APRIL 2009
HPIMPACT
SPECIALREPORT
FORECAST
Economy, capacity
pressure polyolefins
PETROCHEMICAL
DEVELOPMENTS
ACHEMA 2009
No short-term recovery
for Asian demand
Innovation sustains
profits and safety
Trade associations
report on chemicals
markets and outlook
www.HydrocarbonProcessing.com
sky's the limit
OneWireless solutions give you the freedom
to extend beyond your limits.
From helping you manage your rotating equipment to making
your employees mobile and more efficient, Honeywell has
helped our customers solve process and business challenges
with innovative wireless-enabled solutions. Our OneWireless
TM
universal mesh network supports multiple industrial protocols and applications
simultaneously, giving you flexibility without sacrificing reliability or bandwidth. Why stay
chained to multiple networks, when there is one that will let you soar. OneWireless.
To learn more about OneWireless solutions, please call
1-877-466-3993 or visit www.honeywell.com/ps/wireless
© 2008 Honeywell International, Inc. All rights reserved.
Select 52
51 at www.HydrocarbonProcessing.com/RS
APRIL 2009 • VOL. 88 NO. 4
www.HydrocarbonProcessing.com
SPECIAL REPORT: ACHEMA 2009/
PETROCHEMICAL DEVELOPMENTS
ACHEMA 2009: A Special Report
29
57
29 Middle East; 39 Asia-Pacific; 51 South America; 55 North America
Lead or get out of the way
We do have choices in shaping our future energy market
J. D. Morris
61
Improve product ethylene separation
71
Reevaluate your process safety systems
for hazardous material storage
New high-capacity trays enable retrofitting existing splitter superfractionator
to expand unit capacity and conserve energy
A. Bernard, W. de Villiers and D. R. Summers
How safe is ‘safe enough’ when it comes to managing
potentially risky processes in chemical plants?
M. P. Sukumaran Nair
81
Update catalyst technology for syngas production
Changes in bed support maintain lower pressure drop across
shift reactor in ammonia processes
W. Khalid
RELIABILITY/MAINTENANCE
Extreme failure analysis: never again a repeat failure
87
Apply root-cause failure analysis to recurring reliability problems
K. Bloch
COMPUTER TECHNOLOGY/PIPING
Computational fluid dynamics simulation
of solid–liquid slurry flow
Cover The Ludwigshafen site is BASF’s
largest production facility. With
approximately 32,600 workers, the
company at Ludwigshafen is the largest
employer of the metropolitan Rhine
Neckar region. This site was established
143 years ago. Over 200 production
enterprises are linked together via a
2,000-km aboveground pipeline network.
Photo courtesy and copyright by BASF, The
Chemical Co.
HPIMPACT
17 Economy, capacity
additions pressure
polyolefins markets
19 Asia’s thirst for oil
likely to swell again,
but when?
19 EPA chemicals oversight
questioned in new GAO
report
99
The resulting model’s predictions showed reasonably good agreement
with the experimental data
S. K. Lahiri and K. C. Ghanta
SAFETY
Apply new trends for safety-instrumented systems
107
Take a closer look at advancements for emergency shutdown designs
P. Gruhn
111
Maximize up-time for sulfur testing
117
Rethink your overpressure systems
New analyzer determines trace level amounts quickly
R. Van Der Windt and A. Van Strien
Consider multiple relief valve designs
S. Rahimi Mofrad
ASSET MANAGEMENT
Transforming refining best practices with 3D virtual models
121
The technology, from laser scanning to management of change,
is mature, functional, cost-effective and proven
K. M. Renner and C. Lanza
ENGINEERING CASE STUDIES
Case 49: Isolating foundations
from machinery vibrating forces
COLUMNS
9 HPIN RELIABILITY
Pump suction strainer
issues
11 HPIN EUROPE
CO2 constraints
‘may be the best news
for Shell’—CEO
13 HPINTEGRATION
STRATEGIES
Reducing cost
through an integrated
approach to power and
automation
134 HPIN AUTOMATION
SAFETY
Are you the designated
jailee?
129
Vibration can be detrimental to nearby equipment
T. Sofronas
DEPARTMENTS
7 HPIN BRIEF • 15 HPIN ASSOCIATIONS • 17 HPIMPACT •
21 HPINNOVATIONS • 25 HPIN CONSTRUCTION •
130 HPI MARKETPLACE • 133 ADVERTISER INDEX
View this month’s
LETTERS TO THE EDITOR
online at: www.
HydrocarbonProcessing.com
www.HydrocarbonProcessing.com
Houston Office: 2 Greenway Plaza, Suite 1020, Houston, Texas, 77046 USA
Mailing Address: P. O. Box 2608, Houston, Texas 77252-2608, USA
Phone: +1 (713) 529-4301, Fax: +1 (713) 520-4433
E-mail: editorial@HydrocarbonProcessing.com
www.HydrocarbonProcessing.com
London Office: Nestor House, Playhouse Yard London, EC4V 5EX, UK,
Phone: +44 (0) 20 7779 8800, Fax: +44 (0) 20 7779 8996/8899
Publisher Mark Peters mark.peters@gulfpub.com
EDITORIAL
Editor Les A. Kane
Senior Process Editor Stephany Romanow
Managing Editor Wendy Weirauch
Process Editor Tricia Crossey
Reliability/Equipment Editor Heinz P. Bloch
News Editor Billy Thinnes
European Editor Tim Lloyd Wright
Contributing Editor Loraine A. Huchler
Contributing Editor William M. Goble
Contributing Editor Y. Zak Friedman
Contributing Editor ARC Advisory Group (various)
MAGAZINE PRODUCTION
Director—Editorial Production Sheryl Stone
Manager—Editorial Production Chris Valdez
Artist/Illustrator David Weeks
Manager—Advertising Production Cheryl Willis
ADVERTISING SALES
See Sales Offices page 132.
CIRCULATION +1 (713) 520-4440
Director—Circulation Linda K. Johnson
E-mail: circulation@gulfpub.com
SUBSCRIPTIONS
Subscription price (includes both print and digital versions): United
States and Canada, one year $140, two years $230, three years $315.
Outside USA and Canada, one year $195, two years $340, three
years $460, digital format one year $140. Airmail rate outside North
America $175 additional a year. Single copies $25, prepaid.
Because Hydrocarbon Processing is edited specifically to be of greatest
value to people working in this specialized business, subscriptions are
restricted to those engaged in the hydrocarbon processing industry, or
service and supply company personnel connected thereto.
Hydrocarbon Processing is indexed by Applied Science & Technology
Index, by Chemical Abstracts and by Engineering Index Inc. Microfilm
copies available through University Microfilms, International, Ann
Arbor, Mich. The full text of Hydrocarbon Processing is also available
in electronic versions of the Business Periodicals Index.
ARTICLE REPRINTS
If you would like to have a recent article reprinted for an upcoming
conference or for use as a marketing tool, contact us for a price quote.
Articles are reprinted on quality stock with advertisements removed;
options are available for covers and turnaround times. Our minimum
order is a quantity of 100.
For more information about article reprints, call Cheryl Willis at
+1 (713) 525-4633 or e-mail EditorialReprints@gulfpub.com
HYDROCARBON PROCESSING (ISSN 0018-8190) is published monthly by Gulf Publishing Co., 2 Greenway Plaza,
Suite 1020, Houston, Texas 77046. Periodicals postage paid at Houston, Texas, and at additional mailing office.
POSTMASTER: Send address changes to Hydrocarbon Processing, P.O. Box 2608, Houston, Texas 77252.
Copyright © 2009 by Gulf Publishing Co. All rights reserved.
Permission is granted by the copyright owner to libraries and others registered with the Copyright Clearance Center
(CCC) to photocopy any articles herein for the base fee of $3 per copy per page. Payment should be sent directly to
the CCC, 21 Congress St., Salem, Mass. 01970. Copying for other than personal or internal reference use without
express permission is prohibited. Requests for special permission or bulk orders should be addressed to the Editor.
ISSN 0018-8190/01.
www.HydrocarbonProcessing.com
GULF PUBLISHING COMPANY
John D. Meador, President/CEO
Mark Peters, Vice President
Ron Higgins, Vice President
Maggie Seeliger, Vice President
Pamela Harvey, Business Finance Manager
Part of Euromoney Institutional Investor PLC.
Other energy group titles include:
World Oil®
Petroleum Economist
Publication Agreement Number 40034765
Printed in U.S.A
䉳 Select 151 at www.HydrocarbonProcessing.com/RS
INT ENS E HE AT. A GGR E S S IVE CHE MICALS . E XT R E ME COLD.
WE’RE PUSHING THE
LIMITS OF ENDURANCE.
NOT YOUR PATIENCE.
MATERIAL TECHNOLOGY
ENGINEERED FOR
REFINERIES
THERMICULITE®
835 Spiral Wound Filler
UÊÊ>˜`iÃÊÌ iÊ̜Õ} iÃÌÊ>««ˆV>̈œ˜Ã
UÊÊ"ÕÌ«iÀvœÀ“ÃÊ}À>« ˆÌiÊ>˜`ÊwLiÀ
UÊÊ*ÀœÛˆ`iÃÊ̜Ì>ÊvÀii`œ“ÊvÀœ“ʜ݈`>̈œ˜
UÊÊ"vviÀÃÊÌÀÕiʜÕÌ>}i‡Ìœ‡œÕÌ>}iÊ>ÃÃÕÀ>˜Vi
UÊÊ,i`ÕViÃʈ˜Ûi˜ÌœÀÞÊÀiµÕˆÀi“i˜ÌÃ
*
G
AS
ALSO AVAILABLE IN:
U 815 Tanged Sheet
U 815 Cut Gaskets
UÊ845 Flexpro™ (kammprofile) Facing
Select 93 at www.HydrocarbonProcessing.com/RS
IÊÓäänÊÀœÃÌÊEÊ-ՏˆÛ>˜Ê œÀÌ Ê“iÀˆV>˜Ê*Àœ`ÕVÌÊ6>ÕiÊi>`iÀà ˆ«ÊœvÊÌ iÊ9i>ÀÊÜ>À`Ê,iVˆ«ˆi˜Ì°
R
UR GLOBAL
YO
K ET
P R O VI
DE
log onto:
www.flexitallic.com
or call:
US +1 281.604.2400
UK +44 (0) 1274 851273
As an internationally renowned engineering
partner and plant construction company,
Uhde offers complete service packages from
the initial concept to the turnkey plant.
Uhde provides these services to refineries
around the world. Two of our main specialities
are naphtha and middle distillate processing.
In line with the trend towards improving the
quality of gasoline and diesel, our Edeleanu
Refining Technologies Division has executed
numerous hydrodesulphurisation projects
during the last few years. Several plants, not
only based on world-class technologies
supplied by well-known licensors such as
·
·
·
·
Axens
Haldor Topsoe
Kellogg Brown & Root
UOP
but also proprietary Edeleanu technologies
designed in co-operation with catalyst
suppliers such as Albemarle or BASF, are
currently under construction.
Middle Distillate Desulphurisation Unit for
Shell Deutschland Oil GmbH in Wesseling, Germany
The total capacity of all our naphtha and
diesel hydrotreating projects since 2001 now
exceeds 15 million tonnes per year. The
treated products meet the European Clean
Fuels Directive.
Isomerisation of light gasoline or gas condensate yields another valuable blending component for gasoline. Our Edeleanu Refining
Technologies Division executes projects for
grassroots plants or revamps of catalytic
reformers for that purpose.
Solutions in Refining
Technologies
C5/C6 Isomerisation, PCK Schwedt, Germany
In keeping with our slogan Engineering with
ideas, we provide a comprehensive range of
supplies and services which extends from the
initial feasibility study and financing right
through to operation of the turnkey plant.
Uhde GmbH
Edeleanu Refining Technologies Division
Friedrich-Uhde-Str. 2
65812 Bad Soden
Germany
Phone +49 (61 96) 205 1711
Fax +49 (61 96) 205 1717
www.uhde.eu
Uhde
A company of ThyssenKrupp Technologies
Select 81 at www.HydrocarbonProcessing.com/RS
Visit us at
Frankfurt a.M., May 11 - 15, 2009,
Hall 9.1, Stand O33 - R40
ThyssenKrupp
HPIN BRIEF
WENDY WEIRAUCH, MANAGING EDITOR
WW@HydrocarbonProcessing.com
Now’s the time to ‘position yourself for the next curve,’ says Donald
L. Paul, founder and president of Energy and Technology Strategies, LLC and retired chief
technology officer of Chevron. In examining enterprise-wide solutions to industry threats, he
posited in a keynote presentation that cyber-security is a game that cannot be won, but is an
ongoing challenge. “Get better” at fighting the battle, he advised. Devote more intellectual
resources to IT now that those departments are not as busy in this economic downturn.
However, it is not necessary to throw more capital investment at the problem. Regarding the
industry’s carbon-reduction controversy, he favors a carbon tax as more efficient than the cap
and trade alternative, but doesn’t think this will be “the way political winds will go.”
Integrated look at product quality for EU refiners in terms of demand
changes, investment requirements, energy consumption and CO2 emissions is the subject
of a new study from CONCAWE. Meeting the EU policy goal of reducing the absolute
level of CO2 emissions from refineries is a tough challenge because mitigating measures
available to refiners are limited. Energy efficiency improvement still presents opportunities. This analysis, however, questions whether feedstock substitution would indeed result
in global emissions reductions. “Increased reliance on lighter crude oils might reduce EU
refinery emissions, but would simply cause the opposite switch somewhere else in the
world,” according to the association’s research (www.concawe.org).
An owner/operator’s perspective on the EPC project handover. With
over 100,000 documents on each project, ChevronTexaco’s expectation of an engineering,
procurement and construction contractor (EPC) is to see most of the project information
generated. So says Steven Fowlkes, manager of information management support for major
capital projects with that corporation. In handling information migration, the contract
stipulates how the information is transferred. What system an EPC uses to manage project
information is not a deal-breaker in his organization on whether that EPC receives the
contract, he says. However, he wonders if that policy might change in the next 10 years. Mr.
Fowlkes noted that, with owners now focusing more on using project data for operations
and maintenance purposes, it becomes a waste of the EPC’s high-level design information
if that intelligence is not transferred to the owner.
Criticality of cost and schedule engineers. J. Phil Wilbourne, a retired general
manager of Texaco and presently an associate professor at Tennessee Tech University, examined the role of the cost engineer at an international conference on project management
best practices held recently in Houston (www.bmc-online.com). Cost engineering requires
a specific expertise. “The problem with most projects is the substitution of another discipline for a cost engineer,” according to Mr. Wilbourne. Cost engineering in the 1970s was
generally a corrosion engineer’s role; in the 1980s, it was a safety engineer; in the 1990s, it
was an environmental engineer’s responsibility. Presently, he says that the expertise of cost
engineering is being incorporated into everyone’s job description and that the “jury’s still
out” on whether the position will continue being a separate function.
The US Air Force has purchased ultra-clean synthetic jet fuel from
Rentech, which produces the product at its fully integrated synthetic fuels and chemicals
facility in Commerce City, Colorado. According to the company, the Air Force will use
the purchased synthetic fuel for performance and emissions testing in a turbine engine.
Previously, the Air Force conducted laboratory testing of the company’s synthetic jet fuel,
which confirmed that the quality and characteristics of the fuel met the Air Force’s specifications for synthetic fuels. The company’s proprietary technology is claimed to convert
synthesis gas from biomass and fossil resources into hydrocarbons that can be processed and
upgraded into ultra-clean synthetic fuels, specialty waxes and chemicals. The lower density
of the fuel has the potential to enable aircraft to reduce take-off weight, thus conserving fuel
and decreasing operating costs. HP
■ Harnessing
social networking
Shell faces similar business challenges as
its peers in the oil and gas industry, says
Mike Hinkle, lead IT architect with Royal
Dutch Shell. Key issues include: managing costs, reducing travel, leveraging the
disappearing expertise and knowledge
of experienced staff, and getting new
and younger hires “up to speed” and
engaged in high-value activities quickly.
Shell views social networking (SN) as a
set of viable methods to address many
of these problems. SN can “amplify
informal flows” and is a “richer method
to connect to other people in an organization,” he says. He estimates that
over 50,000 Shell employees are using
wikis and discussion forums. Thus, SN
becomes a different way to digitize
informal but important information
flows within the business.
Ideas and solutions can be shared broadly, and SN makes it possible for others
to find these ideas at the right time.
For example: external websites such
as LinkedIn, Facebook and MySpace
may be useful for corporate employees,
according to Mr. Hinkle. Companies
should anticipate their employees’ use
of public messaging services like blogs,
instant messaging and Twitter.
The challenge, however, is to manage
the confidential information, as the
information might not stay within the
enterprise intranet. Mr. Hinkle recommends “controlled but not restrictive”
security so that good communications
still happens.
Confidential information must be
managed appropriately, however. The
most effective management method
is to follow the corporate Information,
Confidentiality, Privacy and Usage policies, according to Mr. Hinkle. These
policies should be updated to account
for the new SN realities, and reviewed
by all staff at least annually. HP
HYDROCARBON PROCESSING APRIL 2009
I7
You Get More Than Just a Process Gas Compressor
Lubricated up to 1’000 bar, non-lubricated up to 300 bar
For longest running time: We recommend our own designed,
in-house engineered compressor valves and key components
Designed for easy maintenance
We are the competent partner with the full range
of services – worldwide
Your Benefit:
Lowest Life Cycle Costs
More benefits: www.recip.com/api618
Select 55 at www.HydrocarbonProcessing.com/RS
HPIN RELIABILITY
HEINZ P. BLOCH, RELIABILITY/EQUIPMENT EDITOR
HB@HydrocarbonProcessing.com
Pump suction strainer issues
Does your process piping have strainers located just upstream
of the pump suction nozzles? Perhaps you are using them to protect pumps from unintended ingestion of tower packing, nuts,
bolts and other debris. While it would be smart to investigate why
this stuff shakes loose, we will confine our comment to common
misunderstandings about strainers.
Whenever strainers are used because the upstream equipment
is flawed, be sure to understand the important requirements
imposed on strainers by reliability-focused engineers. These engineers recognize, first and foremost, that a distinction is to be made
between temporary and permanent strainers.
Temporary strainers are generally installed with the tip pointed
in the upstream direction, which places the material in compression instead of tension. These temporary strainers must be
removed about one week after commissioning the piping loop.
They are often fabricated on site using the general configuration
shown in Fig. 1.
In contrast, permanent strainers are designed to be left in place
and must be cleanable without shutting down the pump. They
are typically available from a variety of commercial sources, must
be made of high-grade corrosion-resistant materials and can be
expensive.
Here are the strainer guidelines found in Maximizing Machinery Uptime:
Identification tab at
top for raised-face
flanges. Mount on
flange bolts.
Preferred flow
direction
Strainer screen
Spool piece
Screen seam
Install gasket on each
side of strainer flange.
Strainer assembly
12 gauge x 1-in. wide
identification tab.
½-in.
Mount 20-gauge wire mesh
inside a three-mesh guard
screen and stagger the
longitudinal seams.
½-in.
12 gauge
ASTM “A”
167 type
316
90°
Screen section
See detail “A”
FIG. 1
Temporary strainer.
1-in.
1. Strainers (both temporary and permanent designs) may be
cone- or basket-shaped and shall be installed between the suction
flange and the suction block valve. The preferred orientation is
shown in Fig. 1.
2. The strainer mesh size (typically per Fig. 1) shall be
selected to stop all objects too large to pass through the pump
main flow passage.
3. Temporary strainers shall be used during flushing and
initial (one week) operating periods, unless permanent strainers
are specified.
4. Piping layout shall permit removal of strainers without
disturbing pump alignment; spool pieces are typically used.
5. If permanent strainers are selected, the design and location
of these strainers shall permit cleaning without removing the
strainer body.
6. Strainer arrangement shall permit cleaning without interrupting the pumping service.
7. For installations with permanent strainers and equipped
with a spare pump, a permanent strainer shall be installed in the
suction line of each pump.
8. Twin or self-cleaning strainers may be used for pumps
without spares.
9. Y-type strainers shall be restricted to 2-in. maximum size.
10. Suction lines for proportioning pumps shall be chemically
or mechanically cleaned to permit operation without strainers.
There are three very important points we wish to emphasize:
• Best-practices companies (BPCs) distinguish between
startup strainers and permanent strainers. They insist on removing startup strainers long before they will have become a serious
disintegration risk. Also, BPCs have established that strainers are
not needed upstream of most conventional process pumps after
the initial startup period.
• On the other hand, once BPCs determine strainers should
be left in place for some reason, they allocate the resources needed
to upgrade entire systems in order to reduce failure risk and maximize equipment uptime.
• Because BPCs are serious about maximizing pump uptime,
they insist on best practices being implemented at all times. At
those facilities deviations from best practice have to be justified
in writing and a manager is asked to accept responsibility in
those instances. HP
Detail “A”
Both sides of strainer
flange must be free of
gouges, weld spatter,
or other imperfections
that might impair proper
gasket seating.
The author is HP’s Equipment/Reliability Editor. A practicing engineer and ASME
Life Fellow with close to 50 years of industrial experience, he advises process plants on
maintenance cost reduction and reliability upgrade issues. His 16th and 17th textbooks
on reliability improvement subjects were published in 2006. The excerpt on strainers is
taken from Bloch-Geitner, Maximizing Machinery Uptime, pp. 629–630 (Gulf Publishing, ISBN 10:0-7506-7725-2).
HYDROCARBON PROCESSING APRIL 2009
I9
Select 75 at www.HydrocarbonProcessing.com/RS
HPIN EUROPE
TIM LLOYD WRIGHT, EUROPEAN EDITOR
tim.wright@gulfpub.com
CO2 constraints ‘may be the best news for Shell’—CEO
As the voluminous correspondence on climate change sparked
by Editor Les Kane’s editorial (HP, July 2008) continues, it’s good
to hear that the reader debate it started is powering ahead on the
worldwide web.
HP has run extra correspondence on climate on its online
pages, and one reader has even been in touch to say he’s setting
up a dedicated website. Refining engineer, and passionate HP
reader, Jeffrey Temple, has created www.CCD4E.org—or Climate
Change Debate for Engineers.
Online topic. Mr. Temple says that he wanted to set up a site
where all parties, “climate sceptics” included, could discuss the
science of climate change. He’s been approaching those who have
written in to the magazine to ask them to join the dialogue there.
“Les Kane really got a debate going, but it’s not very easy to
follow a discussion across a period of a year,” he told me when I
called him up in Kazakhstan, where he’s been technical manager
of the Chinese-owned Shymkent refinery. “The debate can now
be read side-by-side, instead of from month-to-month.”
Mr. Temple makes clear he’s not interested in debate for its
own sake: “Action on climate change needs to be taken with
urgency – not delayed until after some notional ticker-tape parade
when the debate is won,” he says. He mentions the newsletter he’s
just had from McKinsey, the consultants, which is about climate
change (search the web using “What Matters” and “McKinsey”).
“Nowhere, repeat nowhere, among all the voices they’ve brought
to the debate—from Bjorn Lomborg to Jeffrey Sachs—is there
any doubt expressed that anthropogenic emissions are indeed
causing serious climate change,” he says.
Conference topic. And that’s certainly how it felt when I
attended the plenary sessions and some of the seminars (and a lot
of parties) at International Petroleum Week in London in February.
Climate change was referred to in almost every plenary paper, and
at length by keynoters such as Nobuo Tanaka of the International
Energy Agency (IEA) and Jeroen van der Veer, chief executive of
Shell. But the problem description wasn’t in question—the discussion was about how best to respond.
For better and sometimes for worse, that response is taking
shape, and it’s already affecting your operations in ways you may
not yet have noticed. It’s partly due to the response that, if you
live in the world’s rich nations, “peak oil demand” lies several years
behind us in 2005. It’s partly due to policies enacted to date that
a staggering 84% of non-OPEC oil supply growth in 2009, or
335,000 bpd, is set to come from plants growing and capturing
carbon today, or recently harvested ones, rather than fossil fuels.
The IEA estimates that at least two thousand significant pieces
of new law are under development at national level worldwide.
Most noteworthy, as I write, is the new transatlantic consensus
on climate policy. It means that for the first time there is agree-
ment between Europe and the US administration that greenhouse
gas emissions must be cut by at least 80% by 2050. In fact, the
Obama budget proposal calls for cuts of 83% and anticipates that,
between 2012 and 2019, billions of dollars will be raised through
a cap and trade system.
We have one of those systems over here, already making itself
felt on refining and power generation through the local permit-tooperate process. It’s taken some stick from its critics recently because
the price of CO2 emission permits has plummeted to less than $10/
metric ton. The money supply crisis and the global recession it
spawned have cut fossil fuel demand and CO2 emissions since last
fall. But it’s a rather useful feature of a cap and trade system that the
burden on industry is light when economic times get tough.
Of course, the low carbon price means that you would need
nerves of steel to invest in a carbon-capturing coal project right
now, and it’s hard to invest in other projects that make undeniable
long-term sense. Shell recently dropped out of a sea-based wind
park and the Shell CEO has a point when he says, “We could
open a zero-emission refinery, but it would be out of business in a
week.” However, that doesn’t mean that there aren’t tremendous
opportunities for companies like his in the policy response to
climate change if the policy framework is far-reaching and stable.
As Jeroen van der Veer says, “Constraints on the emission of CO2
may be the best news for companies like Shell.”
The World Business Council for Sustainable Development’s
Electricity Utilities Sector Project estimates that capital investment
and infrastructure development to deploy existing climate mitigating technology through 2030 will be approximately $11.6 trillion.
This includes carbon capture and storage, electrification and grid
upgrades; Europe is estimated to need 60,000 wind turbines,
accounting for €450 billion in construction costs right there.
