Chemical Process Retrofitting and Revamping

Gade Pandu Rangaiah, Department of Chemical & Biomolecular Engineering, National University of Singapore, Singapore.

• List of Contributors xiii Preface xvPART I OVERVIEW1 Introduction 3G.P. Rangaiah1.1 Chemical Process Plants 31.2 Process Retrofitting and Revamping 41.3 Stages in Process Retrofitting/Revamping Projects 61.4 Conceptual Process Design for Process Retrofit/Revamp Projects 81.5 Research and Development in Process Retrofit/Revamp 91.6 Scope and Organization of this Book 121.7 Conclusions 16References 172 Project Engineering and Management for Process Retrofitting and Revamping 19C.C.S. Reddy2.1 Introduction 192.2 Key Differences between Revamp and Grassroots Designs 202.3 Revamp Design Methodology 202.4 Project/Process Engineering and Management of Revamp Projects 242.4.1 Revamp Objectives and Pre-Feasibility Study 242.4.2 Conceptual Design (Pre-FEED) 242.4.3 FEED (Front End Engineering Design) 312.4.4 Detailed Engineering, Procurement and Construction 332.4.5 Project Completion 352.5 Key Elements of Project Management 352.5.1 Project Schedule 392.5.2 Project Execution and Progress Monitoring 392.5.3 Project Cost Control 402.5.4 Risk Management 412.5.5 Final Project Deliverables 412.6 Revamp Options for Process Equipment 412.7 Conclusions 53Acronyms 53References 543 Process Safety in Revamp Projects 57Raman Balajee and C.C.S. Reddy3.1 Introduction 573.2 Lessons from Past Process Safety Incidents 593.3 Preliminary Hazard Review during Conceptual Design 603.3.1 Risk Matrix for Qualitative Judgments 613.3.2 What-If and Process Safety Check Lists 623.3.3 Plot Plan and Layout Review 633.3.4 Area Classification Reviews 653.3.5 Pressure Relief System Considerations 663.3.6 Fire Safety for Revamp Projects 723.4 Process Hazard Analysis (PHA) 743.4.1 Process Plant Hazard Review using HAZOP 743.4.2 Failure Modes and Effects Analysis (FMEA) Tool 793.4.3 Instrumented Protective System Design 813.4.4 Fault Tree Analysis 823.4.5 Event Tree Analysis 843.4.6 Layer of Protection Analysis (LOPA) 853.4.7 Safety Instrumented System (SIS) Life Cycle 883.5 Revision of PSI and Operator Induction 883.6 Pre-Start-up Safety Review (PSSR) 903.7 Management of Change (MOC) 913.8 Conclusions 92Acronyms 93Exercises 94References 95PART II TECHNIQUES FOR RETROFITTING AND REVAMPING4 Mathematical Modeling, Simulation and Optimization for Process Design 99Shivom Sharma and G.P. Rangaiah4.1 Introduction 994.2 Process Modeling and Model Solution 1014.2.1 Process Modeling 1014.2.2 Model Solution 1034.2.3 Model for Membrane Separation of a Gas Mixture 1044.3 Process Simulators and Aspen Custom Modeler 1074.4 Optimization Methods and Programs 1084.5 Interfacing a Process Simulator with Excel 1124.6 Application to Membrane Separation Process 1134.7 Conclusions 116Acronyms 116Appendix 4A: Implementation of Membrane Model in ACM 117Appendix 4B: Interfacing of Aspen Plus v8.4 with Excel 2013 119Appendix 4C: Interfacing of Aspen HYSYS v8.4 with Excel 2013 122Exercises 125References 1255 Process Intensification in Process Retrofitting and Revamping 129D.P. Rao5.1 Introduction 1295.1.1 Retrofitting and Revamping 1295.1.2 Evolution of Chemical Industries and Process Intensification 1305.1.3 Flow Chemistry 1305.2 Methods of Process Intensification 1305.2.1 Intensification of Rates 1315.2.2 Process Integration 1325.3 Alternatives to Conventional Separators 1325.3.1 Rotating Packed Beds (HIGEE) 1335.3.2 HIGEE with Split Packing 1345.3.3 Zigzag HIGEE 1355.3.4 Multi-rotor Zigzag HIGEE 1365.3.5 Applications of HIGEE for Retrofitting 1375.3.6 Podbielniak Centrifugal Extractor 1385.3.7 Annular Centrifugal Extractor 1395.3.8 Adsorbers 1405.4 Alternatives to Stirred Tank Reactor (STR) 1425.4.1 HEX Reactor 1425.4.2 Advanced-flowTM