23

2015033565

Cover images: Main image: Courtesy of the editor and authors. Background image: from GettyImages, at http://www.gettyimages.com/photos/187591800?license=rf&family=creative&phrase=187591800&sort=best&excludenudity=true

A catalogue record for this book is available from the British Library.

CONTENTS

List of Contributors

Preface

Part I: Overview

Chapter 1: Introduction

1.1 Chemical Process Plants

1.2 Process Retrofitting and Revamping

1.3 Stages in Process Retrofitting/Revamping Projects

1.4 Conceptual Process Design for Process Retrofit/Revamp Projects

1.5 Research and Development in Process Retrofit/Revamp

1.6 Scope and Organization of this Book

1.7 Conclusions

References

Chapter 2: Project Engineering and Management for Process Retrofitting and Revamping

2.1 Introduction

2.2 Key Differences between Revamp and Grassroots Designs

2.3 Revamp Design Methodology

2.4 Project/Process Engineering and Management of Revamp Projects

2.5 Key Elements of Project Management

2.6 Revamp Options for Process Equipment

2.7 Conclusions

Acronyms

References

Notes

Chapter 3: Process Safety in Revamp Projects

3.1 Introduction

3.2 Lessons from Past Process Safety Incidents

3.3 Preliminary Hazard Review during Conceptual Design

3.4 Process Hazard Analysis (PHA)

3.5 Revision of PSI and Operator Induction

3.6 Pre-Start-up Safety Review (PSSR)

3.7 Management of Change (MOC)

3.8 Conclusions

Acronyms

Exercises

References

Notes

Part II: Techniques for Retrofitting and Revamping

Chapter 4: Mathematical Modeling, Simulation and Optimization for Process Design

4.1 Introduction

4.2 Process Modeling and Model Solution

4.3 Process Simulators and Aspen Custom Modeler

4.4 Optimization Methods and Programs

4.5 Interfacing a Process Simulator with Excel

4.6 Application to Membrane Separation Process

4.7 Conclusions

Acronyms

Appendix 4A: Implementation of Membrane Model in ACM

Appendix 4B: Interfacing of Aspen Plus v8.4 with Excel 2013

Appendix 4C: Interfacing of Aspen HYSYS v8.4 with Excel 2013

Exercises

References

Chapter 5: Process Intensification in Process Retrofitting and Revamping

5.1 Introduction

5.2 Methods of Process Intensification

5.3 Alternatives to Conventional Separators

5.4 Alternatives to Stirred Tank Reactor (STR)

5.5 Process Integration

5.6 Fundamental Issues of PI

5.7 Future of PI

5.8 Conclusions

Acknowledgement

Appendix 5A: Monographs, Reviews and Some Recent Papers

References

Chapter 6: Using Process Integration Technology to Retrofit Chemical Plants for Energy Conservation and Wastewater Minimization

6.1 Introduction

6.2 Graphical Design Tools for Retrofitting Process for Energy Conservation by Designing Heat Exchange Networks

6.3 Graphical Design Tools for Retrofitting Processes for Wastewater Reduction by Designing Water Recycle Networks

6.4 Conclusions

Appendix 6A: Illustrating the Water Recycle Network Design Guidelines

Exercises

References

Chapter 7: Heat Exchanger Network Retrofitting: Alternative Solutions via Multi-objective Optimization for Industrial Implementation

7.1 Introduction

7.2 Heat Exchanger Networks

7.3 HEN Improvements

7.4 MOO Method, HEN Model and Exchanger Reassignment Strategy

7.5 Case Study

7.6 Results and Discussion

7.7 Conclusions

Appendix 7A: Calculation of Nodal Temperatures

Exercises

References

Chapter 8: Review of Optimization Techniques for Retrofitting Batch Plants

8.1 Introduction

8.2 Batch Plant Typical Features

8.3 Formulation of the Batch Plant Retrofit Problem

8.4 Methods and Tools for Retrofit Strategies

8.5 Conclusions

References

Part III: Retrofitting and Revamping Applications

Chapter 9: Retrofit of Side Stream Columns to Dividing Wall Columns, with Case Studies of Industrial Applications

9.1 Introduction

9.2 Side Stream Column

9.3 Dividing Wall Column

9.4 Retrofit of an SSC to a DWC

9.5 Case Studies of Industrial Applications

9.6 Other Case Studies

9.7 Conclusions

Acknowledgements

Nomenclature

References

Chapter 10: Techno-economic Evaluation of Membrane Separation for Retrofitting Olefin/Paraffin Fractionators in an Ethylene Plant

10.1 Introduction

10.2 Olefin/Paraffin Separation in an Ethylene Plant

10.3 Membrane Model Development

10.4 Retrofitting a Distillation Column with a Membrane Unit

10.5 Formulation of Multi-objective–Optimization Problem

10.6 Results and Discussion

10.7 Conclusions

Appendix 10A: Membrane Model Validation

Appendix 10B: Costing of HMD System

Exercises

References

Notes

Chapter 11: Retrofit of Vacuum Systems in Process Industries

11.1 Introduction

11.2 Vacuum-generation Methods

11.3 Design Principles and Utility Requirements

11.4 Chilled-water Generation

11.5 Optimization of Vacuum System Operating Cost

11.6 Case Study 1: Retrofit of a Vacuum System in a Petroleum Refinery

11.7 Case Study 2: Retrofit of a Surface Condenser of a Condensing Steam Turbine

11.8 Conclusions

Nomenclature

Exercises

References

Notes

Chapter 12: Design, Retrofit and Revamp of Industrial Water Networks using Multi-objective Optimization Approach