Shell sees a lot of value added in the company’s engineering skills,
its patents in gasification, its offshore experience, its trading skills—
even one day that pie-in-the-sky hydrogen economy stuff. We’re not
there yet, but the sooner the industry engages and embraces the challenge, the better the solutions will be. Perhaps then we can avoid some
of the false dawns we’ve seen in the biofuels and fuel cell sagas.
According to the IEA, you can have your cake and eat it. The
world’s going to need fossil fuels and more of them even as it
aims to reduce the impact of their use. “Don’t be afraid of this
development,” says Mr. Tanaka. “The world will need a lot of your
products—12 million bpd more from OPEC by 2030.” We’d best
use them efficiently. By the same period, he says, emitting CO2
will cost at least $180/metric ton. HP
The author is HP’s European Editor and has been active as a reporter and
conference chair in the European downstream industry since 1997, before which
he was a feature writer and reporter for the UK broadsheet press and BBC radio.
Mr. Wright lives in Sweden and is founder of a local climate and sustainability
initiative.
HYDROCARBON PROCESSING APRIL 2009
I 11
Select 80 at www.HydrocarbonProcessing.com/RS
HPINTEGRATION STRATEGIES
LARRY O’BRIEN, CONTRIBUTING EDITOR
lobrien@arcweb.com
Reducing cost through an integrated approach
to power and automation
Industry is the number one power consumer, yet, as a whole, it
has a remarkably poor sense of how much power is being used at
different times across manufacturing processes. In the HPI, many
potential cost-saving opportunities related to power and energy consumption are ignored simply because people in refineries and petrochemical plants don’t have the appropriate visibility or control.
Using automation to cut energy costs. Energy ranks
as one of the top cost pressures affecting manufacturers today.
However, the benefits of a sound energy management strategy
go beyond simple cost reductions. Effective energy management
is essential for a “triple bottom line” business strategy addressing
social, economic and environmental concerns.
According to the US Department of Energy, industry accounts
for about a third of all energy used in the US. The most energyintensive industries also just happen to be the process industries,
including refining and chemicals. Most of this energy goes to fired
heaters, steam generation and machine drives.
Automation and electrification, however, remain largely separate islands of functionality in today’s plants, as are drives and
motor control centers. Process operators, and even maintenance
personnel, have limited visibility into what is really happening
in their electrical systems, or control over how much energy
their manufacturing and automation assets are consuming. ARC
believes that taking a more proactive stance toward integrating
the automation and power/energy domains of the manufacturing
process can yield significant energy cost savings.
HPI owner-operators can benefit in several areas from integrating their power and automation assets. Typically, this would
involve integrating electrical distribution systems with automation
systems and plant asset management (PAM) systems; integrating
intelligent motor control centers and drives; deploying intelligent
field devices to more efficiently monitor and control energy usage;
using optimization, simulation and process modeling technologies; and adopting common hardware platforms that can handle
control tasks spanning process control and power applications.
IEC 61850 brings digital network technology. IEC
61850, a global communication standard for substation automation,
defines the communication between intelligent electrical devices
(IEDs) in switchgear and associated systems. IEC 61850 is the key
enabler for integrating automation and electrical systems. By providing a greater level of interoperability between electrical devices from
different suppliers, the IEC 61850 standard also does for electrical
products what process fieldbus does for instrumentation and control
valves. IEC 61850 also promises the same level of enhanced diagnostics and PAM capabilities offered in process fieldbus devices.
Intelligent motor control. Motors are a major source of energy
consumption. HPI plants can significantly reduce their energy costs
just by addressing inefficiencies that reside in their motor loads. A
good rule-of-thumb is that, in a single year, a motor can consume
enough energy to account for 10 times its initial cost.
Deploying variable-speed drives and intelligent motor control
centers integrated with the automation system can significantly
reduce energy costs. For example, it is common practice to control
the output of variable-torque loads (such as in pumps, fans and
blowers) by inefficiently throttling their input or output. In contrast, applying AC drives to large fans and pumps to control flow by
modulating their speed can produce significant energy savings.
Using intelligent field instrumentation. HPI plants can
also use intelligent field instrumentation to help reduce energy
cost. Intelligent Coriolis flowmeters, for example, can be used to
improve fuel gas measurement. Electrical and motor control centers can also be integrated into PAM systems, enabling early detection of impending device failures. Intelligent relays, for example,
can provide valuable diagnostic data to PAM systems, such as
circuit-breaker wear indication, transformer temperature and
life expectancy, motor thermal capacity and statistical data, and
time-stamped sequence-of-events reports. Some suppliers are also
integrating machinery health management into PAM systems.
Optimization, simulation and modeling approaches.
Optimization and simulation software can also be used to significantly reduce energy costs. In most energy-intensive operations,
such as in a refinery or chemical plant, energy consumption can
vary considerably due to changing operating conditions, equipment degradation and inefficient control strategies. The result is
that plants typically use more energy than necessary, yet are unable
to improve efficiency because they lack the means to collect and
analyze real-time performance information.
End users not only need real-time solutions that inform when
energy consumption in a plant is higher than it needs to be, they also
are looking for intelligent solutions that provide plant personnel with
specific advice for bringing the plant back to optimal energy usage.
ARC believes that energy savings on the order of 10% can be
achieved in many process plants by integrating power and automation. However, successful implementation will require some
changes in the work processes and also depends on implementing
a coherent energy management strategy. HP
Larry
O’Brienis ispart
partofofthe
theautomation
automationconsulting
consultingteam
teamatat ARC
ARC covering
covering the
the
The author
process
editor.
HeHe
is responsible
for for
tracking
the
processindustries,
industries,and
andananHPHPcontributing
contributing
editor.
is responsible
tracking
market
for process
automation
systems (PASs)
and(PASs)
has authored
PAS market
the market
for process
automation
systems
and hasthe
authored
the studPAS
ies
for ARC
sincefor
1998.
O’Brien
hasMr.
alsoO’Brien
authored
market
research,
market
studies
ARCMr.
since
1998.
hasmany
also other
authored
many
other
strategy
custom
research
reports
on topics
including
fieldbus,
collaborative
market and
research,
strategy
and
custom
research
reportsprocess
on topics
including
process
partnerships,
total automation
market trends
and others. He
has been
with
ARC
since
fieldbus, collaborative
partnerships,
total automation
market
trends
and
others.
January
his career
with 1993,
marketand
research
in the
instrumentation
He has1993,
been and
withstarted
ARC since
January
started
his field
career
with market
markets.
research in the field instrumentation markets.
HYDROCARBON PROCESSING APRIL 2009
I 13
HEURTEY & PETRO-CHEM GROUP
PROUD TO BE THE REFLECTION OF A MOVING WO
ORLD
World largest independent group Expert in design & fabrication of Process Fired Heaters
Paris - New York - Houston - Tulsa - Mumbai - Saint Petersburg - Seoul - Singapore - Johannesburg - Bucharest - Hamburg - Istanbul
www.heurtey.com
Select 58 at www.HydrocarbonProcessing.com/RS
HPIN ASSOCIATIONS
BILLY THINNES, NEWS EDITOR
bt@HydrocarbonProcessing.com
Association news in brief
Aker Solutions manager wins
award in India
Pothen Paul, Aker Solutions’ India country manager, has been named the “business
leader of the year for engineering services” by
the Chemtech Foundation, India’s process
industry body. This award is in recognition
of Paul’s contribution to the engineering
and construction (E&C) sector in India.
Mr. Paul has over 40 years of experience
in organization management, operations
management, construction management
and plant design. During his time with
Aker Powergas Pvt. Ltd., he oversaw the
development of a project management culture and an organizational mind set and
focused on high standards of quality within
project execution. Currently, he is also the
executive chairman of Aker Powergas Pvt.
Ltd., and the president of Aker Solutions’
global process business. Mr. Paul has also
served as chairman of the Process Plant
and Machinery Association of India and is
a member of the National Council of the
Confederation of Indian Industry (CII).
The Chemtech Foundation recognizes exceptional contributions to Indian
industry, the environment and research
and development through the ChemtechCEW Awards. This award and others were
announced in February at the Chemtech
World Expo 2009 in Mumbai, India.
Syngas professionals
converge on Tulsa
The SynGas Association is hosting SynGas 2009 in Tulsa, Oklahoma,
from April 20–22. This association,
which describes itself as an organization
of “ammonia, hydrogen, ammonium
nitrate/nitric acid, urea and methanol
producers—along with the material and
service suppliers that support these industries,” is featuring economist and author
Jeff Thredgold as its keynote speaker. Mr.
Thredgold wrote econAmerica: Why the
American Economy is Alive and Well... And
What that Means to Your Wallet and currently works as an economic consultant
to Zions Bancorporation. His remarks
will no doubt reflect the mission statement of the SynGas Association, which
seeks to “provide a forum where there is an
open exchange of ideas and information
to promote better safety, technical, environmental, operational and maintenance
techniques for the mutual benefit of the
organization and its participants.”
“SynGas holds the leading conference
for producers of ammonia, hydrogen,
methanol and coal/coke gasification syngas where common topics, issues and solutions are discussed,” said Darrell Allman of
PCS Nitrogen and the chairman of SynGas
2009. “Key information updates that will
impact all of our industries and facilities are
presented. Breakout sessions are smaller to
allow more information to be exchanged in
a casual roundtable format and to promote
excellent networking opportunities. Suppliers of various products and services to
the synthetic gas industries are showcased
in the exhibit area where key producer personnel, who are the potential customers,
have the opportunity to view the most current technology and services.”
Another much anticipated presentation will feature Charles Farnam and Roger
Sharp of FM Global. They will discuss fire
protection for steam turbine-driven syngas
compressors and share their belief that these
compressors, housed at chemical manufacturing sites, are essential to plant production, even though they are costly and difficult to replace and under constant exposure
to serious oil and syngas fire hazards. Mr.
Farnam and Mr. Sharp will point out that
while the likelihood of a fire involving one
of these pieces of equipment is relatively
low, the consequences can be severe, with up
to millions of dollars in damage and many
months of interrupted production.
In addition to general sessions on the
economy, employee diversity and plant
safety topics, there will also be specific
breakout sessions, including topics
related to safety, environment, maintenance, reliability, operations and new
technologies. For more information, visit
www.syngasassociation.com.
Rajiv Gandhi Institute
of Petroleum Technology
appoints professor
Jeet Bindra, president of Chevron
Global Manufacturing, was recently
named a distinguished honorary professor at the Rajiv Gandhi Institute of Petroleum Technology (RGIPT) in Jais, India.
RGIPT was established in 2007 by India’s
Ministry of Petroleum and Natural Gas
to produce high-quality professionals and
provide practical solutions to a variety of
energy-related challenges.
ExxonMobil wins safety
awards from Gas Processors
Association
ExxonMobil’s US operations have
earned the Gas Processors Association
(GPA) 2009 Company Safety Award and
the President’s Award for Safety Improvement. Some 500 employees at the company’s gas processing facilities received
the honors for outstanding safety performance during more than a million
work hours.
Gas Processors Association President
Bob Dunn presented the awards at the
88th annual GPA Convention in San
Antonio, Texas.
“These safety awards are among the
most important recognition we provide at
this convention each year, because safety is
a primary focus within all of our member
companies,” said Mr. Dunn, announcing
the recipients. “The gas processing industry is one of the safest in the world.”
The President’s Award for Safety Improvement recognizes continuous improvement in
safety performance measured by a reduction
of 25% or more in recordable incident rates
over the past three years.
“The company has always set very high
standards for safety performance,” said
Randy Cleveland, ExxonMobil US production manager. “The achievement by
our employees at gas processing facilities
demonstrates their commitment to excellence in pursuing our vision that nobody
gets hurt.” HP
HYDROCARBON PROCESSING APRIL 2009
I 15
Lurgi – your clean conversion partner.
Lurgi is the worldwide leading partner when clean conversion is postulated. We command
sustainable processes which allow us to make better use of oil resources or biomass than
ever before.
With our technologies we can produce synthesis gases, hydrogen or carbon monoxide: for
downstream conversion to petrochemicals. Based on resources like natural gas, coal and tar
sand we produce synthesis gas which we convert into low-pollutant fuels.
Enhanced sustainability: from biomass which does not compete with the food chain, we
can recover ultra-pure fuels burning at a low pollutant emission rate which are excellently
suited for reducing the carbon footprint. You see, we are in our element when it comes to
sustainable technologies.
Build on our technologies.
Call us, we inform you: +49 (0) 69 58 08-0
www.lurgi.com
1127_e
A member of the Air Liquide Group
Select 92 at www.HydrocarbonProcessing.com/RS
Visit us in Hall 9.1
Stand K32–N40
HPIMPACT
WENDY WEIRAUCH, MANAGING EDITOR
WW@HydrocarbonProcessing.com
Economy, capacity
additions pressure
polyolefins markets
PP
HDPE
LLDPE
LDPE
Actual
stocking of the value chain. North America and Western Europe were particularly
affected, while the Asian market, a strong
performer in recent years, saw minimal
growth. ChemSystems’ outlook projects
a relatively high growth rate, which can be
attributed to the penetration into end-use
applications served by traditional materials, and also with polypropylene benefiting from inter-polymer competition with
polystyrene, ABS and HDPE.
Supply. Total polyolefins capacity
increased by 51 MMton from 1998 to
2008. In 2008, however, the industry experienced a somewhat quiet year for capacity additions as skills shortages delayed the
startup of many units.
In 2008, LDPE net additions were relatively low. In contrast to modest growth
in LDPE capacity, combined LLDPE and
HDPE capacity has been growing at an
average of over 2 MMton/yr. Polypropylene is also forecast to see unprecedented
new capacity of over 5 MMton/yr coming
onstream during 2009–2011.
The near-term investment wave is
focused in regions with advantaged feedstock such as the Middle East, or regions
of high market growth such as Asia. “Looking further ahead, a period of low investment is expected for all polyolefins during
2014 and 2015, followed by a new wave of
capacity additions in the second
half of the decade,” according to
Nexant ChemSystems.
Scenario
Global trade. Mature mar-
Million tons/yr
The first half of 2008 saw polyolefins
prices rising to record highs as industry
supply and demand balances enabled producers to pass through extraordinary feedstock prices. In contrast, second-half 2008
witnessed an unprecedented demand crash
as a result of problems in credit markets
and its effects on economic activity.
“The decline in demand was exacerbated by falling feedstock prices, with crude
prices dropping 70% from July 2008 values
by the end of the year,” according to a new
outlook from Nexant ChemSystems (www.
chemsystems.com). With falling polymer
prices, purchasers withdrew from the market, and inventories along the value chain
were significantly reduced.
The degree of inventory contraction
is reflected in a demand drop-off that far
exceeded what industry analysts anticipated
from the economic downturn. The 2008
consumption is estimated to have shrunk
by 1.6%, compared to an estimated 3%
growth in global economic output.
Demand is expected to improve slightly
over 2008 figures, but is not projected to
return to 2007 levels in mature economies.
This small increase in demand will be dwarfed
by new capacity additions coming onstream
in the Middle East and Asia.
Over the next few years,
12
global trade patterns are forecast
to evolve noticeably as the US
10
and Western Europe become
major net importers of LLDPE,
8
HDPE and polypropylene. The
6
Middle East takes its position as
supplier to the world.
4
The following are other key
highlights from Nexant Chem2
Systems’ outlook.
combined LLDPE/LDPE market has continued to climb every year. In 2008, it reached
over 51%. Demand for LDPE is projected
to remain flat due to this continued pressure
from competitively priced conventional and
second-generation LLDPE.
Consumption of LLDPE fell an estimated 1.2% in 2008, after growing 5.6%
in 2007. “In spite of this, LLDPE is still
the polyolefin with the brightest demand
outlook, and is projected to grow at almost
6%/yr for the next seven years,” says this
analysis. Single-site/metallocene LLDPE
was one area that continued to grow in
2008, albeit at low rates.
Global HDPE demand shrank by 2.1%
in 2008 compared to 2007. “HDPE will
recover growth in the next few years as the
industry restocks the inventory chain and
as the economic outlook improves,” according to this research (Fig. 1).
Approximately half of this projected
growth in demand will be in Asia. Bimodal
HDPE continues to be a focus for much
of the uptick based on an expanding product performance envelope. The supply side
will also be boosted by the potential for
single-gas-phase reactor production, giving
a lower capital and production cost.
After a 6% growth in 2007, polypropylene global demand is estimated to have
declined by almost 1% in 2008 due to
the economic climate and significant de-
0
Demand. Global polyolefins
demand is estimated at 113 million
tons (MMton) in 2008, a decline
of 1.6% compared to 2007.
The demand growth for LDPE
continues to be impacted by competition from LLDPE. The degree
of penetration of LLDPE into the
-2
-4
2001
2004
2007
2010
2013
2016
2019
Source: Nexant ChemSystems
FIG. 1
A look at demand growth along the polyolefins chain.
kets such as Western Europe
and North America will experience limited polyolefins capacity
additions, and even closures of
less competitive units.
While demand is expected
to be heavily focused in China,
Western Europe and North
America are projected to see
growth. Although low in terms
of rate, this growth will have
an impact in terms of absolute
demand increment. These regions
are therefore expected to become
far more dependent on imports
over the coming decade.
HYDROCARBON PROCESSING APRIL 2009
I 17
How
H
ow m
much
uch nitrogen
nitrogen
do you
do
you waste
waste during
during your
your
ethylene cracker
ethylene
cracker shutdown?
shutdown?
The one company you can rely on to deliver efficient world-class
nitrogen performance during your shutdown is BJ Services.
Nitrogen is critical to a safe and successful ethylene cracker turnaround. Why risk using your operational
resources or a gas supply company when BJ Services provides a dedicated, engineered nitrogen capability
that can save you time and money while reducing your risk?
The BJ Services difference is our expertise and focus on achieving an efficient turnaround by minimizing
nitrogen consumption and time. BJ has built a resource capability that optimizes product freeing,
accelerated cooling, hot stripping and safe inerting operations to get your cracker unit ready for access
quickly. And when you are ready to start up, BJ will help ensure that you achieve a clean, dry, leak-free
and inert unit ready to receive product.
For a no-cost assessment of your ethylene cracker needs, contact your BJ Services process and
pipeline representative.
Real world. World class. Worldwide.
www.bjservices.com
Select 72 at www.HydrocarbonProcessing.com/RS
HPIMPACT
Asia’s thirst for oil
likely to swell again,
but when?
1,000
800
600
“Missing” demand
and the bursting of the technology bubble.
In fact, the surprise 2-MMbpd
surge in Asian demand in the
second halves of 2003 and 2004
set the stage for the 2004–2008
price run-up. “We would not
be surprised—and in fact we
expect—the cycle to repeat itself
starting in late 2010 or 2011,”
according to FACTS.
In short, the combination of
Asia’s huge population and continued economic progress ensure
that its thirst for oil products
will grow, albeit with stops and
starts. Over the mid- to longterm, oil supply will struggle to
keep pace.
Thousand bpd
Over the past decade, Asian
400
demand growth has been a critical
driver of the global oil market—
200
typically accounting for about
0
40% to 50% of global incremen-200
tal demand. In 2003–2004, a
surge in Asian demand stretched
-400
global oil supply, setting the stage
-600
for a four-year price run-up.
During 2006–2008, the
-800
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
market focus was on supply con2008
2009
2010
2005 2006
2007
straints, but attention quickly
Source:
FACTS
Global
Energy
switched back to the demand
side when OECD oil consumpFIG. 2 Dramatic sweeps in Asian oil product demand, year-onyear changes.
tion collapsed as the impact of
the credit crisis spread. “For
a time, some thought Asia’s develop- particularly dramatic. Japan, Korea, and EPA chemicals
ing economies (and oil demand) would Taiwan all experienced y-o-y declines in
emerge relatively unscathed, but it is now naphtha consumption as the petrochemi- oversight questioned
obvious that the region is suffering as the cal sector is highly exposed to the impact in new GAO report
scope of the crisis has broadened,” reports of an economic downturn. Additionally,
The Environmental Protection Agena new analysis from FACTS Global Energy Asia’s energy-intensive industrial sector is cy’s (EPA) assessment and control of toxic
(www.fgenergy.com).
particularly hard hit. Chinese manufactur- chemicals has been added to a “high-risk”
ing, which accounts for over 40% of GDP, category on a newly updated government
Financial contraction. Initially, Asia contracted for the fifth consecutive month report. Biennially, the US Government
appeared well positioned to weather the cri- in December. India’s industrial output fell Accountability Office (GAO) updates its
sis. Most monetary authorities had accumu- for the first time in 14 years in October.
list of federal programs, policies and operlated substantial foreign reserves and regional
FACTS anticipates that, overall, there ations that are in danger of waste, fraud,
banks were typically well capitalized. Regula- will be some recovery in Q3-Q409 com- abuse and mismanagement or in need of
tory oversight had also improved following pared to a weak 2008 baseline, but regional broad-based transformation.
the 1997–98 Asian economic crises.
demand is only expected to fully recover in
“EPA’s ability to protect public health
In the past few months, it has become 2010. This, of course, is contingent on a and the environment depends on credible
clear that talk of an Asian “de-linkage” from recovery in the regional economy.
and timely assessments of the risks posed by
the global economy was misguided. After
toxic chemicals. Its Integrated Risk Inforaveraging a 14% annual growth since 2002, Implications for HPI. Asia’s demand mation System, which contains assessments
Chinese power demand was down by 3% weakness comes at about the worst possible of more than 500 toxic chemicals, is at seriyear-on-year (y-o-y) in October and 8% time for regional and global refiners. Approx- ous risk of becoming obsolete because EPA
in November. Auto sales have also slowed imately 1.5 million barrels/day (MMbpd) of has been unable to keep its existing assesssharply in both China and India. The impact new crude distillation unit capacity is com- ments current or to complete assessments of
of lethargic global/regional trade on highly ing online in Asia alone in the first half of important chemicals of concern,” according
export-dependent economies, such as Singa- 2009. Additionally, 950 Mbpd of conver- to the GAO’s report.
pore, Taiwan, and Hong Kong, has become sion capacity will come online.
Other programs added to the listing this
readily apparent. This will impact demand
Viewed y-o-y, Asia’s crude distillation year are the regulatory system governing US
for transport fuels as well as industrial use.
unit capacity will increase by 1.7 MMbpd in financial institutions and markets, and the
first-half 2009 versus first-half 2008. Conver- Food and Drug Administration’s oversight
Oil demand. Asian oil demand is expected sion capacity will increase by 1.1 MMbpd. of medical products.
to decline by 575 thousand barrels/day Over the same period, regional demand will
Overall, EPA has finished only nine assess(Mbpd) in 1Q09 versus 1Q08. This follows decline by approximately 270 Mbpd.
ments in the past three years. At the end of
on a 520-Mbpd y-o-y decline in 4Q08. On
2007, most of the 70 ongoing assessments
an annual basis, Asian demand will expand Path forward. Once Asian economies had been underway for more than five years.
by only 82 Mbpd in 2009. Viewed against a do recover, we expect to see a substantial The analysis concludes that EPA “urgently”
baseline regional growth expectation of 600 rebound in demand driven by a surge in needs to streamline and increase the transparMbpd to 800 Mbpd in “normal” times, the consumer spending and investment. The ency of its assessment process and also “shift
contrast is striking (Fig. 2).
same phenomenon was observed in 1999 more of the burden” to chemical companies
There is weakness across all products, following the Asian economic crisis and in to demonstrate the safety of their products.
but the decline in naphtha demand is 2003–2004 following the SARS epidemic To view the report, go to www.gao.gov. HP
HYDROCARBON PROCESSING APRIL 2009
I 19
Thousands of CCC customers worldwide don’t think so.
In the industrial environment, no one can afford to sacrifice the high quality
of a control system and a responsive customer service, which is often a
key to a long-lasting protection of your plant, process, and equipment (your
own peace of mind should not be overlooked either!).
CCC offers real value in turbomachinery control. We call it the CCC Value
Triangle: Profit Enhancement Opportunity. Quality. Service.
CCC high-quality, precision-designed control systems and field-proven
proprietary control algorithms along with the unsurpassed lifetime
engineering support provide real profit enhancement opportunities
resulting from:
Preventing unnecessary process trips and downtime
Minimizing process disturbances
Preventing surge, overspeed and associated damage
Automating startup and shutdown
Operating close to limits, safely
Operating at lowest possible energy levels
Minimizing antisurge recycle or blow-off
Optimizing load sharing of multiple units
We are on your side, at your site and at your service,
24/7, offering lifetime support, guaranteed by our large
body of technical resources, experience on thousands of
installations worldwide, and institutional memory.
The Right Solution —
The First Time, Every Time
P o w e r B e h i n d B e t t e r Tu r b o m a c h i n e r y C o n t r o l ™
International Headquarters:
4725 121st Street • Des Moines, Iowa 50323-2316, U.S.A. • Tel: (1) 515 - 270 - 0857 • Fax: (1) 515 -270 -1331
E-mail: solutions@cccglobal.com • Web site: http://www.cccglobal.com
Select
at www.HydrocarbonProcessing.com/RS
www.HydrocarbonProcessing.com/RS
Select 74
77 at
HPINNOVATIONS
SELECTED BY HYDROCARBON PROCESSING EDITORS
editorial@gulfpub.com
New process produces
methanol from waste
Isis Innovation, the technology transfer
company for the University of Oxford, has
announced that researchers in the school’s
chemistry department have discovered a
new way to produce methanol (MeOH)—
a valuable biofuel—from glycerol. About
90% of MeOH is produced from natural
gas; this new process offers an alternative
that does not rely on fossil fuels.
The new catalytic process converts
glycerol, an unwanted byproduct from
biodiesel production, to MeOH, which is
a high-value petrochemical and alternative
transportation fuel (Fig. 1). Glycerol is the
major byproduct in biodiesel production
with applications in foods and personal
care industries. However, glycerol has no
large-scale industrial demand.