Reactor (AFR) 1435.4.3 Agitated Cell Reactor (ACR) 1455.4.4 Oscillatory-flow Baffled Reactors (OBR) 1465.4.5 Spinning Disc Reactor (SDR) 1475.4.6 Spinning Tube-in-tube Reactor (STTR) 1485.4.7 Stator-rotor Spinning Disc Reactor (Stator-rotor SDR) 1505.4.8 Reactor Selection 1505.4.9 Microchannel Devices 1515.5 Process Integration 1515.5.1 Heat and Mass Integration 1525.5.2 Reactive Separations 1525.5.3 Hybrid Separation 1535.5.4 Conversion of Crosscurrent into Countercurrent Process 1535.5.5 Process-specific Integration 1545.5.6 In-line Processing 1575.5.7 Twister® - A Supersonic Separator 1585.6 Fundamental Issues of PI 1595.7 Future of PI 1595.8 Conclusions 160Acknowledgement 160Appendix 5A: Monographs, Reviews and Some Recent Papers 160References 1636 Using Process Integration Technology to Retrofit Chemical Plants for Energy Conservation and Wastewater Minimization 167Russell F. Dunn and Jarrid Scott Ristau6.1 Introduction 1676.1.1 Heat Integration Networks 1686.1.2 Water Recycle Networks 1696.2 Graphical Design Tools for Retrofitting Process for Energy Conservation by Designing Heat Exchange Networks 1706.2.1 The Temperature–Interval Diagram (TID) 1716.2.2 The Heat Pinch Composite Curves (Temperature–Enthalpy Diagrams) 1726.2.3 The Enthalpy-Mapping Diagram (EMD) 1746.2.4 Identifying Heat Integration Matches Using the TID and EMD 1746.2.5 Graphical Tools Facilitate HEN Design for Large-scale Industrial Problems 1776.3 Graphical Design Tools for Retrofitting Processes for Wastewater Reduction by Designing Water Recycle Networks 1796.3.1 The Material Recycle Pinch Diagram 1796.3.2 The Source–Sink Mapping Diagram 1816.3.3 Suggested Guidelines for Identifying Water Recycle Matches Using the Material Recycle Pinch Diagram and Source–Sink Mapping Diagrams 1816.4 Conclusions 182Appendix 6A: Illustrating the Water Recycle Network Design Guidelines 183Exercises 188References 1907 Heat Exchanger Network Retrofitting: Alternative Solutions via Multi-objective Optimization for Industrial Implementation 193B.K. Sreepathi and G.P. Rangaiah7.1 Introduction 1937.2 Heat Exchanger Networks 1967.2.1 Structural Representation 1987.3 HEN Improvements 1997.4 MOO Method, HEN Model and Exchanger Reassignment Strategy 2037.4.1 Multi-objective Optimization 2037.4.2 HEN Model 2057.4.3 Exchanger Reassignment Strategy (ERS) 2067.5 Case Study 2087.6 Results and Discussion 2087.6.1 Simple Retrofitting 2097.6.2 Moderate Retrofitting 2117.6.3 Complex Retrofitting 2147.6.4 Comparison and Discussion 2167.7 Conclusions 218Appendix 7A: Calculation of Nodal Temperatures 218Exercises 221References 2218 Review of Optimization Techniques for Retrofitting Batch Plants 223Catherine Azzaro-Pantel8.1 Introduction 2238.2 Batch Plant Typical Features 2248.3 Formulation of the Batch Plant Retrofit Problem 2288.3.1 Design versus Retrofitting Problem 2288.3.2 Design/Retrofit Problems: A Four-Level Framework 2298.4 Methods and Tools for Retrofit Strategies 2308.4.1 General Comments 2308.4.2 Key Approaches in Batch Plant Retrofitting: Deterministic vs Stochastic Methods 2388.4.3 New Trends in Batch Plant Retrofitting: Steps for More Sustainable Processes 2428.5 Conclusions 243References 244PART III RETROFITTING AND REVAMPING APPLICATIONS9 Retrofit of Side Stream Columns to Dividing Wall Columns, with Case Studies of Industrial Applications 251Moonyong Lee, Le Quang Minh, Nguyen Van Duc Long, and Joonho Shin9.1 Introduction 2519.2 Side Stream Column 2549.2.1 Side Stream Configuration 2549.2.2 Heuristic Rules for the Use of SSCs 2569.2.3 Pros and Cons of SSC 2579.2.4 Design of SSC 2579.3 Dividing Wall Column 2589.3.1 Introduction 2589.3.2 Design and Optimization of DWC 2599.4 Retrofit of an SSC to a DWC 2609.4.1 Introduction 2609.4.2 Design and Optimization of Retrofitted DWC 2609.4.3 