12.1 Introduction

12.2 Mathematical Model of a Water Network

12.3 Water Network in a Petroleum Refinery

12.4 Multi-objective Optimization Problem Formulation

12.5 Results and Discussion

12.6 Conclusions

Acknowledgement

Nomenclature

Exercises

References

Chapter 13: Debottlenecking and Retrofitting of Chemical Pulp Refining Process for Paper Manufacturing – Application from Industrial Perspective

13.1 Introduction

13.2 Fundamentals of Chemical Pulp Refining

13.3 Theories of Chemical Pulp Refining

13.4 Types of Commercial Refiners

13.5 Laboratory and Pilot-scale Refining Investigation

13.6 Case Studies of Retrofitting Refining Process for Paper Mills

13.7 Conclusions

Exercises

References

Index

EULA

List of Tables

Chapter 1

Table 1.1

Chapter 2

Table 2.1

Table 2.2

Table 2.3

Table 2.4

Table 2.5

Table 2.6

Table 2.7

Table 2.8

Table 2.9

Table 2.10

Table 2.11

Table 2.12

Table 2.13

Table 2.14

Table 2.15

Table 2.16

Chapter 3

Table 3.1

Table 3.2

Table 3.3

Table 3.4

Table 3.5

Table 3.6

Table 3.7

Table 3.8

Table 3.9

Table 3.10

Chapter 4

Table 4.1

Chapter 5

Table 5.1

Table 5.2

Table 5.3

Table 5.4

Chapter 6

Table 6.1

Table 6.2

Table 6.A.1

Table 6.3

Table 6.4

Table 6.5

Table 6.6

Table 6.7

Chapter 7

Table 7.1

Table 7.2

Table 7.A.1

Chapter 8

Table 8.1

Table 8.2

Chapter 9

Table 9.1

Table 9.2

Table 9.3

Table 9.4

Chapter 10

Table 10.1

Table 10.2

Table 10.3

Table 10.4

Table 10.5

Table 10.6

Table 10.7

Table 10.8

Table 10.A.1

Table 10.A.2

Table 10.A.3

Table 10.A.4

Table 10.A.5

Table 10.B.1

Table 10.B.2

Chapter 11

Table 11.1

Table 11.2

Chapter 12

Table 12.1

Table 12.2

Table 12.3

Table 12.4

Table 12.5

Table 12.6

Chapter 13

Table 13.1

Table 13.2

Table 13.3

Table 13.4

Table 13.5

Table 13.6

Guide

Cover

Table of Contents

Preface

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List of Contributors

Catherine Azzaro-Pantel, Professor of Chemical Engineering, Université de Toulouse, Laboratoire de Génie Chimique, LGC UMR CNRS 5503, France (email: [email protected])

Raman Balajee, Process Safety Lead – Asia, Air Products Singapore Private Limited, Singapore (email: [email protected])

Russell F. Dunn, Department of Chemical and Biomolecular Engineering, Vanderbilt University, Nashville, USA and Polymer and Chemical Technologies, LLC, Nashville, USA (email: [email protected])

Ajit K. Ghosh, AKG Process Consulting, 33 McFarlane Court, Highett, Australia (email: [email protected])

Moonyong Lee, School of Chemical Engineering, Yeungnam University, Republic of Korea (email: [email protected])

Nguyen Van Duc Long, School of Chemical Engineering, Yeungnam University, Republic of Korea (email: [email protected])

Le Quang Minh, School of Chemical Engineering, Yeungnam University, Republic of Korea (email: [email protected])

W. Niu, Department of Chemical and Biomolecular Engineering, National University of Singapore, Singapore (email: [email protected])

S. (Shruti) Pandey, Department of Chemical and Biomolecular Engineering, National University of Singapore, Singapore (email: [email protected])

G.P. (Gade Pandu) Rangaiah, Department of Chemical & Biomolecular Engineering, National University of Singapore, Singapore (email: [email protected])

D.P. Rao, Formerly Professor of Chemical Engineering, Indian Institute of Technology, Kanpur, India and Managing Partner, Process Intensification Consultants, India (email: [email protected])

C.C.S. Reddy, Lead Process Design Engineer, Singapore Refining Company Private Limited, Singapore (email: [email protected])

Jarrid Scott Ristau, Department of Chemical and Biomolecular Engineering, Vanderbilt University, Nashville, USA and Polymer and Chemical Technologies, LLC, Nashville, USA (email: [email protected])

Shivom Sharma, Department of Chemical & Biomolecular Engineering, National University of Singapore, Singapore (email: [email protected])

Joonho Shin, Basic Materials & Chemicals R&D, LG Chem, Moonji-dong, Yuseong-gu, Republic of Korea (email: [email protected])

B.K. (Bhargava Krishna) Sreepathi, Department of Chemical & Biomolecular Engineering, National University of Singapore, Singapore (email: [email protected])

X.Z. Tan, Department of Chemical and Biomolecular Engineering, National University of Singapore, Singapore (email: [email protected])