Catalytic hydrogenolysis of glycerol
has been studied, but the main products
from glycerol and hydrogen reaction are
propanediols and ethylene glycols, which
require a degree of carbon-oxygen bonds
cleavage accompanied by hydrogen addition under harsh conditions. Conversely,
choosing the right catalyst under appropriate mild conditions may allow only the
total breakage of C-C bonds with hydrogen addition without cleaving the C-O
bonds, thus avoiding the production of
hydrocarbon gases such as methane and
carbon dioxide.
In this case, catalytic hydrogenolysis of
glycerol to MeOH can be formed selectively. MeOH is one of the key chemicals
with a huge potential as a renewable energy
source and also a building block for other
chemicals. The new MeOH technology is
a carbon-neutral process using a supported
precious metal catalyst. The reaction proceeds under mild conditions of 100°C and
20 bar hydrogen to produce methanol as
the exclusive product.
Select 1 at www.HydrocarbonProcessing.com/RS
Breakthrough separator
removes oil from water
Aqueous Recovery Resources, Inc. has
developed what is claimed to be an innovative oil/water separation system called
the Suparator. This technology incorporates a three-step separation mechanism
that requires no moving parts or media.
This unit takes advantage of the Bernoulli
effect—the phenomenon whereby increased
stream velocity in a fluid results in internal
pressure reduction.
These forces facilitate removing oil
from process water and wastewater in a
three-step process:
Step 1. Collection. Water and oil enter the
first compartment, where, ultimately, only
water is sucked out through an opening at the
bottom. This design ensures that any amount
of oil, even small traces, is collected.
Step 2. Concentration. The oil, still
containing some water and chemicals, is
concentrated into a floating layer of considerable thickness, while water and chemicals
migrate toward the interface and re-enter
the water flow. The oil is then further concentrated to force water and chemicals out
to yield an oil-only layer.
Step 3. Separation. The upper fraction of the accumulated floating layer
is “skimmed off,” thus isolating the oil.
Finally, this “dry” (typically less than 1%
free water) oil is separated and ready for
downstream refining or storage.
The Suparator’s special construction is
claimed to collect any amount of oil, even
Hydrogen
Glycerol
(byproduct)
Methanol
Exclusive
product
Low T
Low P
Biodiesel
and veg. oil
manufacture
FIG. 1
Fuel and
industrial
use
Process takes byproduct glycerol
and converts it directly to
methanol.
As HP editors, we hear about new products,
patents, software, processes, services, etc.,
that are true industry innovations—a cut
above the typical product offerings. This section enables us to highlight these significant
developments. For more information from
these companies, please go to our Website
at www.HydrocarbonProcessing.com/rs and
select the reader service number.
the smallest traces. The oil is concentrated
to force water and chemicals out of the
Suparator; thus no consumables such as
absorbents, coalescing media, absorbing
filter bags, etc., are used. This processing
method eliminates costs for the consumables and expenses for disposal of spent
consumables. Finally, the dry oil is separated and removed.
Select 2 at www.HydrocarbonProcessing.com/RS
Gas-to-liquid process
lowers capital costs
Energix Research, Inc. has successfully
produced liquid fuels from natural gas
with a process that is claimed to be more
efficient— ultimately reducing capital
costs and enabling mobility. The company’s tests indicate that its technology
enables the entire gas-to-liquids (GTL)
process to consume a lower percentage
of the energy in the gas source. Due to
the lower capital costs, production can be
competitive with conventional, large-scale
refineries that produce these fuels from
crude oil.
Energix expects to develop affordable,
micro-GTL plants to monetize under-utilized resources, such as abandoned natural
gas fields, coal-bed methane fields, flared
gases, etc.
“We believe our process can affordably
produce 50 to 200 tons/day of methanol, gasoline, diesel or DME with truckmounted units using methane derived
from biogas sources, such as landfills.
Another source would be abandoned gas
wells with very small reserves, which currently are not viable due to the inability to
economically transport the fuel from the
site,” according to Juzer Jangbarwala, the
company’s CEO.
The company aims to first focus on
producing methanol and DME. Its vision
is to eliminate the carbon footprint associated with transporting fuel or other hydrocarbon chemical products such as solvents
and alcohols.
Energix Research executed the GTL
process via the syngas and Fischer-Tropsch
synthesis route at a high conversion rate
(87%) and selectivity rate (99%) using
its patent-pending, electrically activated
nanocatalyst process. The proprietary proHYDROCARBON PROCESSING APRIL 2009
I 21
HPINNOVATIONS
EVERY PROCESS
RECIPROCATING
COMPRESSOR
COMES WITH
A PROMISE.
Visit us at OTC .09, Booth 10839
cess uses local electronic excitation to the
catalyst, using conductive nanofibers and
nanocatalysts and applies a low-level DC
current to them.
This technique is claimed to reduce
the required bulk feed gas temperatures to
less than 50% of conventional processes,
as the energy of reaction and activation
of catalyst is provided directly where it is
needed to create very narrowly targeted
reactions with high selectivity and yields.
The lower bulk gas temperature reduces
the capital costs typically associated with
exotic metals and energy recovery equipment in GTL refineries while increasing
energy efficiency.
Select 3 at www.HydrocarbonProcessing.com/RS
Industrial mass flow controller
with ANSI or DIN flanges
Sierra Instruments is offering Max-Trak
Model 180 industrial mass flowmeters and
controllers with 316 stainless steel (ANSI
or DIN) flange mounting for gas flowrates
up to 1,000 slpm (pipe sizes up to 1 in.).
The significant design enhancement expands the processes and applications where the flanges can be installed.
The company’s Dial-A-Gas technology is
claimed to make Max-Trak the industry’s
only multigas-capable industrial mass flow
controller. The model has excellent accuracy (±1% of FS) and repeatability (±0.2%
of FS) as well as unsurpassed instrument
stability. These characteristics result from
a patented, inherently-linear design,
advanced platinum sensor technology and
a strong, flexible and forgiving valve. The
controller can communicate to a user workstation via RS-232, RS-485 or one of four
analog signals.
The product line is an industry
NEMA 6/IP67-rated mass flow controller conforming to rigorous water-resistant
requirements.
Select 4 at www.HydrocarbonProcessing.com/RS
Virtual reality tool
‘revolutionizes’ training
www.dresser-rand.com
Select 152 at www.HydrocarbonProcessing.com/RS
Invensys Process Systems (IPS) has
unveiled its Immersive Virtual Reality Process technology, a next-generation human
machine interface solution that the company claims will “revolutionize” the way
engineers and operator trainees see and
interact with the plant and the processes
they control.
The innovative process can create a
3D computer-generated representation of
either a real or proposed process plant. Via
a stereoscopic headset, users enter a totally
immersive environment in which they can
move through the plant in any direction.
Such freedom is made possible because
the virtual environment is rendered at 60
frames/second, significantly faster than
what can be achieved by traditional, nonreal-time rendering.
“The ability to simulate complex processes in connection with virtual actions
allows the user to directly experience an
environment that changes over time, making it more effective at transferring skills
learned in training to the work environment,” according to Maurizio Rovaglio,
director, IPS global consulting. “And
because rarely performed volatile tasks
such as plant shutdowns can be rehearsed
in a stable, realistic environment, users and
operator trainees have the opportunity to
learn and make mistakes without putting
themselves, the community or the environment at risk.”
IPS is making Immersive Virtual Reality
Process truly realistic by applying its proprietary DYNSIM software to emulate the
plant environment, linking process simulation models with physical-spatial models
to create virtually any scenario that a user
could encounter in real life.
Select 5 at www.HydrocarbonProcessing.com/RS
Unmatched early detection
of equipment problems
SmartSignal’s EPI*Center software,
based on its patented Similarity Based
Modeling (SBM) technology, is claimed to
provide better insight into potential equipment reliability problems than was previously possible. Backed by over 40 patents,
the technology is successfully being used by
progressive super majors in oil and gas.
These companies are using the software
to detect, diagnose and prioritize developing reliability problems caused by faulty
process operation and mechanical issues to
prevent equipment outages. When avoiding an outage is not possible, the early
warning allows for proper maintenance
planning and minimizes equipment damage. This is claimed to provide tremendous
cost benefits.
The software is successfully being used
to monitor reciprocating and centrifugal
compressors, many varieties of pumps,
steam and gas-fired turbines, turboexpanders, blowers, heat exchangers, reactors, distillation columns and fired heaters. Some
of the reliability problems that have been
detected weeks and sometimes months
The new RecipCOM
delivers diagnostics,
protection and
therapy for your
reciprocating
compressors.
Spread the word!
For more information please contact compressor-mechatronics@hoerbiger.com
Select 61 at www.HydrocarbonProcessing.com/RS
www.hoerbiger.com
at the
Visit us
nkfurt
09, Fra
0
2
a
m
Ache
y
German 4–P37
3
Booth P
,
0
.
8
l
Hal
HPINNOVATIONS
before normal engineering monitoring are
turbine blade fouling, precursors to seal
damage like pump cavitation and liquid
in compressors, bearing damage prevention from poor lubrication, weak valves in
reciprocating compressors, malfunctioning instrumentation, efficiency loss, reactor
channeling, tower and exchanger fouling,
and heater coking.
SmartSignal works by sifting through
all the mounds of data that most companies have from their data infrastructures.
The solution uses prognostic models for
online process monitoring and diagnosis.
The models produce estimates for each
sensor as a function of current signal data
and historical data collected during normal process operation. The differences
between current signal data and model
estimates, termed residuals, are used to
generate “alerts” when the deviations in
the residuals are statistically significant.
These alerts and residuals are analyzed
to determine if the process is operating abnormally. If an abnormal condition is detected, diagnostic algorithms
are used to identify the cause as being a
process upset, degraded sensor response
or mechanical fault specific to the monitored equipment.
One significant advantage of using SBM
is that process and mechanical sensors can
be modeled together when they are linked
in behavior. No regression or other parametric analysis is needed. The parameters
move together, and identifiable patterns of
behavior will be present.
The prognostic model SBM is a
proprietary multivariate-state estimation technique using a nonparametric
regression approach. This nonparametric method is claimed to simplify model
development and to be very tolerant of
real-world problems, such as bad sensors
and poor data quality.
Select 6 at www.HydrocarbonProcessing.com/RS
Adaptive system automatically
learns process dynamics
Emerson Process Management offers
a newly developed adaptive capability for
DeltaV InSight that is claimed to enable
the control system to automatically learn
process dynamics, diagnose control problems and re-tune control loops for optimal performance.
Further extending the predictive intelligence of PlantWeb architecture, this
new capability is embedded in the digital
control system with automatic configuration to provide increased performance and
availability for all DeltaV and Foundation
fieldbus-based control loops. The technology is uniquely automatic—it provides
system-wide performance monitoring and
diagnostics with no additional configuration or maintenance effort.
Performance monitoring is automatically updated for any changes made to
the system. The technology also accounts
for process changes by automatically
learning process dynamics from normal day-to-day operations. This process
knowledge may be applied to improve
plant performance and availability with
adaptive loop tuning, non-linear control,
loop diagnostics, process simulation and
model-based control.
Select 7 at www.HydrocarbonProcessing.com/RS
Select 153 at www.HydrocarbonProcessing.com/RS
24
HPIN CONSTRUCTION
BILLY THINNES, NEWS EDITOR
BT@HydrocarbonProcessing.com
North America
Europe
Lignol Energy Corp. recently provided
an operational update on its fully integrated industrial-scale bio-refinery pilot
plant in Burnaby, British Columbia. Construction of the pilot plant commenced
in June 2008 and was largely complete by
the end of October with extensive unit
mechanical commissioning completed by
mid-January 2009.
Startup is now underway for each of the
various unit operations and integrated production campaigns are scheduled to begin
at the end of April 2009. These production
campaigns will provide important data to
establish process conditions, product characteristics and equipment configurations
as a basis for optimizing the Lignol biorefinery process.
The plant has a rated production capacity of 100,000 lpy of cellulosic ethanol
together with industrial testing quantities
of other biochemical co-products.
Fluor Corp. has an engineering, procurement and construction (EPC) contract
for Galp Energia’s Porto refinery conversion project in Portugal. Fluor began the
front-end engineering and design (FEED)
work in October 2007, which included
conceptual engineering, front-end loading
and early procurement of key equipment.
The total installed cost of the project is
expected to be about €350 million.
When completed, the converted refinery is expected to produce 2.5 million tpy
of diesel, gasoline and kerosene fuels.
Aker Solutions has an EPC contract
to modify and develop the gas plant at
Kollsnes, Norway. This plant is processing
natural gas from the Troll, Kvitebjørn and
Visund fields in the North Sea. Engineering and procurement will start immediately,
and the work will be completed by the end
of December 2011. Estimated value of the
contract is NOK 1.5 billion.
South America
Foster Wheeler Iberia, S.A.U., has a
contract with YPF, S.A. to provide the
basic design package for the new fractionation unit and gas plant for the new
delayed coking unit at the La Plata refinery in Argentina. The basic design package for the delayed coker, based on Foster
Wheeler’s delayed coking technology, has
been completed.
The design for the fractionation unit
and gas plant will be integrated with the
new two-drum delayed coker, which will
replace the existing coker at the refinery.
The new coker will be designed to process 27,925 bpd of feedstock. The basic
design package for the fractionation section and gas plant is expected to be completed by the end of the third-quarter
of 2009.
Burckhardt Compression received
two orders to deliver a hyper compressor
for LDPE plants in Qatar and Venezuela.
Each order also includes an electric motor
with 25,000 kW for the hyper compressor
and a six crank process gas compressor as
a booster/primary compressor. Deliveries
of the hyper compressors are scheduled for
mid-2010.
Russia’s first liquefied natural gas (LNG)
plant, built by Sakhalin Energy, recently
TREND ANALYSIS FORECASTING
Hydrocarbon Processing maintains an
extensive database of historical HPI project information. Current project activity
is published three times a year in the HPI
Construction Boxscore. When a project
is completed, it is removed from current
listings and retained in a database. The
database is a 35-year compilation of projects by type, operating company, licensor, engineering/constructor, location, etc.
Many companies use the historical data for
trending or sales forecasting.
The historical information is available in
comma-delimited or Excel® and can be custom sorted to suit your needs. The cost of
the sort depends on the size and complexity of the sort you request and whether a
customized program must be written. You
can focus on a narrow request such as the
history of a particular type of project or
you can obtain the entire 35-year Boxscore
database, or portions thereof.
Simply send a clear description of the data
you need and you will receive a prompt
cost quotation. Contact:
Lee Nichols
P. O. Box 2608
Houston, Texas, 77252-2608
Fax: 713-525-4626
e-mail: Lee.Nichols@gulfpub.com.
opened for business on Sakhalin Island,
Russia. Nearly all of the 9.6 million tpy
production capacity of the LNG plant has
already been committed in long-term contracts to supply customers in Japan, Korea
and North America.
The plant features two processing
trains, each with a capacity of 4.8 million
tpy. It is expected to reach its design capacity in 2010.
Ukrtatnafta has given Axens a contract for upgrading the gasoline pool at the
Kremenchug refinery in the Ukraine. The
upgrading project will enable the production of Euro V gasoline grade in the 2011
timeframe. The project involves the addition of Prime-G+, naphtha hydrotreating
and DIH isomerization units. The combined naphtha fractions from the two existing fluidized catalytic crackers will be fed
to a 610,000 metric tpy Prime-G+ unit,
where the product sulfur content will be
lowered to 20 ppm. The C5-C6 straightrun and catalytic reforming fractions will
be processed in a 380,000 metric tpy
hydrotreater, then isomerized in a de-isohexanizer-type isomerization unit to produce an 88 research octane number (RON)
light gasoline cut.
Technip has a €10 million contract
with Lukoil Neftochim Burgas for the
front-end engineering design (FEED) of
new units to be built at a refinery in Burgas, Bulgaria. The contract covers a residue
hydrocracking unit with a capacity of 2.5
million tpy; a vacuum gasoil hydrocracking
unit with a capacity of 1.8 million tpy; an
amine unit; a sour water stripper unit; two
hydrogen units with a capacity of 7,500
kg/h each; and relevant utilities and offsite
facilities. The contract is scheduled to be
completed in December 2009.
Jacobs Engineering Group Inc.
has three framework contracts from Eni
S.p.A. to provide multidisciplinary, frontend engineering services to several of Eni’s
operating units, including its refining and
marketing division.
Fluor Corp. has an engineering, procurement and construction (EPC) contract
HYDROCARBON PROCESSING APRIL 2009
I 25
HPIN CONSTRUCTION
for Galp Energia’s Porto refinery conversion project in Portugal. Fluor began the
front-end engineering and design (FEED)
work in October 2007, which included
conceptual engineering, front-end loading
and early procurement of key equipment.
The total installed cost of the project is
expected to be about €350 million. When
complete, the converted refinery is expected
to produce 2.5 million tpy of diesel, gasoline and kerosene fuels.
Foster Wheeler Energy Ltd. has a
contract with BP Chemicals Ltd. for the
design and supply of a steam reforming
furnace. The new reformer will replace the
existing reformer at BP’s chemicals complex
in Saltend, near Hull, UK.
Middle East
Technip has a €20 million plus contract
with State Co. Oil Project (SCOP) for
the front-end engineering design (FEED)
™
by
VISIONARY
INDUSTRIAL INSULATION
( BUDGET
ACCORDINGLY )
THE INDUSTRIAL
INSULATION STANDARD
FOR THE 21 ST CENTURY
H IG H TE M P E RAT UR E E - GL A SS INS UL AT IO N
RAIN ON IT , STAND ON IT
NO PROBLEM!
UNBREAKABLE (REUSABLE)
SHORTER TURNAROUNDS
DESIGN SAVINGS
NO CHEMICAL BINDERS
pH NEUTRAL (7.6)
TEMPERATURE TO 1380°F
NON-COMBUSTIBLE
LOWEST CHLORIDE CONTENT
EXCELLENT DIMENSIONAL STABILITY
LOWEST INSTALLED COST
1-888-984-7776
VISIT OUR WEBSITE FOR MORE INFORMATION
AND FREE PRODUCT SAMPLES
WWW.V ISIONARY I NDUSTRIAL I NSULATION .COM
Select 154 at www.HydrocarbonProcessing.com/RS
26
of a new refinery to be built in Karbala,
Iraq. The refinery will have a total capacity
of 140,000 bpd and will include 18 process units, as well as related utilities, offsite
facilities, infrastructures and a dedicated
power plant.
This refinery is expected to produce liquid petroleum gas, gasoline, jet fuel, diesel
oil, asphalt and fuel oil mainly for the internal needs of the Iraqi market. The project
is scheduled to be completed in the first
half of 2010.
Pearl Development Co. has received a
multi-million dollar contract from an existing client in the UAE. Pearl is contracted
to provide engineering, procurement and
construction management (EPCM) services to support the build-out of a sour
gas processing facility. The value of the
contract is estimated to be $22.5 million.
The unit will be designed to process 60
million scfd of sour gas containing up to
4% H2S. Pearl will commence immediately to provide EPCM services and the
company estimates the project to be completed by year end 2009. New processing
units will be integrated into an existing
gas plant and will consist of new amine
treating and modifications to the condensate stabilization, inlet compression, gas
dehydration, cryogenic processing for LPG
recovery and export compression to the
sales pipeline. The design will also include
provisions for the future installation of a
sulfur recovery unit.
Petrofac has a $2.2 billion engineering, procurement and construction (EPC)
contract for the El Merk central processing facility (CPF) in the Berkine Basin
of Algeria. The contract will be executed
over the next 44 months, with first significant volumes from the project expected
in 2012.
The El Merk CPF, which is located in
Block 208, will be operated by Sonatrach
and Anadarko on behalf of the El Merk
partners: Sonatrach, Anadarko, Maersk
Oil, Eni, ConocoPhillips and Talisman
(Algeria) BV. Block 208 is located 90 km
south of the Sonatrach/Anadarko-operated
Hassi Berkine South (HBNS) facility.
The El Merk central processing facility will serve as a production hub for
the region, processing hydrocarbons initially from Block 208, operated by the
Sonatrach/Anadarko Association, and
from the unitized EMK field located
on a portion of both Block 208 and the
HPIN CONSTRUCTION
Sonatrach/ConocoPhillips operated Block
405a. The combined nominal capacity of
the initially installed processing facilities
will be 98,000 bpd, including 29,000 bpd
of condensate and 31,000 bpd of liquefied petroleum gas (LPG) together with an
NGL train with a nominal capacity of 600
million scfd. The CPF will also include
500 million scf of residue and re-injection gas compression and approximately
80,000 bpd of produced water treatment
and re-injection facilities.
energy consumption at the plants. Work on
the project has begun.
Foster Wheeler Italiana S.p.A. has a
contract with Doosan Heavy Industries
& Construction Co., Ltd. (DOOSAN)
for the front-end engineering design
(FEED) and technical services for a new
gasification island, based on Shell technology, to be built in South Korea. The
plant is to be built in one of the existing
coal-fired power plants and the project is
partially supported by the Korean government.
Foster Wheeler will undertake the
FEED, provide procurement assistance
for long-lead items, develop a capital cost
estimate, and provide technical training
on gasification and technical support during the EPC phase. The IGCC plant is
expected to be completed by the end of
2014. HP
Asia-Pacific
Foster Wheeler Energy Ltd. and Foster Wheeler (G.B.) Ltd. have a contract
with Indian Oil Corp. Ltd. (IOCL) for
a grassroots refinery in Paradip, Orissa,
India. Foster Wheeler will undertake the
role of project management consultant for
the major part of the development of the
new 15 million tpy refinery and will also
execute the engineering, procurement and
construction management (EPCM) for
15 of the key refinery process units, plus
offsites, utilities and infrastructure.
Foster Wheeler’s EPCM scope includes
the crude distillation units, reforming,
alkylation and butane isomerization units,
plus significant offsites, utilities and infrastructure.
LyondellBasell Industries, a partner
with SAT & Co. and KMGEP of Kazakhstan Petrochemical Industries Ltd. (KPI),
recently reaffirmed its ongoing participation in the development and construction
of an integrated petrochemical complex
and a gas separation unit in the Atyrau
region of Kazakhstan. As planned, the petrochemical complex will include a worldscale ethane cracker, a propane dehydrogenation unit, a polypropylene plant and two
polyethylene production facilities using
LyondellBasell’s latest polyethylene and
polypropylene process technologies. The
three plants are scheduled to begin operations in 2014.
KBR has a contract with Krishak
Bharati Cooperative Ltd. (KRIBHCO)
to provide licensing and basic engineering
services to upgrade two KRIBHCO ammonia plants located in Hazira, Surat, India.
KBR is licensing KRIBHCO its ammonia technology as part of its revamp of the
plants. In addition to technology licensing, KBR is providing engineering services
to increase the capacity of each ammonia
plant to 1,890 mtpd and to reduce overall
Mission: Immersion.
Immersion Engineering™™
goes deep to solve your
heat transfer problems.
Even though you may call us on the
phone miles away, we're so deep into
your stuff--your fluid, your equipment,
your system--we can virtually touch it,
see it.
Immersion Engineering is a bundle of
very specialized services that you can
cherry pick. Some are free, some you
pay for. We’re the only company offering
them all.
One thing is for sure; when you need
HTF help you need it now. Nobody
knows more about the chemistry,
Eyeball this selection of services.
■ Fluid Analysis
■ Troubleshooting
■ Fluid Maintenance ■ System Layout
■ Training
performance and applications of heat
transfer fluids than we do.
So pick a service and call one of our
technical specialists. Or, check out our
web site for case histories, data sheets,
comparisons, user’s guide, tip sheets
and technical reports. It’s all there, it’s
deep, it’s Immersion Engineering.
HEAT TRANSFER FLUIDS
4 Portland Road
West Conshohocken PA 19428 USA
800-222-3611
®
®
610-941-4900 • Fax: 610-941-9191
info@paratherm.com
www.paratherm.com
Select 155 at www.HydrocarbonProcessing.com/RS
27
Select 87 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
ACHEMA 2009: A SPECIAL REPORT
Globalization is a world-spanning integration process that
impacts all spheres of life. The foundations of society are not just
banks and financial services, they are energy (in all forms), raw
materials, steel, concrete, chemistry, engineering, technological
developments, intellectual property, etc.—all of the materials and
services used to improve and sustain the quality of life for citizens
of all nations.
ACHEMA 2009 (May 11–15 at Frankfurt, Germany) is an
inspiring showcase of leading-edge technology for chemistry,
biotechnology and environmental protection. This international exhibition and conference is an important platform that
features innovations and ideas for the chemical and petrochemical industries as well as biotechnical and environmental issues.
Middle East
Oversupply in the olefin market?
Siamak Adibi, FACTS Global Energy, Singapore
Generally, the Middle East (ME) holds a great advantage in
the production of ethylene, propylene and their derivatives due
to abundant cheap feedstock. This region is set to become one of
the world’s largest exporters of petrochemicals targeting markets
in Europe and Asia.
At present, several new mega petrochemical projects are under
construction in Saudi Arabia, Iran, Qatar, the UAE and Kuwait.
After the completion of these new projects, ME ethylene production capacity is expected to increase to roughly 28.1 million tpy
(MMtpy) by 2012. ME propylene production capacity is projected to increase to 7 MMtpy in 2012.
The global economic recession is certainly impacting ethylene and polyethylene (PE) demand. As a result, a new wave of
ACHEMA 2009 is expected to attract over 4,000 exhibitors
from all parts of the world as well as 180,000 visitors from 50
different countries.
Globally, scientists, chemists and engineers are working
together to find solutions to many of today’s problems, including
global warming, hunger, clean water, energy efficiency, substitutes
for oil and natural gas, poverty and sustainability. ACHEMA
2009, the 29th international exhibition and congress on chemical
engineering (www.achema.de), is the international meeting place
for the process industry to exchange ideas for solving many of our
shared challenges. In preparation for ACHEMA 2009, Hydrocarbon Processing reviews the state of the petrochemical industry in
major manufacturing countries.
petrochemical projects, especially those coming online in 2009,
may face a market with surplus supply. Large capacity additions
in the ME and Asia during 2009–2012, combined with weakness
in demand, may impact operating rates of ME petrochemical
complexes, which are above 90%. Yet, the present downturn will
be more difficult for Asian naphtha-based projects, especially for
smaller projects—below 300,000 tpy (Mtpy)—which face higher
operating and feedstock costs.