Column Modification and Hardware 2639.5 Case Studies of Industrial Applications 2669.5.1 Acetic Acid Purification Column 2669.5.2 n-BuOH Refining Column 2719.6 Other Case Studies 2759.6.1 Ethylene Dichloride (EDC) Purification Column 2759.6.2 Diphenyl Carbonate (DPC) Purification Column 2769.6.3 Other SSCs 2779.7 Conclusions 277Acknowledgements 278Nomenclature 278References 27910 Techno-economic Evaluation of Membrane Separation for Retrofitting Olefin/Paraffin Fractionators in an Ethylene Plant 285X.Z. Tan, S. Pandey, G.P. Rangaiah, and W. Niu10.1 Introduction 28510.2 Olefin/Paraffin Separation in an Ethylene Plant 28710.3 Membrane Model Development 28910.3.1 Membrane Modeling 28910.3.2 Assumptions for Membrane Separation Simulation 29110.4 Retrofitting a Distillation Column with a Membrane Unit 29210.4.1 HMD Modeling and Simulation 29210.4.2 Techno-economic Feasibility of Retrofit Operation 29610.5 Formulation of Multi-objective–Optimization Problem 30010.6 Results and Discussion 30410.6.1 Case 1: HMD System for EF (Assuming Credit for Reboiler Duty) 30410.6.2 Case 2: HMD System for EF (Assuming Reboiler Duty as Cost) 30610.6.3 Case 3: HMD System for PF 30810.7 Conclusions 310Appendix 10A: Membrane Model Validation 310Appendix 10B: Costing of HMD System 312Exercises 315References 31511 Retrofit of Vacuum Systems in Process Industries 317C.C.S. Reddy and G.P. Rangaiah11.1 Introduction 31711.2 Vacuum-generation Methods 31811.3 Design Principles and Utility Requirements 32011.3.1 Suction Load of Vacuum System 32011.3.2 Steam Jet Ejectors 32311.3.3 Liquid Ring Vacuum Pumps 32511.3.4 Dry Vacuum Pumps 32611.4 Chilled-water Generation 32611.5 Optimization of Vacuum System Operating Cost 32811.6 Case Study 1: Retrofit of a Vacuum System in a Petroleum Refinery 33211.6.1 Analysis of the Results 33511.7 Case Study 2: Retrofit of a Surface Condenser of a Condensing Steam Turbine 34111.8 Conclusions 342Nomenclature 343Exercises 344References 34512 Design, Retrofit and Revamp of Industrial Water Networks using Multi-objective Optimization Approach 347Shivom Sharma and G.P. Rangaiah12.1 Introduction 34712.2 Mathematical Model of a Water Network 35012.3 Water Network in a Petroleum Refinery 35212.4 Multi-objective Optimization Problem Formulation 35212.5 Results and Discussion 35512.5.1 Water Network Design 35512.5.2 Retrofitting Selected Water Networks for Change in Environmental Regulations 35812.5.3 Retrofitting Selected Water Networks for Increase in Hydrocarbon Load 36312.5.4 Revamping Selected Water Networks for Change in Environmental Regulations 36512.5.5 Revamping Selected Water Networks for Increase in Hydrocarbon Load 36712.5.6 Comparison of Retrofitting and Revamping Solutions 36912.6 Conclusions 369Acknowledgement 370Nomenclature 370Exercises 371References 37213 Debottlenecking and Retrofitting of Chemical Pulp Refining Process for Paper Manufacturing – Application from Industrial Perspective 375Ajit K. Ghosh13.1 Introduction 37513.2 Fundamentals of Chemical Pulp Refining 37613.2.1 Refining Effects on Various Chemical Pulp Types 37713.2.2 Effects of Refining on Pulp and Paper Properties 37813.3 Theories of Chemical Pulp Refining 38013.3.1 Specific Edge Load Theory 38113.3.2 Specific Surface Load Theory 38213.3.3 Frequency and Intensity or Severity of Impact 38213.3.4 The ‘C’ Factor 38313.4 Types of Commercial Refiners 38413.5 Laboratory and Pilot-scale Refining Investigation 38413.6 Case Studies of Retrofitting Refining Process for Paper Mills 38613.6.1 Case A: Retrofitting of Existing Refiners to Debottleneck Output of a Modern Paper Machine 38613.6.2 Case B: Retrofitting of Existing Refiners of a Paper Machine to Switch from ‘Flat’ to ‘Semi-extendable’ Sack Kraft Papers 40213.7 Conclusions 406Exercises 407References 408Index 410