VULCAN Systems Nanocatalysis

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Gerard B. Hawkins

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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

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

101 Things That Can Go Wrong on a Primary Reformer - Best Practices Guide

Gerard B. Hawkins

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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

Theory of Carbon Formation in Steam Reforming

Gerard B. Hawkins

Adiabatic Reactor Analysis for Methanol Synthesis Plant Note Book Series: P...

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STEAMING PROCEDURE FOR VULCAN STEAM REFORMING CATALYSTS

Gerard B. Hawkins

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

Calculation of an Ammonia Plant Energy Consumption:

Gerard B. Hawkins

Calculation of Caloric Value and other Characteristic Data of Fuel Gas

Gerard B. Hawkins

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

Pickling & Passivation

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

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

Gerard B. Hawkins

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...

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

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Getting the Most Out of Your Refinery Hydrogen Plant

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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

EMERGENCY ISOLATION OF CHEMICAL PLANTS

Gerard B. Hawkins

PRACTICAL GUIDE TO DEVELOPING PROCESS FLOW DIAGRAMS AND PRELIMINARY ENGINEERING LINE DIAGRAMS PROCESS CONTENTS 1 INTRODUCTION 2 DESCRIPTION OF METHODOLOGY 2.1 Philosophy of the Design Process 2.2 Outline of Methodology 2.3 Additional Aspects of Methodology 3 WORKBOOK 4 EXAMPLE: BATCH NEUTRALIZATION AND STRIPPING PROCESS 4.1 Start of Stage 1 4.2 Stage 1 4.3 Stage 2 4.3 Stage 3 5 REFERENCES TABLES 1 DESIGN OBJECTIVES 2 OUTPUT FROM EACH STAGE 3 STEP BY STEP APPROACH 4 FUNCTION 5 OPERATION 6 FAILURES 7 STAGE 3 PROMPTS (DATA SHEET) 8 PRELIMINARY MASS BALANCE 9 PRELIMINARY EQUIPMENT LIST 10 POTENTIAL PROBLEMS 11 STAGE 2: DEVELOPMENT OF OPERATING STATES AND TRANSMISSIONS 12 POTENTIAL PROBLEMS FIGURES 1 DESIGN PROCESS 2 DESIGN PHILOSOPHY. 3 SUMMARY OF METHODOLOGY 4 POSSIBLE OUTCOMES FROM A KEYWORD PROMPT 5 OPERATING STATES 6 OPERATING STATES/TRANSITIONS 7 EXAMPLE: OVERALL BLOCK DIAGRAM 8 EXAMPLE: “PRIMITIVE PFD” 9 EXAMPLE: STAGE 1 “WORKING DIAGRAM”. 10 EXAMPLE: MAIN OPERATING STATES AND TRANSITIONS 11 EXAMPLE: DETAILED PFD (END OF STAGE 1) 12 EXAMPLE: STAGE 2 “WORKING DIAGRAM” 13 EXAMPLE: STAGE 3 “REV 0” ELD

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Purificación – Mecanismos de Reacción

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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

Amine Gas Treating Unit - Best Practices - Troubleshooting Guide

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VULCAN Systems Nanocatalysis

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