Although the availability of inexpensive gas prompted many
companies to move forward with massive expansion plans, the
region is facing new uncertainties in providing sufficient feedstock. This is a serious concern for new proposed projects, especially in Iran and Saudi Arabia.
ME domestic gas prices are expected to increase as production
costs have risen significantly. This may push governments to set
higher prices for petrochemical feedstock. New feedgas prices for
petrochemical projects in Saudi Arabia could even increase to over
$2 MMBtu—well above the $0.75/MMBtu seen in the past. Even
with higher feed gas prices, ME petrochemical projects are still
economical, but certainly less attractive for new investment.
ME ethylene and propylene production. Ethylene and
propylene are the principal petrochemical products and are major
feedstocks for polymers production. The world’s largest expansion
ever for the construction of new ethylene and propylene plants is
taking place in the ME. These additions have a significant influence on the global petrochemical industry in the near term.
Several new mega petrochemical projects are under construction at Jubail and Yanbu in Saudi Arabia, Bandar Imam and Assaluyeh in Iran and Messaid in Qatar. After the completion of the
HYDROCARBON PROCESSING APRIL 2009
I 29
ACHEMA
30
7
25
6
Propylene production, MMtpy
Ethylene production, MMtpy
2009
20
15
10
5
0
5
4
3
2
1
0
2008
2009
Iraq
Kuwait
2010
UAE
Qatar
2011
2012
Iran
Saudi Arabia
2008
2009
2010
Oman
UAE
Qatar
2011
2012
Iran
Saudi Arabia
Fig. 1. Ethylene production capacity in the Middle East (2008–2012).
Fig. 2. Propylene production capacity in the Middle East (2008–2012).
new projects, ethylene production capacity is expected to increase
from 16.9 MMtpy in 2008 to roughly 28.1 MMtpy in 2012 (13%
average annual growth rate during 2008–2012). Fig. 1 illustrates
the growth of ethylene production capacity in the region.
In terms of propylene production, ME production capacity
is expected to jump from 3.5 MMtpy in 2008 to 7 MMtpy in
2012, representing an average annual growth rate of 18% during
2008–2012 (Fig. 2).
In 2009 alone, FACTS Global Energy expects a 7.3 MMtpy
ethylene capacity increase, which is coming mainly from Saudi
Arabia, Iran and Qatar. Saudi Arabia is expected to play the main
role in propylene capacity increase in this region over the next four
Select 156 at www.HydrocarbonProcessing.com/RS
30
years. The country will add at least 1.4 MMtpy of new propylene
capacity in 2009.
Saudi Arabia. Saudi Arabia is the largest ethylene producer
in the region. The current capacity of ethylene production in the
country is roughly 9.5 MMtpy. Ethylene is being produced by
large Saudi petrochemical complexes such as Sadaf, Yanpet, Kemya,
United, PetroKemya, Tasnee and Yansab.
Overall, propylene capacity in Saudi Arabia increased to 2.2
MMtpy after the completion of the Tasnee and the Yansab petrochemical plants. Propylene is also being produced in other
petrochemical complexes such as AlFassel, Jubail Chevron Phillips and
PetroKemya.
The Saudi petrochemical sector is
expected to see a massive increase in
ethylene and propylene production
capacity, securing the country’s position
as a leader in the global petrochemical
industry. Jubail and Yanbu will be the
focus of Saudi Arabia’s petrochemical
development in the future.
Four key petrochemical projects are
under construction in Saudi Arabia,
and are scheduled for completion during 2009–2010. The new projects are
expected to add 4 MMtpy of ethylene
production capacity. There is an additional 1.9 MMtpy of propylene production capacity, which will be completed
by 2010 (see Table 1).
The recently built ethylene cracker
owned by the Tasnee Petrochemical
Co.—a joint venture (JV) of Tasnee,
Basell, Sipchem and Sahara—was completed in late September 2008 in the
industrial city of Jubail. The complex is
designed to produce roughly 1 MMtpy
of ethylene, 285,000 tpy (285 Mtpy) of
propylene, 400 Mtpy of high-density
PE (HDPE) and, finally, 400 Mtpy of
low-density PE (LDPE).
Looking for
clean fuel solutions?
W W W. T O P S O E . C O M
Check out Topsøe catalysts and technologies
Hydroprocessing
Hydrogen
Major supplier of clean fuels catalyst and licensed
technology. Low pressure, low cost revamps for ULSD.
Leading supplier of hydrogen plant catalysts and the
most efficient and feed flexible technology.
WSA
Selective Catalytic Reduction (SCR)
Cost effective and environmentally friendly method for
turning sulphur containing waste streams and spent
alkylation acid into clean concentrated sulphuric acid.
For FCC and all other flue gas streams. Superior
NOx removal with low SO2 oxidation. High poison
tolerance and low pressure drop.
Select 94 at www.HydrocarbonProcessing.com/RS
ACHEMA
New ME propylene capacity additions, MMtpy
New ME ethylene capacity additions, MMtpy
2009
8
7
6
5
4
3
2
1
0
2009
2010
2011
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
2009
2012
UAE
Qatar
Iran
Saudi Arabia
Kuwait
UAE
Qatar
2010
2011
2012
Iran
Saudi Arabia
Fig. 4. New propylene capacity additions in the Middle East.
Fig. 3. New ethylene capacity additions in the Middle East.
TABLE 1. New ethylene propylene production capacity
in Saudi Arabia (under construction)
Startup
Ethylene
capacity, Mtpy
PetroRabigh
2009
1,300
900
Sharq III
2009
1,300
–
Early 2009
–
460
2009/2010
1,350
550
3,950
1,910
Projects
Saudi Ethylene
and Polyethylene Co.
Saudi Kayan
Total
Propylene
capacity, Mtpy
Total: 4.7 MMtpy
Marun 23%
Tabriz 3%
Amir Kabir
11%
Arya Sasol
21%
Bandar Imam
7%
Arak 7%
Jam 28%
The Yansab complex was completed in late October 2008,
adding more than 4 MMtpy of petrochemical capacity, including
1.3 MMtpy of ethylene, 400 Mtpy of propylene, 700 Mtpy of
mono-ethylene glycol (MEG), 400 Mtpy of polypropylene (PP),
and 800 Mtpy of linear low-density PE (LLDPE) and HDPE as
well as butane, benzene and MTBE.
The first phase of the PetroRabigh complex, which is a JV between
Saudi Aramco and the Japanese company Sumitomo Chemical, is due
to start commercial production in second quarter 2009. It will produce 1.3 MMtpy of ethylene and 900 Mtpy of propylene. The plant
will produce 600 Mtpy of MEG as well. The feedstock is expected to
be roughly 95 million standard cubic feet per day (MMscfd) of ethane
and about 15 Mbpd of liquid petroleum gas (LPG), both provided
by Saudi Aramco. The SABIC Eastern Petrochemical Co. (Sharq III)
is planning to bring its new unit onstream by early 2009, including
1.3 MMtpy of ethylene, 700 Mtpy of ethylene glycol, 400 Mtpy of
HDPE and 400 Mtpy of LLDPE.
Another important petrochemical project is the Saudi Kayan
petrochemical mega complex. The Saudi Kayan petrochemical
complex will be located in the industrial city of Jubail with an
annual production capacity of 4 MMtpy. The complex will add
some specialized chemicals to the Saudi marketplace that will be
produced in the country for the first time. These products include
aminoethanols, aminomethyls, dimethylformamide, choline chloride, dimethylethanol, dimethylethanolamine, ethoxylates, phenol, cumene and polycarbonate. This is in addition to the production of ethylene, propylene, PP, ethylene glycol and butene-1.
More importantly, by 2012, Saudi Arabia’s petrochemical industry will raise ethylene production capacity to 13.5 MMtpy and
32
I APRIL 2009 HYDROCARBON PROCESSING
Fig. 5. Iran’s ethylene production capacity by project (2008).
propylene production capacity to at least 4.1 MMtpy. Saudi Arabia also plans to invest more to produce ethylene and propylene
beyond 2012. Dow Chemicals and Saudi Aramco have signed
a joint venture agreement to build a petrochemical complex for
producing 1.2 MMtpy of ethylene, 400 Mtpy of propylene, 400
Mtpy of benzene, 460 Mtpy of paraxylene and 640 Mtpy of chlor
alkali. Saudi Aramco plans to supply feedstock to the plant from its
nearby 550-Mbpd Ras Tanura refinery and Ju’aymah gas processing
plant. The plant is targeted for completion in 2013. It should be
noted that Saudi Aramco provides feedgas for petrochemical projects at a fixed price of $0.75/MMBtu, and the cheap feedstock is a
great advantage for the petrochemical industry in Saudi Arabia.
Iran. Iran represents the second major petrochemical player in
the region. This country is producing ethylene in Amir Kabir,
Marun, Tabriz, Arya Sasol, Jam, Arak and Bandar Imam. The
current ethylene and propylene capacity is around 4.7 MMtpy
and 1 MMtpy, respectively.
Figs. 5 and 6 illustrate Iran’s ethylene and propylene production capacity by project in 2008. The Jam petrochemical complex
is the largest ethylene producer in Iran. The ethylene production
capacity of the complex is approximately 1.32 MMtpy. The plant
also produces 305 Mtpy of propylene, 216 Mtpy of pyrolysis
gasoline, 444 Mtpy of ethylene glycol and 600 Mtpy of LDPE
and HDPE and other products.
Iran’s ethylene and propylene production capacity is forecast
to increase significantly after the completion of the new pet-
When you want options,
Ashland Distribution
delivers more:
• choices
• suppliers
• products
• people
• warehouses
• trucks
• services
• support
Whether you need amines, methanol, glycols, antifoams and more, Ashland
has you covered. Ashland Distribution is your best source for more than 7,000
chemicals, solvents and additives – in the quantities you need, delivered when
and where you want them. Choose from a broad list of premium suppliers
and count on Ashland for the service and support you deserve.
Call 1.800.531.7106 or email oilandgas@ashland.com today,
and explore your options.
Select 95 at www.HydrocarbonProcessing.com/RS
*Responsible Care and the Responsible Care logo are registered
service marks of the American Chemistry Council in the
U.S. and of different entities in other countries.
®Registered Trademark Ashland ©2008 Ashland
AD-9373
Select 86 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
HAVER & BOECKER
WILL CONVINCE YOU
Total: 1 MMtpy
Arak 12%
Bandar Imam 10%
Jam 29%
ACHEMA 2009
May 11 - 15
Hall 3, Stand Q18/R31
Amir Kabir
15%
Tabriz 5%
HAVER’s
High
Performance
Marun 29%
Fig. 6. Iran’s propylene production capacity by project (2008).
TABLE 2. New ethylene and propylene production capacity in Iran
(under construction)
Ethylene
capacity, Mtpy
Propylene
capacity, Mtpy
11th Olefin (Kavyan
Petrochemical Co.)
2009
2,000
–
13th Olefin (Ilam
Petrochemical Co.)
2011/2012
153
120
Gachsaran Olefin
2012
1,000
–
Assaluyeh Olefin
(Morvarid Petrochemical Co.)
2009
500
–
Fanavaran Petrochemical Co.
2010/2011
Total
rochemical projects (Table 2). By 2012,
Iran’s ethylene production capacity is
expected to increase to 8.4 MMtpy while
its propylene production capacity will
increase to 1.4 MMtpy.
Also, Iran has announced a new planned
project for ethylene and propylene production (Persian Gulf Petrochemical Co.) The
project is expected to be completed in
2014/2015 and will produce 1.3 MMtpy of
ethylene and over 1 MMtpy of propylene.
At present, Iran provides feedgas for
its petrochemical projects in the range of
$0.39/MMBtu to $0.56/MMBtu (2008).
The government’s projects are still paying
$0.39/MMBtu, and new private projects
pay $0.56/MMBtu for feedgas. The feedgas price is fixed with an annual escalation approved by the Iranian government.
A price increase is expected in the future;
however, a massive increase in the feedgas
price is unlikely as the government tries
to encourage industrial development in
the country.
Qatar. Ethylene is being produced by two
major petrochemical companies in Qatar with
a total production capacity of 1.2 MMtpy.
Qatar Petrochemical Co. (Qapco) and Qatar
–
120
3,653
240
Chemical Co. (Q-Chem) are the primary
ethylene producers. Qapco’s ethylene production capacity is roughly 720 Mtpy while
Q-Chem has a production capacity of 500
Mtpy of ethylene. There are several ethylene
crackers planned, but the most important
project in the near term is a 1.3 MMtpy ethylene cracker in Ras Laffan, which is under
construction. The project is expected to
be onstream in 2009. This country has no
propylene production; however, propylene
production is expected to start sometime in
2012/2013 with a capacity of 700 Mtpy.
Also, Qatar Petroleum has two agreements for the construction of ethylene
crackers, which have not materialized
yet. In 2005, Shell and Qatar Petroleum
signed a letter of intent to construct a 1.3
MMtpy–1.6 MMtpy ethylene plant in
Qatar. The project is still in the negotiation stage, and the startup of the project
is unlikely before 2013/2014. In 2006,
ExxonMobil and Qatar Petroleum also
signed a heads of agreement for the construction of a 1.3 MMtpy ethylene cracker
in the industrial city of Ras Laffan. The
proposed petrochemical complex includes a
world-scale, 1.3 MMtpy steam cracker and
associated derivative units, including LDPE
Select 157 at www.HydrocarbonProcessing.com/RS 䉴
NEW – see it
at the
MÖLLERS Stand
Hall 3, Stand D12 - G21
M 904-E4
Startup
Projects
The
FFS DELTA NT
Filling of free-flowing
granular, micro-granular,
or powdery bulk materials
into plastic tubular film
bags made of PE or PP
HAVER & BOECKER
P.O. Box 33 20 • 59282 OELDE, Germany
Phone: +49 2522 30-271
Fax: +49 2522 30-403
E-mail: chemie@haverboecker.com
www.haverboecker.com
HYDROCARBON
PROCESSING APRIL 2009 35
I
Activating Your Ideas. . .
… in stainless for biofuels. Fermentation, storage and pressure vessel tanks for biofuel projects around
the world are now being constructed in LDX 2101® stainless sheet and plate from Outokumpu. This lean duplex is
practical and economical — delivering high mechanical strength for weight reduction savings; low nickel content for
price stability; and high resistance to stress corrosion cracking.
Outokumpu is a global leader in stainless steel. Our vision is to be the undisputed number one in stainless, with success based on
operational excellence. Customers in a wide range of industries use our stainless steel and services worldwide. Being fully recyclable,
maintenance-free, as well as very strong and durable material, stainless steel is one of the key building blocks for sustainable future.
What makes Outokumpu special is total customer focus – all the way, from R&D to delivery. You have the idea. We offer
world-class stainless steel, technical know-how and support. We activate your ideas at www.outokumpu.com/stainless/na.
Select 91 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
(420 Mtpy), LLDPE (570 Mtpy) and ethylene glycol (700 Mtpy). The startup of
the new ethylene cracker is expected to be
in 2013/2014 at the earliest. The feedgas
prices for Qatari petrochemical projects are
extremely cheap, at around $0.50/MMBtu,
providing a great advantage to the petrochemical industry.
Olefin projects in other ME countries. Developments include:
The UAE. Only ethylene is being produced in Abu Dhabi. The Brouge Petrochemical Co. operates a 600-Mtpy ethylene plant
in the Emirate. The second ethylene plant
(Brouge 2), which is under construction, will
be online in 2012. After the completion of
this project; total domestic ethylene production will increase to 2 MMtpy.
Kuwait. In September 2008, Kuwait’s
ethylene production capacity was roughly
800 Mtpy. Equate Petrochemical Co. operates the ethylene plant. In November 2008,
a new expansion by Equate allowed Kuwaiti
ethylene production capacity to increase to
1.6 MMtpy. The new ethane steam cracker
is expected to produce ethylene at its plateau capacity during 2009.
Oman. Oman is producing propylene
at the Sohar refinery. The refinery operates
in an olefin mode to enable it to produce
roughly 327 Mtpy of propylene feedstock
for the polypropylene plant owned by
Oman Polypropylene LLC (OPP).
Iraq. At present, Petrochemical Complex No. 1 (PC1) in Khor al-Zubair, near
Basrah, is producing ethylene. The plant
has the capacity to produce 130 Mtpy of
ethylene, 110 Mtpy of ethylene dichloride,
66 Mtpy of vinyl chloride monomer, 60
Mtpy of polyvinyl chloride and 90 Mtpy
of LDPE and HDPE. However, the plant
is operating below its nameplate capacity
and needs rehabilitation.
Feedstock challenges in ME petrochemical industry. Low gas prices in
the ME provide an attractive environment
for gas-based petrochemical projects, which
is a great advantage for ME petrochemical
producers. Naphtha-based ethylene in Asia
is much higher in cost than ethane-based
ethylene in Saudi Arabia.
However, ME ethylene producers are
expected to face a number of new challenges. The first challenge is uncertainty
in securing feedstock, which has become a
serious concern for new projects, especially
those in Iran and Saudi Arabia.
Except for the Karan gas project, which
could provide 1.5 billion standard cubic feet
per day (bscfd) of dry gas for new industrial
projects in 2011/2012, the prospects for
non-associated production in Saudi Arabia
indicate a supply shortage for new petrochemical projects. Construction of a new
2-MMtpy ethylene cracker by the NEOS/
Delta Oil Co. was put on hold due to feedstock issues.
In Iran, a massive gas shortage, especially in winter 2007, interrupted gas supply for many petrochemical projects. This
gas shortage is expected to continue during
2008–2012.
Delayed South Pars gas projects are
expected to have a significant impact on gas
and ethane supplies to Iranian petrochemical projects. The most critical concerns are
for new PE units in the west and northwest
of the country. New west and northwest
petrochemical projects will receive feedstocks by a 2,163-km ethylene pipeline
(the West Ethylene Pipeline). This project, which is now 50% complete, was to
be completed in 2007. The initial plan was
for the construction of five petrochemical
complexes along the pipeline. However, the
number of petrochemical complexes has
been increased to 11 projects. The availability of feedstock from the West Ethylene
Pipeline is a serious challenge.
In Oman, a new gas-based olefin
plant at Sohar was canceled or postponed
because of gas supply issues. In the UAE
and Kuwait, gas supply to petrochemical
plants has become a critical issue because
these countries have massive gas shortages,
especially in the summer.
Critical market implications. The
global olefin market is expected to be
oversupplied in the near term. This will
impact market prices. However, ME olefin
suppliers will be less affected than Asian
petrochemical producers since the ME has
access to low priced feedstocks. In Asia,
small naphtha-based projects (below 300
Mtpy) will be most affected.
Outlook. For new projects, the era of the
extremely cheap gas prices is over. However, ME governments are not expected to
dramatically increase feedstock prices. The
governments want to encourage industrial
development. The new range for feedstock
prices may be $1.5/MMBtu–$2/MMBtu.
This range still allows some projects to
move forward economically, but other new
projects will be less attractive when compared to the past. ■
www.fgenergy.com
Select 158 at www.HydrocarbonProcessing.com/RS
KBR Technologies
Ideas for growth
Solutions for sustainability
KAAP™ s +2%3™ s 0URIlER0LUS™ s 0HENOL s !NILINE s 3UPERmEX™ s !DVANCED #ATALYTIC /LElNS
2/3%™ s !QUAFORM™ s 2&## s /RTHOmOW™ s -AXOlN™ s 2EGEN-AX™ s #ARBON #APTURE AND 3EQUESTRATION s 42)'™
Optimize processes. Accelerate profitability. Sustain
growth. From refining to ammonia, from chemicals
to coal gasification, KBR Technologies bring success
to grassroots and revamp projects worldwide.
technology.kbr.com
Select 89 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
among China’s rural poor is only now under way to replace lost and/
or destroyed overseas demand. Chinese government legislation on the
environment and rising labor costs, are adding new challenges into
the mix for domestic producers and joint venture (JV) companies.
The approach for the next decade leaves China looking for a
new paradigm in which lower consumption growth rates in North
America and Europe are offset by a much faster development of
domestic demand. New government stimulus to promote vehicle
ownership and consumption of household appliances in the poor
rural areas, is the first step in achieving stimulating demand. These
programs appear to have some initial successes.
China
Lynchpin economy. China exhibited very rapid economic
Qu Guangdong, Regional Vice President, SRI Consulting,
Beijing, China
Converted product exports, thousand tons
The past decade of explosive growth in China’s petrochemical industry was founded on a simple paradigm: 1) add value to
imported oil to produce plastics that can be converted into finished products in China, and 2) export these products to North
America and Europe.
China, as the factory to the world, could absorb new domestic
polymer capacities and output from major startups in the Middle
East. A new axis emerged in the petrochemical industry, and it is
between the Middle East and China. Yet, cracks in this business
model began emerging in early 2005. Even with demand growth
rates that were expected, China would not be able to absorb as
much of the new Middle Eastern capacity as anticipated. The
current global recession has made conditions worse. China is
finding demand in its target markets stalling or declining. At the
same time, Middle Eastern competitors are starting up massive
new capacities. Due to the US recession, China’s exports are being
adversely impacted, as illustrated in Fig. 1.
In addition, the highly erratic and consistently higher feedstock
prices are shifting the long-term profitability models. Government
action to stimulate the domestic economy and demand for plastics
400
350
300
2006
2007
2008
250
growth over the past 10 years due to its ability to make products
for world. Low labor costs enabled China to remain competitive.
Table 1 summarizes China’s GDP growth in constant Renminbi
(RMB) since 1998.
In 2009, the Chinese government is trying to hold GDP
growth at 7%–8%, a level considered necessary to avoid mass
unemployment and social unrest. China is implementing a 4
trillion RMB stimulus program, largely by targeting the nation’s
infrastructure—equal to around 16% of the GDP. Recent news
has indicated that the government will introduce a specific,
$50+billion stimulus program targeted at 20 petrochemical plants.
The details of this plan are set to emerge from the People’s Congress in March 2009.
Major players. Although China has an estimated 40,000 chemical producers, most are small companies. Two companies dominate
the petrochemicals sector; Sinopec and CNPC (PetroChina) have
become significant world players over the past 10 years. Sinopec
ranks sixth in the world with sales of chemicals approaching $30
billion in 2007. PetroChina is ranked twentieth with chemical sales
of $14 billion in 2007. Both companies are likely to rise within the
rankings due to significant growth in the domestic market, and sales
from new investments. Sinopec could become the world’s largest
chemical company by sales within the next decade.
Industry analysis also suggests that Sinopec will be within the
top three ethylene and polyethylene producers in the world by
2015, and also within the top three propylene and polypropylene
producers by the same date. PetroChina, meanwhile, will also be
in the top 10 in both categories by 2015.
TABLE 1. Chinese GDP Growth, 1998–2009
(constant RMB)
200
150
Year
100
50
0
Sacks/bags
Tableware
Sports footwear*
*Pairs of footwear
Note: Sacks and bags exports fell 7.7% overall, for 14% to the US tableware
with exports declining 30%. Sports footwear exports fell 38% overall, but
exports to the US fell 19%.
Fig. 1. US crisis affects China’s converted product exports.
Growth, %
Year
Growth, %
1998
7.8
2004
10.1
1999
7.6
2005
10.4
2000
8.4
2006
11.7
2001
8.3
2007
11.9
2002
9.1
2008
9
2003
10
2009
7–8
Source: SRI Consulting’s China Report
HYDROCARBON PROCESSING APRIL 2009
I 39
ACHEMA
Location
Startup
Date
1,000
2009
PetroChina Dushanzi Petrochemicals Dushanzi, Xinjiang
PetroChina Daqing Petrochemicals
Daqing, Heilongjiang
600
2010
PetroChina Fushun Petrochemicals
Fushun, Liaoning
800
2010
PetroChina Sichuan Petrochemicals Pengzhou, Sichuan
800
2012
Fujian Refining &
Petrochemical Company
Quanzhou, Fujian
800
2009
Sinopec Zhenhai
Refining & Chemical
Zhenhai, Zhejiang
1,000
2010
Sinopec Tianjin Ethylene Project
Tianjin
1,000
2010
Sinopec Yangzi Petrochemicals
Nanjing, Jiangsu
85
80
75
70
65
Spec additions
600
2015
Sinopec Wuhan SK Ethylene Project Wuhan, Hubei
800
2013
Sinopec Zhongyuan Petrochemicals Puyang, Henan
180
2015
Sinopec Shanghai Petrochemicals
Shanghai
600
2013
Sinopec Kuwait Nansha
Ethylene Project
Guangzhou,
Guangdong
1,000
2014
Sinopec Shanghai Chemical Park
Shanghai
1,000
2016
Dalian Shide Group
Lian Liaoning
1,000 2015–2017
Source: SRI Consulting’s World Petrochemicals (WP)
Foreign-direct investment in China. Chinese companies
have not sought chemical JVs or acquisitions outside of China.
Rather, they prefer to create JVs with overseas companies and
to build world-scale plants in the Middle Kingdom. If oil prices
return to their record levels for a sustained period, it is reasonable
to assume that Chinese producers may opt to make more basic
chemicals and petrochemicals overseas in regions with lower feedstock costs rather than to use expensive imported oil at home.
Meanwhile, the world’s major chemical companies continue to
build their businesses in China via JV facilities as well as whollyowned ventures.
World recession slows down ethylene expansions.
