can diagnose and isolate root causes. Utilising AI means identifying the faulty piece of equipment or process the first time, thereby reducing long hours spent investigating poten- tial causes. This in itself helps to reduce overall maintenance costs and increase reliability. When real-time data are available that present how the operating environment is performing in the moment, and the design limits and regulatory requirements are embedded into the system, it is possible to make the operating environ- ment much safer, ensure that hydrocarbons stay in the pipes, and also prevent accidents. Q What are some of the most effective compressor per- formance strategies for improving the mean time between failure (MTBF)? On the other hand, a case study for a plant capacity expansion can be developed without any information about the hydraulic capacities of the existing columns. The case study that will be discussed in Part II of this article is based on the premise that a bottleneck exists at some point in the existing distillation train (or, more likely, throughout the entire distillation train) and that PPD can be employed to increase the throughput at the bottleneck. In the selected case study, the entire distillation train is debottlenecked using PPD concepts to demonstrate how PPD is imple- mented in large throughput expansions. Large and small throughput expansions A Bishwanath Mondal, Manager Global Technical Services (Petrochemicals), bishwanath.mondal@dorfketal.com, and Joice Boll, Global Technical Lead, Petrochemicals, joice@dorfketal.com, Dorf Ketal Chemicals: Changes in feedstock quality, the introduction of side streams, and increases in compressor temperature and residence time are usual factors that can affect compressor performance by increasing the fouling tendency. Some strat- egies that can be adopted to reduce the impact on compres- sor performance and run length are listed as follows: • Maintain discharge temperature towards the lower side (<90°C for CGC) and injection of wash water (BFW) as required In the upcoming Part II of this article, the development of a case study with process simulations will be presented to show the benefits obtained from debottlenecking distil - lation trains using PPD. The case study will examine the debottlenecking of the product recovery section of an ethyl- ene oligomerisation plant. A description of how the design basis and operating conditions for the process simulations were developed will be provided. Part II will provide the reader with approximate levels of ‘small’ and ‘large’ throughput expansions (expressed columns in applications involving reactor product yield dis- tribution shifts. However, it is not a straightforward task to create a design basis for a case study when applying PPD in product yield distribution shifts without knowing the hydraulic capacity limits of each of the existing columns in the product recovery distillation train.
• Use a good-quality wash oil (>85% or >90% of aromatic content) • Ensure there is no corrosion and free form of iron, as it acts as catalyst to promote free-radical polymerisation • Use efficient antifoulant to reduce free-radical polymer for - mation and polymer deposition. Dorf Ketal offers different chemical strategies depending on the compressor character- istics and plant conditions • During periods of low feed flow rate, improve wash oil and antifoulant strategies to minimise the impact of increased residence time • An effective and real-time monitoring tool can help detect early signs of problems while taking a proactive approach. The following advanced monitoring systems are currently used by Dorf Ketal: u Real-time modelling of CGC (by COMPASS) that simu- late the machine’s actual performance digitally compared to ideal conditions. Eliminate all chances of error by considering injection of wash water and other parameters of feed gas composition. COMPASS can detect early signs of fouling and suggest corrective action, which can also help in optimising wash oil and chemical consumption v Fouling Assessment Tool (FAT) is another real-time online monitoring tool that can measure the quantity of foulant and help in collecting a foulant sample online for lab studies and evaluations. Besides traditional monitoring of compressors, the above strategies, along with an efficient antifoulant treatment, have successfully enhanced machine run length in many cases. David Kockler is a Principal at Dividing Wall Distillation and Separa- tions Consulting, LLC. He specialises in the development and imple- mentation of advanced distillation processes for the chemicals and refining industries. He has over 30 years’ process design experience working in the chemicals and refining sectors and holds a bachelor’s degree in chemical engineering from Northwestern University and a master’s degree in chemical engineering from the University of Vir- ginia. Email: dwc-separations-consulting@outlook.com as a percentage of existing capacity) that are obtainable through implementation of PPD. The number of new dis- tillation columns required for large throughput expansions will be discussed (earlier in this article, it was noted that many small throughput expansions can be achieved with the addition of a single new column). A comparison of the energy efficiency of a PPD scheme versus a parallel distilla - tion train configuration will also be provided. References 1 Lappin, G. R., Sauer, J. D., editors, Alpha Olefins Applications Hand - book , 1st ed, CRC Press, 1989. 2 Lappin, G. R., et al ., Olefins, Higher, Kirk and Othmer Encyclopedia of Chemical Technology , 3 (17), 716-721, 1983, Wiley, New York, US. 3 Petlyuk, F. B., Platonov V. M., Slavinskij D. M., Thermodynamically Optimal Method for Separating Multicomponent Mixtures, Int. Chem. Eng. 5(3), 555-561, 1965. 4 Lorenz, H. M., Staak, D., Grutzner, T., Repke, J. U., Divided Wall Col- umns: Usefulness and Challenges, Chemical Engineering Transactions, 69, 229-234, 2018.
MERYT Catalysts & Innovation Your global supplier of catalysts, adsorbents and additives focused on new technologies and sustainable processes.
Improve the profitability of your processes with MERYT catalysts and our outstanding technical knowledge, experience, and excellent service Face the Energy Transition with MERYT as your best partner to achieve your objectives Reduce your energy consumption and your emissions with MERYT Catalysts and Technologies
info@meryt-chemical.com www.meryt-chemical.com
+34 868 086 998 +34 670 518 438
MERYT Catalysts & Innovation c/Berlín Parcela 3F Polígono Industrial Cabezo Beaza 30353-Cartagena Murcia SPAIN
53 11
PTQ Q2 2023 PTQ Q3 2023
www.digitalrefining.com
Powered by FlippingBook