Falling global demand and rising capacity are going to create poor
operating conditions for the olefin industry through 2015. Recent
studies shows that no less than 17.6 million tons (MMtons) of new
ethylene supply will start up in the Middle East between 2008 and
2015. An extra 10 MMtons will come online in China in the same
period. Fig. 2 shows that the trough in the current cycle will occur in
2010. The latest forecast predicts that world operating rates will not
return to 90% levels until 2017. Additional startup delays (especially
of the 5 MMtons of planned new capacity in Iran) would have the
effect of delaying recovery (see Table 2). The Chinese startups will
come mainly from the industry’s two major companies—PetroChina
and Sinopec—plus some new capacity based on coal feedstocks.
Because of the global financial crisis, the planned startup date
of new ethylene crackers in China has been postponed for one or
more years. This will ease worldwide overcapacity, and will also
serve to keep China’s operating rates higher than those in the rest
of the world. Currently, new forecasts show that ethylene operating rates in China will be close to a healthy 90%.
On the demand side, China’s consumption of ethylene equivalents (including imports of all ethylene containing derivatives for
conversion) grew at 7.7%/y between 2002 and 2007. However,
demand is set to fall to 4.7%/y until 2012 and 4.6%/y from
40
90
I APRIL 2009 HYDROCARBON PROCESSING
Nameplate capacity, %
Company
Capacity,
thousand
tons
95
200
180
160
140
120
100
80
60
40
20
1985
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
TABLE 2. Important Chinese ethylene
startup plans (2009–2017)
Global ethylene demand, MMtpy
2009
Production
Operating rate
Fig. 2. World ethylene supply and demand.
2012 to 2017. This fall in ethylene-equivalent demand below
the expected growth of GDP is a result of declining exports to
traditional markets of North America and Europe. The government stimulation of domestic demand should be sufficient to keep
Chinese petrochemical plants running at high operating rates, but
will be insufficient to sustain previous growth rates in demand.
Coal-future resource. With the potential threat that oil
prices will rise back towards $100+/bbl levels as economic activity rebounds, China is also exploring the possibility of building
a fuels/chemicals industry based on coal. China has around 130
billion short tons of recoverable coal—a full 93% of its estimated
domestic recoverable fossil fuels reserves. Only 60% of the reserves
are high-energy-content anthracite and bituminous coals that
would be needed in chemicals production. The remaining reserves
are high-moisture lignite and sub-bituminous coals, which are
suited for power generation. Estimates conclude that China has
less than 50 years of suitable coal reserves for making chemicals.
Recent emphasis looks on producing methanol (MeOH) and
dimethyl ether (DME)—liquid fuels—from coal. These alternative fuels are viewed as replacements for oil imports. Parallel
work is proceeding into the biofuels area; the overall goal is to
maintain China’s oil imports below 55% of total energy needs.
Currently, the majority of 11.4 MMtons of MeOH production
is coal-based—nearly two-thirds of MeOH production. A very
rapid capacity expansion to 81 MMtpy is expected by 2012, with
coal-based plants being a key growth factor.
With a surplus of MeOH possible from this rapid expansion,
coal-based olefins production (MeOH-to-olefins, DME-to-olefins,
MeOH-to-propylene) is also a major thrust of research and commercial-scale developments. As shown in Table 3, there are two major
coal-based ethylene plant planned or under construction in China,
representing over 800,000 tons of new capacity by 2015–2016.
Two limits on this promising work are 1) greenhouse gases
impacts for manufacturing chemicals from coal, and 2) coal-based
processes require large volumes of water. However, these constraints
also offer China the opportunity to pioneer new coal technologies
to bolster the utility of this feedstock. The exploitation of coal,
which is largely in the west and north of the country, is inline with
government policy to favor growth in non-coastal regions.
Policies to stimulate consumer demand. There are
signs that government policies could help China avoid the worst
of the global chemical recession. A good example pertains to
automobiles. Statistics from the National Bureau of Statistics show
ACHEMA
2009
that the number of automobiles for 2008 civilian use in China
rose by no less than 24.5% to 24.38 million units. The number of
privately owned cars rocketed by 28% over 2007 number to 19.47
million units. That compares with a US market that is expected
to experience a loss of six million unit sales in 2009. Chinese
government policy is directed at promoting purchases of hybrid
and small cars, especially in rural areas.
Similarly, government pilot schemes are attempting to boost
rural consumption of consumer goods, such as televisions and
refrigerators, by offering government subsidies on these items.
While the outcome of such programs is uncertain, and the western part of the country will not stay immune from the fall-off of
the export business in the East, the Chinese consumer potentially
does hold the key to the revival of the petrochemical industry. With
consumption in the West, and Japan apparently likely to suffer
from low growth rates, the true axis of the petrochemical industry
is shifting to the Middle East and China. And the evolution of
TABLE 3. Coal-based ethylene projects in China
India–
A polyolefin perspective
refinery capacities, major producers, including India Oil Corp.,
Ltd. (IOCL) have announced new polymer plants. IOCL is commissioning a 1.25-million ton (MMton) plant, which will produce
polyethylene (PE) and polypropylene (PP) by December 2009.
Polymer supplies are set to boom. The key to sustainable growth
is facilitating the increased usage of plastics via a scientific, orderly
manner through well-thought-out initiatives.
B. M. Bansal, Director of Planning and Business
Development, IOCL, Siddharth Mitra, General Manager
of Petrochemicals; IOCL and Mathew George, Senior
Manager of Polymer Marketing, IOCL, New Delhi, India
The Indian economy has come a long way since the economic
reforms in 1991. A decade and half of economic reform and
globalization is yielding returns cutting across all income groups.
Expansion of the economy has accelerated along with higher
growth within the industrial industry and services sectors.
India is forecast to emerge as one of the top five economies by
2025. India’s rapid economic growth over the last few years has
spurred demand for a wide range of petrochemicals. Consumption
of key petrochemicals, such as polymers, are projected to show double-digit growth due to strong support by India’s vast middle class
that is experiencing rising income levels and changing lifestyles.
However, the global recession has entered an unpredicted
dynamic variable into this economy. India is better off than most
countries; but, it is important to focus on areas where progress has
fallen short of expectations. In the coming years, if India sustains this
tempo of rapid growth, then certain areas, which are of developmental relevance to the nation and its people will need more attention.
The polyolefin industry plays an important role in economic
development, and this industry is one of the fastest growing sectors
within the Indian economy. Plastics have not only supplemented
but have substituted conventional materials. Energy efficiency,
competitive alternate sources in packaging, consumer durable and
nondurable applications, advanced materials in high-tech applications, etc., are some of the drivers for substitution. Plastics have
penetrated all sectors and have become essential in daily needs.
Yet, the per capita consumption of polymers in India languishes at a lowly 5 kg/yr compared to a global average of 24
kg/yr. In the developed nations, the per capita consumption of
polymers is over 80 kg/yr.
Benefiting from increased availability of naphtha via increased
Location
Capacity,
thousand
tons
Shenhua Baotou Coal Chemical
Baotou
300
Shenhua Dow Coal
Chemical Industry
Yuilin
500
2016
Shaanxi XinXing Coal and Olefins
Yuilin
500
Postponed
Indefinitely
Company
Startup
Date
2010
Source: SRI Consulting’s China Report
petrochemical consumption is truly in China’s hands. ■
ACKNOWLEDGMENT
Information in this article was taken from SRI Consulting’s China Report and World Petrochemicals research programs.
www.sriconsulting.com
Sulzer SMVTM Static Mixer
The key to crude oil desalting
MOVING AHEAD
CT.29e
• Excellent desalting efficiency due to
large interfacial surface area
• Smallest settler size due to narrow
drop size distribution
• Reduced carry-over and carry-under
• Short payback time
For more information, visit
www.sulzerchemtech.com
Sulzer Chemtech
Europe, Middle East and Africa
Phone +41 52 262 67 20
sulzermixer@sulzer.com
North and South America
Phone +1 918 446 6672
sulzermixer@sulzer.com
Asia Pacific
Phone +65 6515 5500
sulzermixer@sulzer.com
Select 159 at www.HydrocarbonProcessing.com/RS
41
ACHEMA
2009
You Know . . .
■
■
■
Heavy hydrocarbon and water
in natural gas may form
condensate in export lines.
Wet (water saturated) natural
gas may form hydrates
and plug equipment and
transportation lines.
Maul operation of a compressor
may result in “surge” and
“stone wall.” Surge may destroy
a compressor.
But Do You Know . . .
■
■
■
How to avoid condensation
from forming?
How to prevent hydrate
formation and plugging of
equipment and pipelines?
How to safely operate and
protect compressors from surge
and stone wall?
Take the Campbell Gas CourseTM
(G-4 Gas Conditioning and Processing)
to learn these answers and more.
For a list of G-4 course
dates and locations go to
www.jmcampbell.com/HCP
For a FREE subscription
to the Campbell
Tip of the Month go to
www.jmcampbell.com/TIP2
4.5
Polymer supply/demand, MMtpy
Gas Processing
Engineers and
Other Industry
Professionals
Polyolefins. Fig. 1 shows the supply/
demand scenario for polyolefins in India.
As shown in this figure, while PE is more or
less balanced, PP has an exportable surplus
over the short term.
PP demand in India is currently around
1.9 MMton and is estimated to grow at a
compound annual growth rate of approximately 15% for the next five years. PP has the
greatest demand share and accounts for over
40% of the total polyolefins market.
Considering strong intrinsic growth in the
biaxially oriented polypropylene film (several
new units are being commissioned) and raffia segments, coupled with new capacities of
around 1.5 MMton, are coming onstream in
2009 and 2010. PP is performing strongly in
India, and this nation exports 0.2 MMton
of PP. With the new PP capacities coming
onstream, exports are expected to increase to
0.6 MMton coupled with operating rates sliding to 85% from the present rate of 95%.
Low-density PE (LDPE) demand in
India is estimated at 0.2 MMtpy. Around
75% of the LDPE demand is for film and
sheet applications such as packaging and
plastic bags and the remaining balance is
directed to raffia lamination. LDPE continues to be substituted by linear-low-density
PE (LLDPE). Accordingly, LDPE demand is
expected to grow at 2%/y to 3%/y over the
PE supply
PE demand
PP supply
PP demand
4.0
3.5
3.0
Supply-driven
market. Notably,
2.5
2.0
1.5
2009
2011
2012
2013
Year
Fig. 1. India’s PP and PE supply and demand trend, 2009–2013.
KAR
5%
2010
TN
7%
PUD REST
2% 2%
UP 8%
KER 1%
AP 6%
DNH 2%
GDD
12%
PUN 2%
HRN 2%
DEL 2%
HP 1%
RAJ 3%
MP 4%
WB 8%
GUJ
15%
MAH
16%
Fig. 2. Domestic polymer consumption by states.
Select 160 at www.HydrocarbonProcessing.com/RS
next five years, and then probably stagnating. No LDPE capacity additions are planned
since the forecasted volume growth would not
justify building a new world-scale facility.
LLDPE demand in India is currently
estimated at 0.8 MMtpy, with 70% of the
demand used for film and sheet applications.
LLDPE is also the most commonly used
polymer for block-molding of water tanks
and intermediate bulk carriers. Demand
for LLDPE is expected to grow at around
15%/y due to growth in the film and sheet
sector combined with equally strong demand
growth in applications such as water tanks,
automobile components and toys.
High-density PE (HDPE)
demand in India is estimated at
1 MMtpy. The market is varied with 23%
of the demand for film and sheet; whereas
injection and blow-molding applications each
account for 19%. Raffia is also a significant
application for HDPE in India. HDPE pipes,
although currently accounting for only 12%
of the markets, are slated for huge growth by
the agriculture/irrigation and construction
sectors. HDPE also is estimated to record a
healthy growth of around 12%/y. India is
expected to become a net importer of HDPE
as the domestic demand growth exceeds new
capacity additions. The projections as mentioned will result in an investment potential of
$8 billion in upstream
cracker complexes and
polymer plants, and
about $6 billion in
the downstream plastic processing sector.
the Indian polymer
market is supply
driven. The major
consumption states are
Maharashtra, Gujarat,
Daman, West Bengal
and UP (Fig. 2) and
one of the common
threads binding these
states is the presence
of a proximate polymer plant.
Na n d a n Ni l e kani, co-chairman
of Infosys, explains
the existence of a
“double hump” in
India’s demographics.
The first hump came
from southern India
and and resulted in
ACHEMA
2009
economic growth of that region. He also believes that the second
hump, which is yet to peak, will come from the northern states.
The northern population would be younger than that of the south
in the coming years. Moreover, 50% of the population growth in
India would be in the northern states over the next decade.
From Fig. 2, it is clear that the northern region can witness a
demand explosion for polymers, provided supplies are available.
IOCL’s polymer plant at Panipat is a prospective catalyst for new
growth within the polymer industry in northern India. Couple the
new polymer capacities ongoing in northern India with the initiatives
taken by the governments of the northern states of Himachal Pradesh,
Uttarakhand and Haryana to promote industrial hubs within their
territories by way of tax and infrastructure
initiatives, and we have a blueprint for the
growth for the polymer industry.
tribution systems and sewerage systems, building roads, ports,
airports and other components of infrastructure can be made possible by increased usage of plastics in various forms—plastic pipes,
profiles, geo-textiles, etc.
Public health. The role of plastics in enhancing public health
infrastructure is evident. Plastic syringes, blood bags, drip pouches,
etc., are central to any health infrastructure. The rural health infrastructure needs to be significantly improved, and plastics would
play a key role in this process.
Water management. India accounts for 16% of the global
population and 30% of livestock but only 4% of global water
resources. Yet, India faces the formidable challenges of achieving
Demographics. India has a unique advantage in terms of demographics. While demographic trends in other key economies such as
Brazil, China and G8 countries show a decline
in the share of working age population, i.e.,
population age group of 15–60 years; in total
population over the period 2005–2030, this
group is expected to expand for India.
As other nations endure a graying of the
workforce and potential shortage of workers,
India with its growing working age population
will have no shortages of manpower. In addition, as the economy becomes increasingly
globalized, aspirations of the Indian consumer
are rising, which coupled with the increasing disposable income of the people is fueling
demand for various goods and services. India’s
population of 1.1 billion people is the second
highest in the world after China and provides
a tremendous market opportunity.
Key focus areas. Certain key areas are
important not only to the plastics industry of
India but also to the economy as a whole. In
the coming years, if India sustains this rapid
growth in the polymer industry then these
areas would require significant attention:
Agriculture. Enhancing agricultural productivity to meet growing demand for food
and achieving food security is one of the key
objectives facing this nation. Improving postharvest handling and packaging to improve
delivery efficiency by waste minimization is
a key challenge. Plastics are vital inputs in
this area, and only through increased plastics
usage can these targets be achieved. Plastic
pipes, films, drip systems for micro irrigation
projects, packaging films, crates for handling
and storage, etc., can improve agricultural
productivity significantly and contribute to
domestic food security.
Infrastructure. According to the World
Bank, infrastructure improvement will be a
key factor to support high growth in India.
Improving urban infrastructure, water disSelect 161 at www.HydrocarbonProcessing.com/RS
43
ACHEMA
2009
x
Naphtha availability in India (2011-2012)
Supply
Demand
Exportable surplus
2006-07
210-225
135
114
2006
78-93
132
21
Exportable surplus 20112012 ~ 1.5 times of current
Singapore refining capacity
(67 MMtpy)
India’s naphtha
usage trends
2006-07
MM mton*
Naphtha usage
12.4
Petrochemicals
7.4
Fertilizers
2.9
2011-12
Fig. 3. Supply and demand of refined petroleum products.
water and food security—a key step toward the Indian Government’s objective of poverty alleviation. The World Bank estimates
that demand for fresh water could rise to about 105 billion cubic
metric tons (mtons) by 2025 from the current level of around 75
billion cubic mtons. However, projections reveal declining per
capita availability of water as the population continues to grow.
Plastics can play a key role in water management.
Conservation. Globally speaking, plastics play a major role in the
conservation of natural resources such as wood, minerals, etc., by providing a cost-effective and environment-friendly alternative to natural
resources. Expanding India’s forest is of the key targets at the national
level; plastics are likely to play a pivotal role in this process.
Employment. Generating employment opportunities is key
to the concept of “inclusive growth”—one of the priority areas.
Plastics can play a key role in realizing this objective.
In India, the plastic industry provides employment to 3.3
million people (directly and indirectly) and has the potential of
generating an additional 3.7 million jobs. With the adoption of
micro-irrigation, which depends substantially on plastic pipes,
drippers and mulch film, an additional 17 million people can be
employed in the rural sector.
Environment. Lack of awareness about plastics and an appropriate mechanism for separating biodegradable and non-biodegradable waste has created a flawed public perception over
polymers. India is a nation in which the plastics recycling industry
is well developed. Apart from the low weight of plastic, the design
options such as multilayer extrusion have further reduced the
materials requirements for specific end uses. There is a need to
educate the public over the merits of plastics.
Finally, plastics provide a very diverse range of properties and
offer numerous applications. For example, plastics are widely
used in the medical sector in disposable applications. But with
the growing realization over costs of disposing of such disposables,
there is a growing trend to use materials that can be sterilized and
reused. Once again, engineering plastics, which can be sterilized
and reused, have proven to be an alternative to glass.
Growth imperatives. So that India’s market potential is fully
achieved, the government must address these issues:
• Ensuring macro-economic stability, including containment
of core inflation
• Sustaining cost competitiveness and stimulating domestic
demand
• Strengthening education and skill building
• Investing in innovations and technology
• Enabling speedy development of infrastructure
• Providing the right market framework and regulatory envi44
Refining capacity MM mton* 135
Naphtha supply1 MM mton* 15
I APRIL 2009 HYDROCARBON PROCESSING
Power
Net exports
2.1
~2.6
2011-12P
change
2011-12P
+75-90
+8-10
210-225
23-25
2011-12P
change
2011-12P
+
–
–
60%
Naphtha required for
power and fertilizer
to reduce by
2.5 MM mton*
40%
+
Potential for
downstream
petrochemicals
and exports
Note: 1-Naphtha supply has been taken as ~ 11% of the crude supply P-projected
Source: Cris Infac, Business Press, Petroleum Ministry, Tata Strategic Analysis
*Million metric tons.
Fig. 4. Naphtha supplies for petrochemical, fertilizer and power industries.
ronment to reduce transaction costs
• Ensuring effective coordination between central, state and
local levels
• Creating a standing mechanism for resolving manufacturing
policy issues
• Enabling small and medium enterprises to achieve competitiveness
• Enabling public sector enterprises to meet competitive market conditions.
Similarly industry must deal with these challenges:
• Investing in R&D and technology
• Showing continuing commitment to skills development and
knowledge enhancement
• Adopting global standards and benchmarking performance
against the best in the class
• Adopting best manufacturing practices and production
techniques
• Increasing scale of operations and delivering on globally
acceptable quality levels.
Hurdles to India’s market potential. Several economic,
political, infrastructure, environmental, regulatory and petrochemical feedstock hurdles weigh down the market potential of
India. They include:
1. Technology upgrading
2. Rationalization of indirect taxes, duty structures
3. Compliance of quality standards
4. Regulatory framework
5. Creating/upgrading existing plastic clusters/dedicated
plastic parks with quality infrastructure
6. Human resource development
7. Plastic waste management and recycling
8. Feedstocks—Availability and pricing
9. Infrastructure—petroleum, chemicals and petrochemicals
investment regions (PCPIR), cluster formation, dedicated plastic
parks, roads, ports, warehouses, etc.
ACHEMA
2009
Governmental intervention. As a sector, the Indian plastic
industry has received little attention by policymakers. It is time
that this industry is recognized over its role and contributions to
domestic growth and development.
The governmental focus areas should be in facilitating the creation of world-class infrastructure through policy initiatives such
as PCPIR, adapting a cluster approach, developing and promoting
plastic parks and petrochemical export processing zones. Investments in R&D and human resource development, modernization
and technology upgrading to adopt new generation technology,
improved scales of operation, facilitating promotional measures for
adopting environmental friendly and recycling technologies and
removing structural constraints for a sustained
growth of industry in order to remain globally
competitive and achieve desired growth rate.
petrochemical end products.
Thus, raw material supplies would seem to be no more a problem in India. The chemical industry is indeed poised for a supplydriven demand boom given India’s key drivers in demographics
(trained manpower, a large working age population and intrinsic
population growth) and per capita income growth. ■
BIBLIOGRAPHY
Report on Working Group on Chemicals and Petrochemicals, 11th Five Year Plan.
ICIS Website, Plants & Projects
Jacobs Consultancy Reports
Sagia Analysis of CMAI Data
CMAI Market Study for IOCL
Tata Chemical Analysis of Indian Chemical Sector
Next petrochemical boom. During
the early part of this decade, India’s chemical
industry was near stagnation. Capacity additions had virtually stopped. Tariff protection,
approximately 35%–50% until 2000, was
being planned to be reduced 7.5%–10% by
2007–2008. New world-scale capacities were
being proposed take advantage of cheap raw
material sources, e.g., the Middle East, or close
to big demand centers, such as China. Indian
plant capacities designed to cater to the protected domestic market were subscale by new
global standards, and were based on technology
licensing from existing global chemical majors.
Doubts were being raised whether India’s chemical industry would be able to withstand the
onslaught of global competition.
However, in contrast, India’s refining capacity is expected to increase from 135 MMtpy
in 2006–2007 to 210 MMtpy–225 MMtpy
by 2011–2012, translating into an exportable
surplus of refined products of 78 MMtpy–93
MMtpy by 2011–2012 (Fig. 3).
The approximate 60% increase in refining capacity will provide an additional 8
MMtpy–10 MMtpy of naphtha by 2011–
2012. As shown in Fig. 4, there is a reduced
usage of naphtha in power and fertilizers
by 2.5 MMtpy by 2011–2012; this trend
is expected to increase available naphtha by
10.5 MMtpy–12.5 MMtpy.
More naphtha supplies have been
announced through major downstream projects
(naphtha crackers) by refining majors—Reliance, IOCL, Oil and Natural Gas Corp. Ltd.,
Hindustan Petroleum Corp. Ltd., and Mangalore Refining and Petrochemical Ltd. The
olefinic-based chemical capacity is expected
to increase from 4.5 MMtpy to 8 MMtpy–10
MMtpy, while aromatic base chemical capacity is expected to increase from 3.2 MMtpy
to 5 MMtpy–6 MMtpy over the next 5–6
years. Vertical integration of these base chemical capacities would lead to a near doubling
of capacity in fiber intermediates, and basic
Designed specifically to meet the
requirement of API 610, the API Maxum
Series is available in 35 sizes to handle
flows up to 9,900 GPM and 720 feet of
head. Standard materials include S-4,
S-6, C-6 and D-1. A wide range of
options makes this the API 610 pump
for you!
Creating Value.
Carver Pump Company
2415 Park Avenue
Muscatine, IA 52761
563.263.3410
Fax: 563.262.0510
www.carverpump.com
Select 162 at www.HydrocarbonProcessing.com/RS
45
ACHEMA
2009
Japan
Masahiro Yoneyama, Vice President, SRI Consulting,
a division of Access Intelligence, LLC
Japan’s economy showed steady recovery for 2003–2007. Its
real GDP growth rates were 1.9% in 2005, 2% in 2006 and
2.4% in 2007. Owing to this economic growth, together with an
increase in exports, ethylene production increased five consecutive
years through 2007, and recorded the record highest production
Chemicals and Polymers –
of 7.74 million tons (MMtons) in 2007 (Table 1). However,
because of the 2008 recession, domestic ethylene production
dropped to 6.9 MMtons and was 11% lower than 2007 levels.
Ethylene production rates under 7 MMtons have not been experienced since 1995. Ethylene-equivalent demand also increased
during 2003–2007; however, it also decreased in 2008. Aromatics
production increased during 2003–2007, but it dropped by 13%
in 2008, as shown in Table 2.
Domestic demand. As shown in Table 1, domestic ethylene-equivalent demand strongly depends on economic conditions. The correlation of ethylene-equivalent
demand growth and GDP growth is represented in Table 3. Although growth rate for
L
Exp a ca ooki
domestic demand has the same trending as
n
r
ww lore eer c g for
GDP, the growth rate of ethylene-equivalent
w.m opp ha
ust ortu nge?
consumption is less than that for GDP. A
ang nit
eng ies
possible explanation for this is that petroa
.co t
chemical consumer companies have been
m
shifting their manufacturing base from Japan
to other Asia-Pacific countries and have
increased imports of finished goods, such as
electrical appliances, toys and plastic bags.
In 2008, the ethylene-equivalent demand
decreased by 2.6%. The 2009 ethyleneequivalent demand will further decrease by
5%–7%.
For 2003–2007, aromatics demand
increased. However, in 2008, benzene
demand decreased by 17% due to low production for styrene monomer, phenol and
cyclohexane. Toluene demand also decreased
by 12% linked to low operating rates for
Think Mustang.
disproportionation and dealkylation units.
Xylene demand decreased by 6% because of
low paraxylene production, especially in the
fourth quarter of 2008. Aromatics demand is
also expected to decrease in 2009.
We get below the surface.
Mustang has vast experience in conceptual design, front end
loading, project planning and execution. Our veteran process
design team is experienced in all areas of technology and design.
We have developed tools for conceptual planning that analyze the
whole picture for chemical and polymer integration/modernization
projects. Our goal is to provide you with options, tradeoffs and
relative costs during the front end planning process.
At Mustang, our strong front end capability provides accurate
project scope definition, cost estimating and fit-for purpose engineering from concept through commissioning.
When you are planning your next revamp, upgrade or expansion,
contact Mustang. We get below the surface with great teams to
guide you through your project with no surprises.
People Oriented...Project Driven®
16001 Park Ten Place, Houston, Texas 77084 USA
Tel: +713/215-8000 • Fax: +713/215-8506
Web: www.mustangeng.com
E-Mail: robert.stodghill@mustangeng.com
Select 163 at www.HydrocarbonProcessing.com/RS
46
Trade. As shown in Table 1, Japanese eth-
ylene-equivalent exports increased during
2001–2007 due to the steady growth of the
world economy, especially in Asian countries. With the onset of the present financial cool down, Japanese exports decreased
by 23% from 2007 levels. Among major
petrochemicals, exports of styrene monomer, polyvinylchloride and vinyl acetate
monomer (VAM) decreased more than
30%; exports for high-density polyethylene
(HDPE) decreased by 20% and low-density
polyethylene (LDPE) decreased 10%. Conversely, exports of vinyl chloride monomer
(VCM) remained steadfast.
Conversely, ethylene-equivalent imports
increased by 37%; imports of LDPE, HDPE
and ethylene glycol (EG) also increased. As a
result, ethylene-equivalent net exports (exports
– imports) decreased to 1.3 MMtons—levels
seen during the mid-1990s.
2009
TABLE 1. Ethylene equivalent production and demand,
thousand metric tons
Year
Production
Demand
Export
1995
6,944
5,737
1,662
1996
7,138
5,858
1,739
1997
7,416
6,037
1,811
1998
7,076
5,526
1,957
1999
7,687
5,801
2,365
2000
7,614
5,887
2,138
2001
7,361
5,727
2,051
2002
7,152
5,388
2,157
2003
7,367
5,548
2,238
2004
7,570
5,752
2,206
2005
7,618
5,770
2,270
2006
7,522
5,717
2,294
2007
7,739
5,742
2,391
2008
6,882
5,593
1,831
Source: Ministry of Economy, Trade and Industry
Profit of petrochemical companies.
Table 4 summarizes the sales and operating
profits of the petrochemical segment for Japanese chemical companies operating ethylene
crackers. The ordinary profit of the petrochemical segment is cyclic. Since the 2001
trough, profit and sales have increased due
to the tighter supply and demand situation.
However, it is estimated that fiscal 2008 that
is ending March 2009 will not be as favorable
due to the recession. It is estimated that fiscal
year 2009, ending March 2010, will also be a
difficult year for the petrochemical industry
due to the shrinking petrochemical demand,
especially in the automobile industry and the
electrical and electronics industry. Also, petrochemical exports will be lower.
Investment. Japa-
nese petrochemical
companies have been
Import
Net trade actively investing in
both domestic and
454
1,208
overseas projects.
459
1,280
They tend to invest
432
1,379
in commodity chemi407
1,550
cals located in overseas
478
1,887
countries and, in con411
1,727
trast, these companies
invest in high-perfor417
1,634
mance chemicals and
393
1,764
feedstocks in Japan.
420
1,818
Regarding commod388
1,818
ity chemicals, almost
422
1,848
all investments are
489
1,805
made in countries that
394
1,997
have access to lowercost materials (such
541
1,290
as in the Middle East)
or those nations with
strong domestic demand (other Asian countries). Sumitomo Chemical is starting up
its ethylene complex in Rabigh, Saudi Arabia with Aramco in March 2009. Mitsubishi Group companies have invested in the
SHARQ cracker project in Saudi Arabia.
In China, the largest petrochemicals
consumer, several projects are going on;
Mitsui Chemicals started up a bisphenol
A (BPA) plant in 2008, and Mitsubishi
Chemical is starting up a polytetramethyl
ether glycol plant, BPA plant and polycarboxylate plant in 2009/2010. Mitsui
Chemicals has been expanding production
capacities in Indonesia, Thailand and Singapore. Likewise, Mitsubishi Chemicals is
expanding production capacity in India.
TABLE 2. Aromatics production, TABLE 3. Ethylene equivalent demand
thousand metric tons
growth rate vs. GDP growth rate, %
BORSIG
ACHEMA
CHEMA
At the A th B13-E15
, Boo
Hall 9.1
BORSIG GROUP
Leading Technology for
Innovative Solutions
Reciprocating Compressors
acc. to API 618
Pressure Vessels and
Heat Exchangers
Membrane Technology e.g.
Emission Control Systems
Boilers and Power Plant
Technology
Industrial Services
Benzene
Toluene
Xylene
Year
Ethylene equivalent demand, %
GDP, %
1995
4,013
1,374
4,154
1995
4.3
2.0
1996
4,177
1,370
4,004
1996
2.1
2.7
1997
4,502
1,419
4,634
1997
3.1
1.6
1998
4,203
1,349
4,340
1998
–8.5
–2.0
1999
4,459
1,488
4,641
1999
5.0
–0.1
2000
4,425
1,489
4,681
2000
1.5
2.9
2001
4,261
1,423
4,798
2001
–2.7
0.2
For more information,
please contact:
2002
4,313
1,548
4,916
2002
–6.0
0.3
2003
4,551
1,584
5,213
2003
3.2
1.4
BORSIG GROUP
2004
4,758
1,634
5,395
2004
3.4
2.7
2005
4,981
1,676
5,570
2005
0.2
1.9
2006
4,874
1,633
5,727
2006
–0.9
2.0
2007
5,246
1,637
6,006
2007
0.4
2.4
2008
4,580
1,433
5,698
2008
–2.6
–0.7
Source: Ministry of Economy, Trade and Industry
Source: Ministry of Economy, Trade and Industry; Cabinet Office,
Government of Japan
Egellsstrasse 21
D-13507 Berlin/Germany
Phone: +49 (30) 4301-01
Fax:
+49 (30) 4301-2236
E-mail: info@borsig.de
www.borsig.de
A member of KNM Group Berhad
Select 164 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
TABLE 4. Profitability of
petrochemical segment of Japanese
chemical companies, billion yen
Sales
Operating
profit
Profit
on sales, %
FY*1997
2,506
49
2
FY1998
2,094
34
2
FY1999
2,297
91
4
FY2000
2,588
91
4
FY2001
2,398
8
0
FY2002
2,595
43
2
FY2003
2,748
65
2
FY2004
3,420
213
6
FY2005
3,963
175
4
FY2006
4,537
273
6
FY2007
5,274
211
4
Source: Ministry of Economy, Trade and Industry
The table reflect the petrochemical segment of 11 chemical
companies with ethylene crackers
* The Japanese fiscal year runs from April 1 to March 31 of
the next year.
In domestic investment, petrochemical
companies are focusing on propylene and
aromatics rather than on ethylene; because
these products are not produced by low-cost
ethane crackers located in the Middle East.
For propylene, in addition to metathesis
plants by Mitsui Chemicals and Nippon
Petroleum Refining companies, Mitsubishi
Chemicals is starting up metathesis plant
in the Kashima site. Several fluid catalytic
cracking projects are under way by major
oil refining companies.
In addition to large volume petrochemicals, Japanese petrochemical companies are
expanding businesses in value-added products both in Japan and other Asian countries, such as performance materials for IT
and electronics industries. Engineering
plastics are good examples for high-performance products. Japanese companies invest
in high-performance engineering plastics
Singapore–A global energy
and chemical hub
Julian Ho, Executive Director, Energy, Chemicals and Engineering
Services, Singapore Economic Development Board (EDB)
Singapore is a nation well-positioned to capitalize on the growth
in Asia-Pacific. Global economies are struggling to cope with the
present economic crisis driven by the confluence of the financial
industry collapse and falling demand. Singapore is no exception,
with its GDP growth easing from 7.7% in 2007 to 1.1% last year.
Nonetheless, the Singapore economy is resilient and well-positioned to weather the current challenges. The country has a strong
commitment to a well-diversified economy, where manufacturing
remains a key contributor to its GDP, and its domestic financial
strength arising from the government’s prudent fiscal management.
The energy and chemical industry is an essential pillar of Singapore’s economy. It has been the largest contributor to the country’s manufacturing output since 2006. In 2008, the industry’s
output grew to S$97 billion,* accounting for 39%* of Singapore’s
total manufacturing output.
Capitalizing on Asia’s growth story. While Asia has not
been unscathed by the current financial turmoil, the long-term
growth for this region remains intact, especially fueled by the
engines of China and India and increasingly the Association of
South East Asian Nations (ASEAN). Singapore, strategically located
in the heart of Asia, is uniquely positioned to play a critical role in
meeting this region’s longer-term energy and chemical needs.
*Refers to preliminary estimates of EDB and RSU Census and Surveys 2008
48
I APRIL 2009 HYDROCARBON PROCESSING
in Japan and in large-volume engineered
plastics in foreign countries. For example,
Polyplastics, Toray and Sumitomo Chemicals are expanding liquid crystal polymer
capacities in Japan. Toray, Tosoh and DIC
have and are expanding domestic polyphenylene sulfide capacities. Conversely, Polyplastics is planning to start up a polyacetal
plant in Malaysia. Mitsubishi Rayon, Asahi
Kasei Chemical and Sumitomo Chemicals
are investing in MMA plants located in foreign countries.
They are developing new technologies
in both processes and catalysts. To compete with low-cost producers, R&D efforts
for new product development and process
improvements are essential along with
timely capital investment. ■
www.sric-tokyo.co.jp
Building critical mass. One of Singapore’s strategies is to
anchor a critical mass of olefin capacity, which will allow the
country to capture greater value from a deepening and broadening
of chemistry chains. Shell and ExxonMobil are already constructing two world-scale liquid cracker complexes, slated to come
onstream in 2010 and 2011, respectively.
Developing high-value specialty chemicals. The two
projects will double Singapore’s ethylene capacity to 4 million tpy,
providing the critical feedstock mass needed to catalyze downstream
opportunities in specialties and advanced materials. Recognizing the
country’s commitment to moving up the value chain, Swiss chemical
giant, Ciba Specialty Chemicals, is using Jurong Island as a strategic
manufacturing base for its high-value-added specialty antioxidants.
Likewise, Evonik RohMax opened its first Asia manufacturing plant
in Singapore, producing high-performance VISCOPLEX lubricant
additives for its global markets. Dr. Klaus Engel, CEO and chairman of the executive board of Evonik Industries AG, summed it up
nicely, “By bringing world-class expertise and best practices closer
to customers here (Singapore), we can improve collaboration with
customers and partners to deliver innovative solutions.”
Seeding new firsts in technology. Apart from producing
higher-value-added products, Singapore aims to become the ideal
investment location for companies looking to debut proprietary
technologies. This includes the implementation of technologies
at a commercial level.
For one, the British firm, Lucite International has launched its
new alpha technology for methyl methacrylate (MMA) in Singapore. Mid-way across the globe, Japan’s Sumitomo Chemicals
has also built an MMA facility on Jurong Island. Together, both
companies enable Singapore to account for 10% of the global
MMA capacity and propel Jurong Island to become Asia’s leading
site for MMA production.
Think globally. Act responsibly.
Sabin’s precious metals recovery and refining
processes raise environmental protection to an advanced
state for safety and regulatory compliance. Your
advantage: assured peace of mind, and our promise
of maximum value returns from your precious metalbearing materials.
Learn more at sabinmetal.com
1MBUJOVNt1BMMBEJVNt3IPEJVNt3VUIFOJVNt3IFOJVNt(PMEt4JMWFS
Processing facilities and technical service offices in the Americas, Europe and Asia
Select 78 at www.HydrocarbonProcessing.com/RS
Efficiency
Improvements
EnergyManagement
An online Energy Watchdog that
assists you with the operation of your
utilities systems (steam, fuel,
electricity, etc.) to achieve minimum
cost within equipment and emissions
constraints. Generates energyͲrelated
KPIs (Key Performance Indicators).
Monitors imbalances allowing you to
keep track of leaks, measurement
issuesandchangesinthefield.Canbe
usedopenͲlooporclosedͲloop.
HydrocarbonManagement
HydrocarbonManagement
A Production/Yield Accounting system
that becomes the foundation for your
loss control initiatives. It assists you
with your daily sitewide mass balance
on a tankͲbyͲtank and unit level. A
discrete events simulator is also
available to check the feasibility of
your operations schedule including
your docks, tank yards, process units
andpipelines.
EffectiveSolutionsforPlantOperationsManagement
USA:+1(281)829Ͳ3322
Europe:+34(93)375Ͳ3503
LatinAmerica:+54(11)4555Ͳ5703
infousa@soteica.com;www.soteica.com
Select 165 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
product integration while enjoying
Transport
General
cost savings through
Precision engineering
manufacturing
engineering
shared third-party
10%
industries
9%
7%
utilities and services.
Biomedical
manufacturing
In support of the
8%
manufacturing activiElectronics
ties on Jurong Island,
27%
the Chemical Process
Technology Centre
(CPTC) was established to enhance
Chemicals 39%
manpower competencies needed by
Source: EDB RSU Census & Surveys 2008
the growing chemical industry. As the
Fig. 1. Singapore—2008 manufacturing output.
first training center
in the world to contain an industry-scale
Building R&D capabilities and creating knowledge. Singapore not only petrochemical process plant, CPTC allows
wants to play host to first-in-the-world trainees to access state-of-the-art technolotechnologies but also to become a creator gies and undergo comprehensive training
of technology. Instead of competing on in “live” plant operations. Likewise, the
costs, the small city-state differentiates itself similarly located Institute of Chemical and
with innovation and offers companies the Engineering Sciences is focused on improvbest value through holistic R&D packages. ing the science and technology base by proThese are composed of robust intellectual viding highly trained R&D manpower and
property protection regimes, superior infra- on developing technology and infrastrucstructure and strong capabilities to create ture to support future growth.
new knowledge from R&D. Leading companies such as BASF and Mitsui Chemicals Focusing on sustainability. As Sinhave located their corporate R&D centers gapore positions itself for the next growth
in Singapore, putting the chemical indus- phase in its energy and chemical industry,
try well on track in its vision of developing we are acutely aware of the pressing enviinnovative new products that can serve the ronmental challenges that confront us. Singapore aims to be a model of sustainable
Asian and global markets.
Research and innovation remain key development, focusing on resource optimipriorities during these difficult and uncer- zation and emissions management.
Going forward, Singapore aims to
tain times. Singapore’s long-term beliefs are
also shared by our foreign investors. These achieve self-sufficiency on Jurong Island
include 3M, which envisions growing Sin- through desalination and wastewater colgapore into a superhub—one that not only lection. Companies are also investing in
manufactures goods, but also conducts technologies, measures and facilities to
active R&D to deliver new product inno- increase energy efficiency. PowerSeraya, for
instance, is commissioning an 800-megavations to the market.
watts natural-gas-fired co-generation plant
Singapore’s advantage—Jurong by 2010 to replace its three oil-fired steam
Island. Singapore’s ability to move the units to reduce its total carbon footprint by
energy and chemical industry up the value an additional 10%.
chain is very much anchored on its strong
fundamentals and a key advantage that is Industry built on long-term
augmented by the industry’s centerpiece— growth. In the midst of present adversiJurong Island. This buzzing island is home ties lie great opportunities to grow Singato over 95 leading companies engaged in a pore’s energy and chemical industry. The
range of manufacturing activities in petro- long-term growth of Asia remains optileum, petrochemicals, specialty chemicals mistic, and Singapore will continue to be
and supporting industries. Its dedicated a strategic home for leading energy and
plug-and-play environment offers com- chemical companies to serve their regional
panies a unique world-class infrastructure and global needs. ■
characterized by a high level of integration.
Companies can create synergies through www.sedb.com
ACHEMA
2009
it is crucial in constructing low-income homes. PVC will be a part
of the Jose project in Eastern Venezuela.
Crude oil prices have fallen dramatically. Yet, Pequiven will
continue to pursue new projects over the next 5 to10 years.
Pequiven will provide investment opportunities for local and foreign partners. PDVSA has secured an investment fund for several
high-priority projects.
Political highlights. Since assuming the presidency in 1999,
Venezuela
Dr. Rina Quijada, CEO, IntelliChem, Inc.,
Coral Gables, Florida
Fig. 1 shows the quarterly 2006–2008 gross domestic product
(GDP) for Venezuela. During high crude oil prices, Venezuela’s
GDP reflected a healthy economy. First estimates indicate that
Venezuela’s GDP grew by 4.8% in 2008 as compared with 2007.
Meanwhile, economic growth exceeding 3% was reported
for South America in 2007, despite high energy prices. Brazil is
estimated to have increased its GDP by almost 5% in 2008; this
nation accounts for over 55% of total GDP in South America.
We anticipate 2009 will be a challenging and critical year for
South America. Most countries will experience the effects of the
global economic recession, and a weak US economy will limit growth
in the Americas. In South America, we expect limited capital investment, restricted financial liquidity and weak consumer confidence
levels, which will slow economic growth throughout this region.
Venezuela’s petrochemical industry continues to enjoy a competitive feedstock advantage in the region. No other country in South
America enjoys such a privileged feedstock position as Venezuela.
The nation’s petrochemical industry is expected to replace
imports while stimulating local industry. The current administration is trying to develop a petrochemical industry that will
increase supplies of locally produced products while also resolving
Venezuela’s rising social problems. The government is promoting
the fertilizer industry to support Venezuela’s agricultural sector. In
the housing sector, polyvinyl chloride (PVC) is a featured product;
Hugo Chavez has survived a coup, an oil strike and protest movements against him. Due to a recent referendum, he will now be
eligible for re-election in 2013. Chavez’s goal is to create a new
form of socialism in Venezuela.
High oil prices strengthened the Venezuelan economy, but lower
prices mean slower economic growth. Economic growth and political developments seem to go hand in hand. Lower regional growth
will impact future development of the petrochemical industry.
This region has the potential to become a major participant
in the global trade and production of petrochemicals. The availability of feedstocks and low prices makes investing in Venezuela’s
petrochemical industry more attractive.
However, there are cutbacks due to slowing economic growth.
In early March 2009, PDVSA announced plans to reduce its contracting by as much as 40% to adjust to lower oil prices. PDVSA
will not, however, cut spending on social development. The company plans to go ahead with investments of approximately $100
billion in many social programs scheduled for the final four years
of Chavez’s second presidential term (2009–2013).
Natural gas. Among the main countries in the region, Venezuela holds the largest natural gas (NG) reserves. An NG gas pipeline
from Colombia to Western Venezuela supports petrochemical
production on the west coast of Venezuela, near Maracaibo Lake
and El Tablazo (Fig. 2). At El Tablazo, NG production is associated
with crude oil production. This is why NG production is declining
in this region. Lower yields throughout the years have depleted
ethane supply into El Tablazo’s existing ethane/propane crackers.
Investment in exploration continues in Venezuela, and PDVSA
awarded exploration blocks to foreign companies including Chevron and Statoil in the Plataforma Deltana area, located off Venezuela’s northeast coast. Venezuela has an advantage over other
Venezuela GDP change, %
12
Amuay Cardon
10
El Palito
8
Caribbean sea
Pto. La Cruz
El Tablazo
Morón
6
Jose
Columbia
4
Venezuela
2
Refineries
0
IQ
IIQ IIIQ
2006
IVQ
IQ
Source: BVC
Fig. 1. Venezuela’s GDP, 2006–2008.
IIQ IIIQ
2007
IVQ
IQ
IIQ IIIQ
2008
IVQ
Petrochemical
complexes
Guyana
Brazil
Fig. 2. Current petrochemical and refining complexes in Venezuela.
HYDROCARBON PROCESSING APRIL 2009
I 51
Improve Plant
Profitability and
Maximise Your Site’s
Potential with KBC…
OpX – Energy Efficiency Initiative, European Refiner.
In the first phase, KBC conducted a review of the Mesoamérican hydrocarbon markets,
KBC holds a long-term working relationship with a client, which operates a
medium-complexity refinery along the coast of Romania. In an effort to improve the
performance and profitability of its operations, the refiner decided to undertake an
Energy Efficiency Improvement Initiative. The work consisted of:
Benchmarking of Refinery Energy Performance
Gap Analysis of Areas of Inefficiency
Fired Heater Assessment
Steam/Power System Modelling and Optimisation
Selective Process Unit Energy Optimisation, including:
- Selected Heat Integration (Pinch) Studies
- Process Unit Simulation (using KBC Petro-SIM™) and Optimisation
U Equipment-level Analysis (furnaces, turbines, exchangers, fouling)
U
U
U
U
U
After the analysis was complete, KBC presented recommendations to the client, and within
four months, the refiner reported that the benefits implemented and achieved amounted to
USD$4.3 Million/year. KBC was also able to help the client move from the 3rd quartile to
the 2nd quartile of energy efficiency among over 200 other refiners surveyed by KBC
around the world.
KBC has performed successful Operational Excellence (OpX) programs for clients around
the world in the areas of:
U
U
U
U
Operational Planning
Process Optimisation
Energy
HSE
U Reliability, Availability, & Maintenance
U Human Performance Improvement
U Software Solutions
For more information on how KBC can help you
achieve Operational Excellence, contact us at
AMERICAS +1 281 293 8200
EMEA +44 (0)1932 242424
ASIA +65 6735 5488
salesinfo@kbcat.com U www.kbcat.com
Select 82 at www.HydrocarbonProcessing.com/RS
ACHEMA
2009
countries within the region; yet, this nation’s NG reserves are
mostly located on the east coast.
Petrochemical industry. Venezuela can offer competitive
and abundant feedstocks to support significant petrochemical
expansions. Indeed, South America could become a key participant in the global petrochemical industry. However, large capital
investments and strong government support will be necessary.
Pequiven’s expansion program through 2015 aims to increase
production capacity from 11.5 million metric ton/year (MM mtpy)
to more than 36 MM mtpy. More important, the plan is to increase
methane gas use from 440 MMCFD to 1,278 MMCFD.
Pequiven expects to consolidate industrial developments at Jose,
revamp the Moron petrochemical site and add feedstock availability
at the El Tablazo petrochemical site. In a second phase, Pequiven
would like to tap into the resources that the Paraguana refinery may
offer. However, with current market conditions and financial and
credit limitations, we anticipate Pequiven will focus on revamping
existing facilities at El Tablazo and Moron. Projects that are already
underway will continue but at a slower pace (Fig. 2).
Major methane-processing projects at Jose will be the first to
come onstream. Meanwhile, Braskem will continue to work to
complete propane dehydrogenation unit as well as its polypropylene
(PP) unit. In parallel to this, Braskem will pursue an ethane cracker
at Jose. A world-scale ethylene and ethylene derivatives production
site is planned for Jose and the joint venture between Pequiven and
Braskem will continue to work to make this happen.
However, we must ask: Has Venezuela done enough to expand its petrochemical industry? There is no one simple answer. Efforts have been made
to expand Venezuela’s production capacity. But many issues have delayed
their completion. Nonetheless, there have been several good windows
Select 166 at www.HydrocarbonProcessing.com/RS
of opportunity to start up plants in Venezuela. The good news is that,
during upcoming difficult economic times, Venezuela will have another
At Jose, all production sites will continue to be JVs between
opportunity to emerge as a major player in global petrochemical trade.
Pequiven and local or foreign partners. Pequiven is a partner—
Venezuela currently has four production sites, as shown in Fig.
not the sole owner—of the production capacity at Jose. At the
2. The largest petrochemical site is El Tablazo, located on the west
El Tablazo, El Palito and Moron producing sites, Pequiven and
coast. However, the east coast has the greatest
PDVSA have majority ownership. The
potential for capacity expansion in the pet- TABLE 1. Venezuela selected
Paraguana refinery is expected to build
rochemical industry. The Jose petrochemical petrochemical projects, 2010–2015,
several large units. However, these projects
site is where most capacity expansion will thousand tpy
struggle to remain viable, and Pequiven is
occur. El Palito is a refinery with a reformer
re-evaluating costs.
Capacity
that feeds condensates and produces benzene,
For Venezuela, we do not anticipate new
Technology Shutdown Additional grassroots and large units coming onstream
toluene and xylene for local and sporadic El Tablazo
Kellogg
–250
export markets. Moron is mainly a fertilizer Olefins I
sooner than 2014. These units, when built,
production site to supply local demand. It Olefins III (a)
will be efficient world-class facilities that will
800
also has important ammonia and urea pro- LDPE (a)
help supply olefins and polyolefins to this
Basell
–80
300
ducing units as well as other fertilizers such HDPE (a)
region. These new units will also create jobs
Mitsui
300
as ammonium sulfate.
and replace imports with locally produced
Jose ethylene
Pequiven has several large petrochemical
resins. Once enough ethane and propane
Technip
1,100
projects under evaluation. Table 1 lists the Ethylene
is available to feed these new petrochemical
Basell
300
most relevant projects. The exact time frame to LDPE
units, we expect Venezuela to become a key
complete the projects in Jose, El Tablazo and LLDPE
participant in local and regional markets.
Ineos
400
Refineria de Paraguana is uncertain. Because HDPE
In the future, we expect ethylene crackers
Ineos
400
of market conditions and economic recession, PVC
in
Venezuela
to have a wider feedstock slate.
200
most projects in Venezuela are adjusting their
For example, at Jose, in eastern Venezuela, ethJose propylene
time schedules for completion.
ane/propane will continue to be the preferred
400
During 2008, two new joint venture (JV) Propane dehydro UOP
feedstock. Meanwhile, in the state of Falcon
Spheripol
400
companies between Braskem and Pequiven PP
on Venezuela’s western coast, a refinery-based
4,600
were created for developments at Jose. The Total Capacity (e)
petrochemical site is under evaluation. ■
projects are: Propilsur (propylene and PP) Remarks: (e) Estimates
Source: Intellichem, Inc.
and PoliAmerica (ethylene/polyethylene). (a) Considers CCO ethane available for El Tablazo’s expansion
www.intellichem.net
HYDROCARBON PROCESSING APRIL 2009
I 53
!
W 1: IED
O 00 IF E 3
N O 9 RT AT 071
C
E
IS C IFI 00
4
00 RT A
20 CE UQ
.
O
N
ACS Industries can set you free.
UNHAPPY with long lead times for response and product delivery? Don’t
trap yourself into thinking only one source is able to handle your requirements. ACS can replace almost any existing tray, regardless of original
manufacturer. With 70 years’ experience, we use
advanced 3-D modeling and CAD/CAM to design
and make a wide variety of trays and internals.
ACS Separations & Mass Transfer Products
14211 Industry Road • Houston • Texas 77053
TEL: 713-434-0934 or 800-231-0077 FAX: 713-433-6201
Select 76 at www.HydrocarbonProcessing.com/RS
YOU ARE FREE to choose the highest
quality and best price, delivery, and
engineering support. Call ACS Industries
for all your trays and internals.
E-mail: separations@acsind.com
www.acsseparations.com
ACHEMA
2009
United States
Dr. Thomas Kevin Swift, Chief Economist and Manag-
ing Director - Economics and Statistics, American Chemistry
Council (ACC), Arlington, Virginia, US
set the stage for inventory rebuilding as supplies wear thin. Data
collected by the American Chemistry Council (ACC) indicate
that, during the fourth quarter, end-use customers were consuming 5.4 billion pounds of major thermoplastic resins per month.
At that time, however, customers were purchasing only 4.5 billion pounds per month, suggesting a large drawdown of resin
inventories. At some point, customers will run out of inventory,
resulting in renewed orders. Consumer and business spending,
the ingredients of final demand, however, must rematerialize for
a sustained recovery to begin. Only after housing begins to recover
will an upturn in broader economy gain traction.
The severe contraction in the US economy has spread globally
with most of the world’s major economies either in outright recession or at least in the worst downturn in more than a generation.
Trade volumes have declined sharply, in part due to credit difficulties, but also due to an abrupt slowdown in demand worldwide.
The International Monetary Fund is now projecting world GDP to
contract for the first time since WWII (measured on an exchange
rate basis). Despite massive monetary interventions, unprecedented
global coordination and the proposed injection of nearly a trillion
in fiscal stimulus, the outlook remains uncertain.
Looking ahead, we expect the pace of the downturn to moderate as the recession reaches terminal velocity. A harsh first quarter
will be followed by moderate decline in the second quarter before
the economy reaches a trough and subsequently returns to a more
stable footing during the second half of the year. The massive
stimulus being injected into the US and other world economies
will generate demand and the virtuous cycle will kick in, and an
expansion will take shape during the second half of the year. We
expect GDP growth to contract by 2% during 2009 before growing by 2% in 2010 and 2.9% in 2011.
During the past several months, economic conditions have
deteriorated significantly. The recession, which officially began
in December 2007, deepened during the last few months of
2008 and into the beginning of 2009. We are currently witness
to a vicious cycle whereby anxious consumers stop spending,
retailers are left with unsold inventories and slow their purchasing. Then businesses throughout the supply chain cut back their
spending and lay off workers who then stop spending, fueling
the downward spiral. In this cycle, the combination of record
high oil prices, the decline of housing wealth, job losses and the
spectacular financial meltdown pushed consumers over the edge.
And if past experience with financial crises is any guide, this will
be a long and deep contraction. Already, this recession is longer
and deeper than the previous two. The US economy is currently
experiencing the worst downturn since at
least 1982 and, quite possibly, the worst TABLE 1. US business of chemistry growth outlook (by segment)
since the Great Depression.
% Change Y/Y
2004
2005
2006
2007
2008
2009
2010
2011
Total by segment:
4.2
3.5
3.0
1.4
–3.6
–4.5
1.8
2.2
Pharmaceuticals
0.5
4.0
6.3
3.3
0.7
–0.3
2.4
1.9
State of the economy. The US hous- Business of Chemistry Output
ing market, where the financial crisis originated, remains severely damaged. By the end
of 2008, home prices were off 25% from
their 2006 peaks. At this time, new home
construction is less, off over 80% from its
peak level. And automobile makers, after
posting their worst year since 1982, saw
light vehicle sales fall below 10 million units
in January ’09. These sectors are among the
most chemistry intensive, and thus, the
chemical industry has been especially hard
hit during this recession. Manufacturing
production was off 13% in January compared to a year ago.
Throughout the supply chain, businesses
are working off their inventories and, like
consumers, putting off making new purchases as long as possible. This has pulled
output down for manufacturers, but may
Chemicals, excluding pharmaceuticals
6.7
3.1
1.0
0.2
–6.3
–7.1
1.5
2.4
Consumer products
11.9
7.5
4.9
–3.8
1.0
–3.0
1.1
1.6
Agricultural chemicals
4.9
4.1
6.4
–7.4
–5.3
–3.6
0.3
3.1
Specialties
0.2
–1.5
–3.4
0.2
–3.4
–4.2
1.6
2.7
Coatings
6.0
–2.4
–5.9
–3.9
–6.5
–4.6
0.5
1.4
Other specialties
–2.5
–1.0
–2.2
2.2
–2.0
–4.0
2.2
3.3
8.1
2.7
0.5
2.7
–8.9
–10.0
1.6
2.2
Inorganic chemicals
–0.1
3.7
–3.4
2.9
2.8
–7.9
1.1
1.2
Bulk petrochemicals & organics
15.0
0.6
3.1
3.5
–12.6
–11.7
2.0
2.6
Plastic resins
7.6
9.2
–0.9
1.5
–11.6
–9.0
1.9
2.5
Synthetic rubber
–2.9
–1.1
–4.8
4.7
8.6
–7.8
0.7
1.3
Manmade fibers
–4.0
–10.0
–1.3
–4.9
–15.0
–7.8
–1.1
0.6
11.6
2.3
1.7
2.7
–11.9
–13.1
2.4
2.6
Basic chemicals
Addendum:
Petrochemicals & derivatives
HYDROCARBON PROCESSING APRIL 2009
I 55
ACHEMA
2009
Select 167 at www.HydrocarbonProcessing.com/RS
Optimize Your Process with MICROTHERM
Conventional Insulation
Equivalent Volume
• 7” of Ceramic Fiber over 6” NPS
• 138 °F Cold Face
• 465 BTU/ft•hr Heat Loss
•
•
•
•
®
3” of Microtherm MPS over 12” NPS
132 °F Cold Face (6 °F lower)
380 BTU/ft•hr Heat Loss (18% less)
Increased Production 400%!
1450 °F
Internal
Equivalent Personnel Protection
Equivalent Heat Loss
•
•
•
•
•
•
•
•
3” of Microtherm MPS over 6” NPS
127 °F Cold Face (11 °F lower)
228 BTU/ft•hr Heat Loss (51% less)
Save Space, Weight, & Energy!
1 1/4” of Microtherm MPS & Quilt over 6” NPS
187 °F Cold Face
451 BTU/ft•hr Heat Loss (3% less)
Minimize Space and Weight!
Microtherm - Truly the Best Performance at High Temperatures
MICROTHERM
®
Aerogel
Calcium Silicate
Ceramic Fiber
Mineral Wool
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
Thermal Conductivity (W/m-K) at 600 °C Mean
C1676 NEW
ASTM Standard
for Microporous
www.microthermgroup.com
Microtherm Inc.
+1 865 681 0155
Microtherm NV
+32 3 760 19 80
Nippon Microtherm +81 3 3377 2821
Select 168 at www.HydrocarbonProcessing.com/RS
56
0.160
Data Per ASTM
Testing Standards
State of US chemistry industry. As
with much of the manufacturing sector,
American chemistry has also experienced
the worst decline since the 1980s. In January, chemicals output was off by 10.4%
from a year ago (three-month moving average basis) and overall capacity utilization
rates dipped to under 69%, down 10%
from a year earlier. Excluding pharmaceuticals, chemicals output was off 16.1%,
with bulk petrochemicals and organics off
24.8% Y/Y and inorganic chemicals off
7.9% Y/Y. Looking downstream, the latest
data indicate that plastic resins output was
off 26.2% Y/Y and synthetic rubber was
down 7.0% from a year earlier. Manmade
fibers’ output was off 34.3% Y/Y.
Continuing pressures from shrinkage of
final domestic demand and from inventories (especially in the first half of the year),
coupled with soft export markets, indicate
a challenging environment. Recovery of
end-use demand will allow a recovery of
industry activity. For the whole of 2008,
output of US chemistry declined 3.6%
and we now expect chemicals output to fall
4.5% in 2009 before recovering to a 1.8%
gain in 2010, and a 2.2% gain in 2011.
The weak environment in 2009 will
be across-the-board, with every segment
of US chemistry experiencing challenges.
Looking at the details, petrochemicals
and derivative products (plastic resins,
synthetic fibers and manmade fibers) have
borne the brunt of the decline in final
demand (including exports) and inventory
de-stocking, with output falling 11.9% in
2008. In many ways, 2009 will represent
a mirror image of 2008, with soft activity
in the first half and firming in the second
half of the year. For the year as a whole,
this should result in a 10.6% decline in
the output of petrochemicals and derivative products. Based on the consensus
economic outlook, a recovery will emerge
in 2010 and improve in 2011. Although
inventory restocking will play a role within
this cyclical rebound (and sometimes lead
to accelerating activity), prospects are likely
for a tepid recovery, given the state of the
global economy.
A number of risks are present. Although
a synchronized global recession is occurring, a hard landing in China presents risks,
as do further blockage of credit and additional declines in asset values. These and
other sometimes unforeseen factors could
extend the recession and affect the demand
for chemistry. ■
www.americanchemistry.com
HPI VIEWPOINT
Lead or get out of the way
We do have choices in shaping our future energy market
JEFF D. MORRIS, Alon USA, Dallas, Texas
Jeff D. Morris is president and chief executive officer of Alon USA. Mr. Morris joined
the company when it was formed in August
2000 after Alon Israel Oil Co., Ltd. purchased
the downstream operations of Atofina Petrochemicals, Inc. (FINA). He oversees Alon
USA’s businesses, which include four refineries, pipeline operations, terminal networks,
asphalt production and branded fuel marketing activities.
Mr. Morris is a seasoned professional and
former FINA executive with more than 30 years of experience. In 1974,
he began his career with FINA and held technical positions in chemicals
and R&D, before assuming various managerial posts at the Big Spring
Refinery between 1982 and 1988. Mr. Morris became operations manager at FINA’s Port Arthur, Texas, refinery, and was later promoted to
refinery manager of the Big Spring Refinery.
Mr. Morris served as vice president of FINA’s Southwestern Business
Unit from 1995 to 1998 and vice president of the Southeastern Business
Unit from 1998 to 2000. He was responsible for the Big Spring Refinery
and the Port Arthur Refinery respectively, in addition to crude gathering
assets and marketing activities for both business units.
Mr. Morris is a graduate of Texas Tech University and holds a BS
degree in chemical engineering. An active alumnus, he has been recognized as a Texas Tech Distinguished Engineer and was presented with a
Distinguished Alumni award in 2008. Mr. Morris serves as a member of
the Academy of Chemical Engineers. He also holds 10 US and 6 foreign
patents in the field of polymer processing and production. In addition,
he is published on polystyrene in the Encyclopedia of Chemical Processing and Design.
time the data has been collected, the solution is obvious. So
let’s examine the facts. According to a very complete Argonne
National Labs study published in May 2005, on a well to wheels
per mile basis, most transportation systems with which we are
familiar emit about 20% less greenhouse gases (GHGs) or other
pollutants per mile than the gasoline transportation system. This
includes ultra-low-sulfur diesel, hybrids, compressed natural
gas (CNG) and E85 fuels. Thus, a straightforward approach
to reducing emissions from vehicles by 20% without affecting
our quality of life is to move away from gasoline transportation
systems to one of the above. These technologies already exist.
Obviously, this will require retooling of our auto sector and
refineries. But, we know how to do it, and I believe we should
be executing this solution rather than having it legislated or
regulated for us.
e have a choice: we can fret about what the Obama
administration and California have planned for us
or we can lead. As engineers and scientists, we know
how to solve this problem. We know how to provide the energy
our economy needs, how to reduce emissions substantially, and
maintain or even improve our quality of life. We are probably
better prepared to provide the solutions than anyone since we
know how the molecules work and how the steel works. Thus,
we can choose. We can spend our precious time and energies
analyzing and debating over why everyone else is wrong, or we
can spend that time, energy and talent developing and marketing a solution.
Electrical power. Regarding power generation, the facts are
also very clear. We are developing wind, solar and other alternative systems, but I have not seen a study yet that presumes these
systems will provide more than 25% of our future energy needs.
What will we do for the other 75%, especially if our requirements
for power grow via the gradual electrification of the light-duty
transportation fleet? The data is absolutely clear with regard to
GHG and other air emissions, there is no power generation system with the capability to fill this need that is cleaner than nuclear.
The nuclear waste disposal issue is real, but I believe this issue
pales in comparison to the advantages of nuclear power generation over other major power generation technologies such as coal
or natural gas (NG).
With regard to NG, it is the primary feedstock for our petrochemical industry. The petrochemical industry is critical to the
long-term reduction in GHG emissions. We need the insulating
products to make our buildings and homes more energy efficient and we need the strong, lightweight materials to make our
vehicles more energy efficient. We will need these products for
centuries, if not millennia. Is it smart public policy to actively
burn this valuable resource to move our vehicles or produce
our power when we have other viable alternatives? Coal can
and will be used to produce power simply due to its vast availability, although the environmental issues around this fuel are
very challenging.
First things first. The first thing we are taught as engineers
Batteries. Another breakthrough that I am convinced will
and scientists is to gather data. We must follow the facts. Many
times the most difficult part of solving a technical problem
is collecting accurate and sufficient data. Many times, by the
occur is in battery technology. We are making great progress and
are adding research dollars every year. These investments will be
rewarded, which will enhance our ability to produce relatively
W
HYDROCARBON PROCESSING APRIL 2009
I 57
HPI VIEWPOINT
low-cost electric light-duty vehicles and will significantly improve
the economics of wind and solar by allowing improved utilization of our electrical transmission systems. I believe all these facts
lead us to the conclusion that the crude refining sector will be
substantially different decades from now than it is today. But we
are making the investment choices today that will be operating
at that time. Much of the steel we are operating with today was
built decades ago, and it still has significant life left as long as we
properly maintain and upgrade it.
■ Transportation: We must retool our
auto sector and refineries to move away
from gasoline toward existing alternative
solutions such as clean diesel and hybrid
vehicles.
Power generation: Nuclear power and
battery technology are clean and efficient
solutions that will play a significant role
in meeting our future energy needs.
Investing for the future. I believe one of the best ways for
Select 169 at www.HydrocarbonProcessing.com/RS
58
I APRIL 2009 HYDROCARBON PROCESSING
us to lead today is to take the initiative in our investment decisions. I believe it is very clear that we will be required to retool
our refineries, thus as scientist and engineers it is critical that we
visualize and design the refineries of the future and communicate
that design to our constituencies. We must also convince those
who provide the investment capital to allow us to begin the execution of this retooling. Some already have and will be advantaged
because of their early start. I believe that the trend lines are pretty
clear. Crude oil will continue to be the basic feedstock for transportation fuels, gradually being reduced by electricity production from a variety of sources. This transition could be accelerated based on the pace of battery research. NG will trend more
toward producing lightweight, energy-efficient materials and will
gradually be utilized less and less as a utility fuel. Future crudebased fuels will tend to be denser, containing more carbon per
gallon and more hydrogen. Hydrogen injection technologies—
hydrotreating and hydrocracking—will be much preferred over
hydrogen-rejection technologies—catalytic cracking and coking.
Reforming will continue to be the major hydrogen transferring
mechanism to allow removal of hydrogen from the light portions
of the hydrocarbon mix, both crude and NG, for reinjection into
heavy portions of the hydrocarbon mix. The remaining carbon
heavy light hydrocarbons will most beneficially continue to find
their way into polymers to improve our energy efficiency. The
remainder will unfortunately likely be burned, creating electricity
and carbon dioxide.
I believe the data will support this type of future, assuming
nuclear energy is aggressively implemented, and new technologies
will allow us to substantially reduce our GHG emissions and will
maintain or improve our quality of life while using the technologies we possess today. HP
Select 79 at www.HydrocarbonProcessing.com/RS
THIS TIME,
SPEED AND
RELIABILITY
BOTH WIN!
Tunable Diode Laser Analyzers:
Fast and reliable!
SS2100 TDL Analyzer offers robust and
reliable measurements in seconds using
advanced diode laser technology. Our
analyzers have little or no consumables and
require minimal routine maintenance.
Industries
Refining
-
H2 Recycle - H2O / H2S
Fuel Gas - H2S
Flare Gas - H2S
Gas Processing
-
Raw Gas Feed – H2S / CO2
LNG Dry Gas Feed - H2O / H2S
Residue Gas / LNG - H2O / H2S
Olefins
Measures:
-
Select 56 at www.HydrocarbonProcessing.com/RS
Ethylene Purity - H2O / C2H2
Acetylene Converter - C2H2
Dry Cracked Gas - H2O
PETROCHEMICAL DEVELOPMENTS
SPECIALREPORT
Improve product ethylene separation
New high-capacity trays enable retrofitting existing splitter
superfractionator to expand unit capacity and conserve energy
A. BERNARD, Nova Chemicals (Canada) Ltd., Sarnia, Ontario, Canada;
W. DE VILLIERS, Shell Global Solutions, Houston, Texas, and D. R. SUMMERS,
Sulzer Chemtech USA, Inc., Tulsa, Oklahoma
T
he Nova Chemicals (Canada) Ltd. complex located in
Sarnia, Ontario, Canada, was recently revamped in 2005
to improve a previously upgraded C2 splitter tower performance. After careful examination of the existing design, desired
operation and future capacity, new high-capacity distillation trays
were chosen to replace older tower trays. This approach would
replace the internals at larger tray spacings with fewer trays. An
increase in tray efficiency was expected and required to achieve
the overall performance goal of the revamp. After a successful
installation, the unit was restarted and the desired performance
was achieved. This article presents the operating information for
the tower so that others may evaluate the performance, capacity
and efficiency of high-capacity trays in C2 splitter service.
Main condenser
Overhead
Vent
Reflux
Tray 1
1
Tray 9
Tray 10
Ethylene
Tray 80
Dilute ethylene
6
DA-2410
Tray 85
Vapor feed
Reflux drum
Tray 93
Tray 96
Tray 123
DA-2404
Side reboiler
Background. In 2001, Nova Chemicals wanted to upgrade the
Reboiler
55.0
54.5
Feed nozzle
54.0
53.5
53.0
Actual feed tray
52.5
52.0
5.4 %
51.5
51.0
50.5
50.0
70
75
85
80
Feed tray, from top of tower
90
95
Side Qr = 39 MMBtu/hr
Column PFD. This distillation tower has three main products;
polymer-grade ethylene, dilute ethylene and ethane recycle. There
is also a minor vent product taken off the top of the six tray vent
condenser tower. The polymer-grade ethylene is withdrawn nine
trays from the top of the C2 splitter and is used locally to make
polyethylene and styrene. The dilute ethylene is withdrawn from
tray 80 and was added to the C2 splitter in 1995 as a means to
provide extra capacity. The local styrene facility can accommodate
some of the low-grade ethylene. The ethane stream is the bottom
product and is recycled back to the furnaces for further cracking.
Ethane
Process flow diagram of Nova’s C2 splitter, with six
different tower sections.
FIG. 1
Bottom reboiler duty, MMBtu/hr
capacity of its ethylene cracker in Corunna, Ontario. They sought
a 25% increase in production.1 It was determined that the existing C2 splitter would be a bottleneck and that additional capacity
was needed. The existing trays had operated quite successfully for
more than 10 years. The 1989 revamp had increased the number
of trays in the C2 splitter from 125 to 153 to reduce the reflux
ratio, thus increasing capacity and purity. The greater number of
trays was achieved by placing the trays at very small tray spacings
(15 in.)2 To increase capacity required a device that provided even
higher capacity and, most importantly, greater tray efficiency.
Many different operating conditions and revamp scenarios
were explored. Ultimately, a revamp at larger tray spacing (for
most of the trays) would result in the highest potential capacity.
The final answer was to install new high-capacity trays back at the
old 20-in. tray spacing—a spacing height used before 1989. The
very bottom section would remain at 12-in. tray spacing and the
pasteurization section (the trays above the polymer ethylene draw)
would remain at their existing 24-in. tray spacing.
FIG. 2
Simulation results to determine the optimum feed point
and to conserve energy consumption of the main reboiler.
Fig. 1 shows the basic process flows for the C2 splitter with its
ancillary equipment.
A side reboiler removes excess heat from the unit’s charge gas.
Also, the vapor feed enters the tower well below the actual tray
that has the feed distributor. The feed enters the tower between
trays 91 and 92 and passes up through seven trays until it is disHYDROCARBON PROCESSING APRIL 2009
I 61
K T I C O R P : F I R E D H E AT E R S & S C R S Y S T E M S
World Leader in Fired Heaters and SCR Systems
ENGINEERING - FABRICATION - CONSTRUCTION
Fired Heaters:
SCR Systems:
Refinery Applications
Steam Reformers
Petrochemical Applications
OTSGs
Global E-3 Services
Gas Turbines
Heaters
Boilers
FCC Units
other fired sources
Please visit www.kticorp.com for a complete list of
our products, services & contacts.
KTI Corporation
1990 Post Oak Blvd., Suite 1000, Houston, TX 77056
Tel: (281) 249-2400 Fax: (281) 249-2328 E-mail: sales@kticorp.com
KTI - KOREA
#612, Kolon Science Valley II, 811, Guro-dong, Guro-gu, Seoul, 152-050, Korea
Tel: 82-2-850-7800 Fax: 82-2-850-7828 E-mail: BSKim@kti-korea.com
Select 96 at www.HydrocarbonProcessing.com/RS
PETROCHEMICAL DEVELOPMENTS
tributed above tray 85. This feed location is the optimum feed
point; it was determined by simulating the tower with varying
feed points and identifying those conditions that resulted in the
lowest energy requirements (see Fig. 2). From Fig. 2, the difference
in main reboiler duty was 5.4%, which translates into an overall
reboiler duty savings of 2.9%. Alternatively, this energy savings
can also be represented as extra capacity at the same duty.
Simulation. Simulations of this tower were performed with
a commercially available vapor liquid equilibrium (VLE) model
based on proprietary binary interaction parameters applied to an
SRK equation-of-state equilibrium model. Data used to determine the proprietary interaction parameters was taken from the
literature.3 This model was established in the late 1990s and is
calibrated to actual operating data from several C2 splitters. Based
on past experiences, the overall tray efficiency of 80% could be
achieved with the new high-capacity trays with this model.
SPECIALREPORT
The high-capacity trays used are composed of multiple sloped
and truncated downcomers with active areas between. The prominent feature of the trays is its long weir length, which enables high
liquid loaded systems (such as C2 splitters) to operate at reduced
weir loading and to achieve much higher capacity than conventional multi-pass trays. The other prominent feature is a defined
flow path length that enables the tray to get flow path enhancement and higher tray efficiency.4 Fig. 6 illustrates the full layout
of the trays (tray 93) for the C2 splitter at Nova.
Small fixed valves. These devices are new. However, small
hole sieve trays have been known for years to provide higher
capacity than trays with larger holes. Therefore, the corollary
with fixed opening valves made sense for this application. These
fixed opening devices with smaller opening, provide for a much
“calmer” froth on the tray decks and providing more tray vapor
capacity over much larger devices. This “calmer” lower average
froth height provides these trays with improved vapor capacity.
Tray design. The process flow diagram (PFD), as shown in Fig.
1, has six different tower sections. In reality, there are seven tower
sections when one accounts for the separate design of the trays
with the feed-duct work going through them.
Each of the tray sections identified in Table 1 resulted in different tray designs. Needless to say, this was a complex tray design with
each section optimized for capacity and maximum tray efficiency.
To maximize capacity and efficiency, several unique features were
applied. This included applying very small fixed valves on the tray
decks along with push valves, downcomer enhancing devices and a
lip-slot design. Fig. 3 shows the use of all four devices on one tray.
TABLE 1. Tray sections.
Section
Tray Nos.
Tray spacing, in
1
Pasteurization
1–9
24
2
Above dilute ethylene draw
10–80
20
3
Above feed
81–84
20
4
Below feed (with duct)
85–91
20
5
Below feed (without duct)
92–93
18
6
Between side reb. draw and return
94–95
15
7
Below side reboiler
96–123
12
FIG. 3
Push valve, small fixed valves and lip-slot are utilized on
one tray to maximize efficiency and eliminate stagnate
zones of liquid on the tray.
Push valves. These devices have been around since the early
1970s.5 They are needed to push tray liquid in directions that the
liquid would ordinarily not prefer to go. These valves are used to
enhance liquid movement close to the vessel wall. The intent is
to maximize tray efficiency by eliminating potentially stagnant
zones on the trays.
Downcomer enhancement devices. These devices are
added to the tops of the downcomers to enhance liquid handling
capacity. The vanes that are the integral part of these devices provide a mechanism by which heavier liquid can be drawn off the
tray more easily near the outlet weir. This then allows the center
vanes to handle the lighter froth/spray and provides a “chimney”
for escaping vapors to physically bypass the heavy liquid. This
enables increased downcomer liquid handling and higher entrance
velocities for systems prone to downcomer choking.
Lip-slot design. This feature not only helps ease installation of
distillation trays, but it also enables close spacing of the tray deck
openings. A sufficiently large open area keeps tray pressure drop
and downcomer backup within design parameters. This feature
enables adjacent tray decks to lock together tightly once they are
placed horizontal to one another thus eliminating the need for
time-consuming threaded fasteners.
FIG. 4
Welding of new support rings old ring stubble.
HYDROCARBON PROCESSING APRIL 2009
I 63
SPECIALREPORT
PETROCHEMICAL DEVELOPMENTS
FIG. 5
Downcomer wedge clamp and lip-slot application on new
high-capacity tray for C2 splitter.
FIG. 6
Full tray assembly during trial layout at the shop—Tray 93.
FIG. 7
Vapor feed sparger and methanol injection piping at tray
85 within C2 splitter.
FIG. 8
Vapor feed ducts through the trays.
Installation. Installing these trays took considerable time,
especially with all the complexities of changing the trays spacing
back to their original locations. As seen in Fig. 4, it was not easy
to place new support rings where old ring stubble and ring segments were located. From vessel entry to final manhole closure,
the installation time was 35 days. To expedite installation, two
features were incorporated into the tray design. These were lipslot decks and wedge clamp downcomer attachments. The lip-slot
design was described earlier. The wedge-clamp downcomer attachments (Fig. 5) enabled the deck/downcomer attachments to be
accomplished in half the time of threaded fasteners.
Each tray was crated individually, and the tower had an elevator attached. Both factors minimized downtime, thus enabling the
tower revamp to not be the critical bottleneck of the shutdown.
Feed piping/internal duct work. The vapor feed to this
tower is unique; it passes upward through seven trays in two ducts
before it is distributed above tray 85. It was not straightforward
to determine how best to get this feed to pass through the trays
without impacting the capacity, performance and structure of the
affected trays. It was ultimately decided on sending the vapor up
through the tray panels with ducts and then dispersing the vapor
with an “H” pipe sparger—see Figs. 7 and 8. The two ducts each
have a cross-sectional area of 0.55 ft2, and the velocity in each one
is 34.3 ft/sec at design. Along with the feed, there is an associated
64
I APRIL 2009 HYDROCARBON PROCESSING
2-in. methanol injection line. This line comes into the tower at
the same elevation as the feed and is intended to be dispersed in
the tower at the feed point. This small piping also passes through
the trays and can be seen in Fig. 7. Methanol injection breaks the
hydrates that can form in this cold tower if water is present.
Operation. In October 2006, one year after installation, we
had the opportunity, and a light enough feedstock, to examine
tray capacity and efficiency. The feed to the unit was not up to
maximum design because the revamp of the furnaces was not
completed. However, the feed to the available furnaces had sufficient light material to artificially load the tower up internally. It
was important to Nova to know how much capacity the new trays
could support when the revamped furnaces came online.
A performance test was planned for the week of Oct. 15, 2006.
The side reboiler was limited by the charge gas available. So the only
way to increase internal loads was by increasing the main (bottom)
reboiler duty. The advanced process control (APC) algorithm on this
tower can manage three major products at one time. The test runs
were conducted using the APC and operating the tower semi-manually within the constraints of the APC. The test program was designed
to “push” the operating limits of the tower. The APC program was
set to give progressively tighter purities for polymer-grade ethylene
while holding the bottom product purity. The APC program accom-
K T I C O R P : R E VA M P G RO U P
Fired Heater
Global
E-3
Services
EVALUATE - ENGINEER - EXECUTE
FIRED HEATER STUDIES
ENGINEERED REVAMPS
EMERGENCY REBUILDS
CONSTRUCTION SERVICES
REPLACEMENT PARTS
KTI Corporation
1990 Post Oak Blvd., Suite 1000, Houston, TX 77056
Tel: (281) 249-2400 Fax: (281) 249-2328 E-mail: sales@kticorp.com
KTI - KOREA
#612, Kolon Science Valley II, 811, Guro-dong, Guro-gu, Seoul, 152-050, Korea
Tel: 82-2-850-7800 Fax: 82-2-850-7828 E-mail: BSKim@kti-korea.com
Please visit www.kticorp.com for a complete list
of our products, services, and contacts.
Select 97 at www.HydrocarbonProcessing.com/RS
SPECIALREPORT
PETROCHEMICAL DEVELOPMENTS
TABLE 2. Raw operating data
Time
Date
9:00 AM
2:30 PM
3:00 PM
11:30 AM
10/17/2006 10/17/2006 10/18/2006 10/19/2006
control of the tower. We will examine Oct.
19’s data more carefully.
2T-458
°C
–12.3
–12.3
–12.5
–13
Data reduction. The first step was to
check the overall material balance around
the vessel. Using Oct. 19 data (see Table
2), one can calculate the material balance
within 0.3% as shown here:
Feed pressure
PIC-402A
psig
340
340.4
340
340
Feed
100.00
Mlb/hr
Upper Delta-P
2PDI-408
psi
8
8
8.1
8.8
Bottoms
-21.14
Mlb/hr
Lower Delta-P
2PDI-409
psi
1.8
1.7
1.7
1.8
Vent
-0.50
Mlb/hr
Bottom flowrate*
FIC-454A
Mlb/hr
20.74
20.81
21.03
21.14
Dilute ethylene
-6.28
Mlb/hr
2T-465
°C
–5.01
–5.01
–5.72
–6.28
Ethylene product
-71.85
Mlb/hr
0.23
Mlb/hr
C2 splitter DA-2404
Item description
Tag no.
Units
Value
Value
Value
Value
Feedrate*
2FI-409
Mlb/hr
100
100
100
100
Feed temperature
Bottom temp
Top pressure
PIC-409
psig
274.1
273.8
269.9
270
Reflux flow*
2FIC-417
Mlb/hr
337.52
341.89
340.48
348.57
Reflux temperature
2TI-468
°C
–32.8
–32.8
Vent Flow*
FIC-420
Mlb/hr
0.51
0.51
Vent temperature
2T-469
°C
Side reb. flow*
FIC-416
Mlb/hr
88.55
89.40
–20.9
Next, we estimated the compositions of
the
various streams. Two samples of the feed
0.51
0.50
stream were collected during the week (Table
–43.4
3). From this and knowledge of the feedrate
89.23
91.66
and vent rate, we estimated the vent com–22.1
–22.9
position. This was 3.7 mole % hydrogen,
–18.8
–20.5
0.014 mole % CO and CO2 combined, and
26.82 mole % methane, with the remain6.04
6.28
der being ethylene. The bottoms stream was
71.76
71.85
also adjusted to make the heavies in the feed
71.49
71.39
match the feed composition. The polymer–29.9
–29.9
grade ethylene product and dilute ethylene
164.1
102.3
product compositions were known and are
114.4
114.1
listed in Table 2. These four streams were
added together to establish the feed compo0
0
sition for the tower simulation.
0.66
1.67
Table 4 summarizes the simulation results.
20.8
19.2
The simulation was conducted by varying
127.28
131.54
the tray efficiency in the simulation program
16.48
14.36
until the reflux rate was met. We were also
79.91
79.8
able to check the heat balance around this
tower. We checked the vent condenser with
5.47
5.36
the third stage ethylene flowrate—the cooling medium for this exchanger. This liquid
ethylene flowrate was 14,060 lb/hr at a temperature of –38.1°C and
a pressure of 383 psig. This liquid flashes down to a pressure of 103
psig providing 2.1 MMBtu/hr of cooling. The simulation shows the
vent condenser to be doing 1.92 MMBtu/hr which is within 9%.
2T-459
°C
–21.1
Side reb. return temp.
2T-460
°C
–18.3
–18
Dilute ethylene draw*
2FI-4107
Mlb/hr
5.78
5.85
Ethylene draw*
2FI-418
Mlb/hr
70.70
71.81
Ethylene draw*
2FI-426
Mlb/hr
70.47
71.46
Ethylene draw temp.
2TI-470
°C
–29.4
–29.4
Ethylene product - ethane
AI404:1A
ppm
251
192.4
Ethylene product - methane
AI404:1B
ppm
121.4
119.4
Ethylene product - acetylene
AI404:1C
ppm
0
0
Bottom product - ethylene
AI302:3A
%
0.56
0.49
Dilute ethylene - ethylene
AI437-1
%
21.6
21.1
C3 to EA-2412A/B*
2FIC-507
Mlb/hr
126.79
128.08
C3 temp to EA-2412A/B
2T-556
°C
13.09
14.36
C3 press to EA-2412A/B
2PIC-512
psig
79.87
79.83
Ethylene refrig to EA2409*
FIC-606
Mlb/hr
*All flows adjusted to a 100 Mlb feed basis to mask the true capacity of the unit
TABLE 3. C2 splitter feed
samples laboratory results
(balance is ethylene)
modated these changes
from the original 500
ppm ethane in ethylene
purity to 100 ppm.
Component Oct. 16 Oct. 19 Molar units
Data was collected
Hydrogen
190
224
ppm
over several days, as
Methane
1620
1627.1
ppm
listed in Table 2, which
CO
0.3
0.05
ppm
shows four sets of raw
data. With each proCO2
0.0
0.8
ppm
cessing change, the
Acetylene
0.0
0.0
ppm
APC would need about
Ethane
20.0
19.8
%
two to three hours to
Propane
63
45.6
ppm
stabilize the tower,
Propylene
2325
1965.6
ppm
which is very fast for
916
912.3
ppm
C4+
such a large tower. We
waited an additional
three to four hours before recording information and grabbing
samples. Every data set taken resulted in excellent tray efficiency.
Only on the very last day with the 100-ppm purity specification,
we were able to get the APC to push the main reboiler to a perceived drain-pot constraint maximum and still maintain steady
66
I APRIL 2009 HYDROCARBON PROCESSING
–33.6
110
100
Tray efficiency, %
Side reb. draw temp.
–33.3
Difference
90
Observed reflux rate-79% eff.
80
70
60
50
300
350
400
Reflux rate*, Mlb/hr
400
*Based on Mlb/hr feed
FIG. 9
Tray efficiency sensitivity at varying rates and reflux rates.
PETROCHEMICAL DEVELOPMENTS
TABLE 4. Heat and material balance
TABLE 5. Observed and calculated
pressure drop at various C2 splitter
sections
Oct. 19, 2006 operation simulation results
C2 splitter and vent condenser tower
Pressure drop
per tray, mmHg
Section pressure
drop, mmHg
Feed
Vent
Ethylene
product
Dilute
ethylene product
Ethane
bottoms
0.0016%
0.26%
0.21 ppm
0
0
1–9
4.11
37.0
3.39
240.7
3.33
13.3
35.0
Composition: wt%
Hydrogen
SPECIALREPORT
Trays
CO2
0.0001%
0.0006%
0.0002%
0.61 ppm
0
10–80
Methane
0.091%
14.45%
0.007%
0.007%
0
81–84
Ethylene
77.77%
85.28%
99.98%
80.44%
1.55%
85–95
3.18
Ethane
21.66%
0.0002%
0.0109%
19.56%
96.17%
96–123
2.05
Total
Propylene
0.291%
0
0
0.002%
1.37%
Propane
0.0071%
0
0
0
0.033%
Isobutane and heavier
0.187%
0
0
0
0.88%
Total
100,000*
588
71,853
6,292
21,265
Phase
Vapor
Vapor
Liquid
Liquid
Liquid
Temperature, °C
–13.0
–43.4
–29.8
–26.1
–7.0
340
250
270.5
276.2
279.7
Pressure, psig
DA-2410 condenser pressure
250
Psig
DA-2410 top pressure
251
Psig
DA-2404 condenser pressure
269.9
Psig
DA-2404 top pressure
269.9
Psig
Vent condenser duty**
0.73
MMBtu/hr
Condenser duty**
49.87
MMBtu/hr
Reboiler duty**
23.18
MMBtu/hr
Side reboiler duty**
13.17
MMBtu/hr
Reflux rate to DA-2410*
4,730
lb/hr
DA-2410 reflux temperature
–43.4
°C
DA-2410 top temperature
–36.1
°C
Vapor rate to DA-2410*
5,318
lb/hr
DA-2404 reflux rate*
349,370
lb/hr
DA-2404 reflux temperature
–33.7
°C
DA-2404 top temperature
–30.4
°C
*All Flows adjusted to a 100-Mlb feed basis to mask the true capacity of the unit
**All duties adjusted to a 100-Mlb feed basis
The main reboilers have a propylene vapor flowrate of 345,300 lb/
hr at a temperature of 14.36°C and a pressure of 79.8 psig. Condensing these vapors yields a reboiler duty of 57.7 MMBtu/hr. The
simulated main reboiler duty is 60.66 MMBtu/hr, which is 5%
above the observed. This is an excellent heat balance.
tray efficiency of the new high-capacity trays
over the entire C2 splitter (except the pasteurization section) must be greater than 75.1%.
Typically, the tray efficiency in the rectification
section of such a tower is higher than in the
stripping section by about 3% to 5%. Since
no side samples could be taken, there is insufficient information to determine the tray efficiency in the various sections of this tower, and
we are left with good overall tray efficiency.
We believe that there is more than enough
information provided here that people could
simulate this data with their own models to
determine the tray efficiency. This would
enable readers to calibrate their VLE models
for such trays in C2 splitter service.
Tray capacity. The Oct. 19th data had
the highest duties and reflux flowrate. This
would yield the highest internal loads to
verify that the trays are capable of handling
future capacity when the new furnaces are
brought online. Based on the heat and material balance in Table 4, internal loads and
physical properties were generated for each
tray. These loads were applied to the tray
design resulting in operating points as shown in Figs. 10–13.
From these charts, you can see that the internal loads are very
250
200
Vapor, cfs
Tray efficiency. The resulting tray efficiency is 78.8%. We had
hoped for a value as high as 80% during design. But this value
is satisfactory and it is well above the minimum predicted value
needed to ensure that product qualities are met. We performed a
sensitivity study to examine if a small inaccuracy in the reflux rate
or the heat balance around this tower would have a severe effect
on the value of the tray efficiency.
The tower was simulated repeatedly with different tray efficiencies,
and the resulting reflux rate was then plotted in Fig. 9. By examining
this plot carefully, one can easily see that tray efficiency is not very
sensitive to the reflux rate. For example, the error in heat balance is
potentially 3 MMBtu/hr, based on reboiler duty. A 3 MMBtu//hr
change in condenser duty translates into a reflux rate change of only
21,000 lb (at a latent heat of 143 Btu/lb). The tray efficiency needed
to match this reflux rate is still high at 75.1%. Therefore, the average
57.4
383.4
150
100
80% froth backup
80% hydraulic flood
0.3 in. H2O dry drop
80% DC-Vel
0.8 gpm/in.
Design
Operation
50
0
0
FIG. 10
1,000
2,000
3,000
GPM
4,000
5,000
6,000
Tray hydraulics for Trays 1–9, pasteurization.
HYDROCARBON PROCESSING APRIL 2009
I 67
SPECIALREPORT
PETROCHEMICAL DEVELOPMENTS
250
200
200
150
150
100
Vapor, cfs
Vapor, cfs
250
80% froth backup
80% hydraulic flood
0.3 in. H2O dry drop
80% DC-Vel
0.8 gpm/in.
Design
Operation
50
FIG. 11
1,000
2,000
3,000
GPM
100
50
0
0
80% froth backup
80% hydraulic flood
0.3 in. H2O dry drop
80% DC-Vel
0.8 gpm/in.
Design
Operation
4,000
5,000
0
6,000
0
Tray hydraulics for Trays 10–84, above feed point.
FIG. 12
close to the original design and even higher for the bottom sections.6 The high-capacity trays demonstrated that they could easily accommodate the original design loads without flooding.
Tray pressure drop. The observed pressure drop across the col-
umn on Oct. 19th was 10.6 psi. This pressure drop is measured with
two localized pressure measurements and the values are subtracted at
the control room. The calculated pressure drop is listed in Table 5.
This pressure drop of 383.4 mmHg (or 7.41 psi) does not
include the vapor head on each tray. There is approximately 185 ft
68
1,000
I APRIL 2009 HYDROCARBON PROCESSING
2,000
3,000
GPM
4,000
5,000
6,000
Tray hydraulics for Trays 85–93, below feed point.
of height between the top and bottom pressure taps. This elevation
has a gas head of 83.6 in. of water, assuming a vapor density of 2.35
lb/ft3. This equals 3.02 psi. When added to 7.41 psi, the total pressure drop is 10.4 psi, which is within 2% observed value. HP
1
2
LITERATURE CITED
Bernard, A. and R. Hayden, “Planning and Designing the Modernization
of the Recovery Area of a Flexible Cracker,” AIChE Spring Meeting, New
Orleans, Ethylene Producers Conference, April 2004, unpublished.
Summers, D. R., S. T. Coleman and R. M. Venner, “Ethylene fractionator
Select 170 at www.HydrocarbonProcessing.com/RS
PETROCHEMICAL DEVELOPMENTS
6
250
90% froth backup
80% hydraulic flood
0.3 in. H2O dry drop
80% DC-Vel
0.8 gpm/in.
Design
Operation
175
150
Vapor, cfs
125
100
25
0
0
FIG. 13
5
ACKNOWLEDGEMENT
Revised and updated from an earlier presentation at the AIChE Spring
National Meeting, Distillation Symposium, April 24, 2007, Houston, Texas.
(Canada) Ltd. He has over 20 years of experience in plant operations and process design. He holds BS and MS degrees in chemical
engineering from l’École Polytechnique de Montréal in Canada.
He is a registered professional engineer in the province of Ontario
and Québec in Canada.
50
4
Summers, D. T., “Performance Diagrams – All your tray hydraulics in one
place,” AIChE Annual Meeting, Austin, Texas, Distillation Symposium-Paper
228f, Nov. 9, 2004, unpublished.
André Bernard is a process engineer with NOVA Chemicals
75
3
SPECIALREPORT
1,000
2,000
GPM
3,000
4,000
Tray hydraulics for Trays 96–123, bottom trays.
revamp results in 25% capacity increase,” Oil & Gas Journal, Aug. 10, 1982
pp. 52–56.
Barclay, Flebbe and Manley – “Relative Volatilities of the Ethane-Ethylene
System from Total Pressure Measurements,” Journal of Chemical Engineering
Data, Vol. 27, pp. 135–142, 1982.
DeVilliers, E., P. Wilkinson and D. Summers, “Developments in Splitter
Revamps,” AIChE Spring Meeting, New Orleans, Ethylene Producers
Conference, April 2004, unpublished.
Summers, D. T., “Push Valve Experience on Distillation Trays,” AIChE
Spring Meeting, Atlanta, Distillation Symposium – Session 4, April 12, 2005,
unpublished.
Daniel R. Summers, P.E., is the tray technology manager
for Sulzer Chemtech, USA at their Tulsa, Oklahoma facility. He has
been involved with separations ever since he graduated with a BS
degree in chemical engineering from the University of Buffalo in
1977. He has also worked for Union Carbide, Praxair, UOP, Stone
& Webster and Nutter Engineering. Mr. Summers has been involved in the design,
operation, and troubleshooting of all forms of tower internals in the hydrocarbon,
ethanol, specialty chemical, refining, air separation and natural gas industries. He is
a registered professional engineer in the states of New York and Oklahoma and the
chair of FRI’s Design Practices Committee.
Waldo de Villiers is a distillation specialist with Shell Global
Solutions (US), in Houston, Texas. He has 20 years of fractionation
and extraction experience with Shell Global Solutions and Sasol.
He holds BS and MS degrees in chemical engineering from the
University of Stellenbosch, South Africa. He is a member of the FRI
Design Practices Committee.
Select 171 at www.HydrocarbonProcessing.com/RS
HYDROCARBON PROCESSING APRIL 2009
I 69
Spray
Nozzles
Spray
Control
Spray
Analysis
Spray
Fabrication
Spray Injector Solutions
Improve Performance, Extend Service
Life and Reduce Maintenance
We have dozens of ways to help optimize the performance of your spray injectors,
quills and spool pieces. Here are just a few:
U Assistance with nozzle selection and injector placement in the gas stream –
critical factors to application success
U Validation using 3D modeling capabilities and spray testing in our labs
based on your operating conditions ensure performance goals are met
U Recirculating, air- or liquid-cooled, multiple nozzle designs and more
to meet any quality standard or extreme engineering requirement
U Retractable, flexible and multi-directional designs are available
to minimize maintenance and service interruptions
Learn More at spray.com/injectors
Visit our web site for helpful literature on key considerations in
spray injector design and guidelines for optimizing performance.
Our solutions include injectors for:
U Distillation columns
U Regenerator bypass
Computational Fluid Dynamics
(CFD) is often used to help fine
tune injector performance
requirements and placement
U FCCU water wash
U Fractionator water wash
U Pollution control equipment
U Steam quench
U And more
In the US and Canada: 1-800-95-SPRAY | 1-630-665-5000 | spray.com | info@spray.com
Select 62 at www.HydrocarbonProcessing.com/RS
PETROCHEMICAL DEVELOPMENTS
SPECIALREPORT
Reevaluate your process
safety systems for hazardous
material storage
How safe is ‘safe enough’ when it comes to managing potentially risky
processes in chemical plants?
M. P. SUKUMARAN NAIR, Travancore Cochin Chemicals Ltd., Cochin, India
M
uch public concern exists over hazardous material bulk
storages at vulnerable locations. This concern has grown
into alarming proportions after the “Bhopal” incident.
Considerable improvements have occurred in almost all aspects
of the design, construction, operation, maintenance and troubleshooting, risk assessment and mitigation from bulk storage units.
By applying inherent safety methods in conjunction with modern
instrumentation and renewed operating philosophy, these units
now operate under a higher degree of safety and reliability.
Response plans. Competent emergency management and
response plans are also in place to handle emergency situations
that may arise under the remotest probability. In this article, we
trace developments for increasing process safety and addressing
public concerns and risks to neighboring communities. The case
discussed here is a port-based refrigerated atmospheric pressure
ammonia storage tank that stores and handles large quantities of
imported ammonia for fertilizer manufacturing.
Safety is No. 1 priority. Global governments remain focused
on potential industrial accidents in response to loss of lives and damage to property and environment. Such incidents adversely affect
society and cause heavy economic strain. Along with the growth of
the processing industry, problems linked to industrial accidents pose
a big question with regional and global implications.
Efforts are underway to minimize the damages and to ensure
safer working environments around industrial installations.
Experiences from accidents have educated the petrochemical
industry about the price of process safety. Safety is now considered a profit center, key to employee morale and vital for the
facility’s public image.
Growth and development of the processing industry is not
deterred by occasional mishaps. At the same time, the lessons
from past accidents urge plant operators to continue efforts that
improve safety standards and enhance public perception of the
industry. Incidents such as Flixborough, Sevaso, Bhopal, Chernobyl, North Sea and recently Toulouse, have taught lessons
on where we (the petrochemical industry) stand on achieving
an accident-free operating environment; what direction is the
industry prepared to follow, and what commitments are needed.
Especially in the matter of process safety, Murphy’s Law holds
true, and it provides the impetus for continuous research and
improvement to identify and overcome hidden potential risks in
the petrochemical industry.
Safety is everyone’s concern. Safety and environmental
concerns are often shared by public interest groups, who lead to
outcries, initiate litigations, and in certain cases, even cause closure
of industrial units. Losses from plant closures can be enormous.
Accordingly, it is in the best interest of the industry and the community to develop dialogues that address conflicts between these
groups. This may seem to be a simple solution; however, it is very
difficult to practice. More often, a cultural change is needed to
understand and to effectively address the community’s right to know
and the government’s concern on public health and safety. Efforts
should be organized from the industry’s viewpoint to help the public
understand what is happening within the processing facilities and to
effectively communicate the risks from such operations.
Major industries have a specific role in building public understanding as a first step to enhance confidence and to facilitate a
better, realistic perception about industry by the community. At
the state level, efforts should organize effective mechanisms to
ensure public safety through well-defined policy programs and
Factors causing accidental releases
14%
1%
11%
43%
5%
Mechanical failure
Operational error
Design error
Natural hazards
Industrial accidents
Sabotage/arson
Unknown
5%
21%
FIG. 1
Contributory factors to accidental releases in the
hydrocarbon–chemical industries.
I
HYDROCARBON PROCESSING APRIL 2009 71
SPECIALREPORT
PETROCHEMICAL DEVELOPMENTS
TABLE 1. Risk levels—frequency and severity
Frequency
potential event. Once it happens, it is irreversible. So, prudence
dictates taking positive action.
Risk level
Descriptor
Occurrence
The ammonia tank. The 10,000-metric ton (mton) double-
5
Frequent
1/year
4
Probable
1/10 years
3
Occasional
1/100 years
2
Remote
1/1,000 years
1
Improbable
wall, double-integrity refrigerated atmospheric ammonia tank
was built as per API Code 620 including Appendix R in 1976.
This tank receives imported ammonia consignments for the
phosphatic fertilizer plants of FACT at Ambalamedu, located
30 km from the Cochin Port. The tank is 41.6 m in diameter
and is 17.4 m tall. Thickness of the bottom plate is 5 mm and
thickness of the annular plate is 8 mm. The inner cup shell consists of six courses with design thickness varying from 8 mm to
11.2 mm. The outer shell consists of 14 courses, and the design
thickness varies from 5 mm to 22 mm. The roof is constructed
with built-up support beams in the spherical segments and with
connection between the roof plates and beams. The thickness of
the roof plate is 5 mm. The outer tank is anchored to a reinforced
concrete foundation with tie rods.
During the construction phase, while the tank was hydraulically tested at a water load of 8,000 mton, 6 piles (among 217)
in the outer row, were found to be cracked. A detailed investigation was done by the Central Building Research Institute, and a
thorough rectification was done. Subsequently, the water-load test
was conducted at a maximum of 10,000 mton, plus 1,600 mton
of over-pressure loading. Thus, the tank was tested at a water load
of 11,600 mton after the repairs. The differential settlement was
found to be within acceptable limits.
Clearance for loading ammonia was given. After the test, the
tank operated continuously through 1985. The tank was decommissioned and inspected thoroughly in 1985. During this time,
FACT engaged the Indian Institute of Technology (IIT) in Chennai to ascertain the soundness of the foundation and integrity of
the tank. After exhaustive studies, IIT Chennai concluded that
the foundation was in sound condition after 10 years of operation. The tank and associated facilities were inspected. Suggested
measures were recommended to avoid normal deterioration of the
tank while in service. FACT implemented the recommendations
and put the tank back in service.
The tank is insulated by polyurethane foam and the bottom
of the tank is insulated with polystyrene foam board. This tank is
protected against over pressure and vacuum by two relief/vacuum
valves. Other associated facilities included two large capacity
refrigeration compressors (for use during tank loading), two pressure holding compressors (one motor driven and the other diesel
engine powered), a diesel generator to provide power during
power failures, three pumps to load rail cars and barges, three sets
for rail-car loading and one set of barge loading arms, connected
piping, cooling tower, instruments and a flare system.
1/10,000 years
Severity
Risk level
Descriptor
Consequences
5
Catastrophic
Multiple deaths
4
Severe
Death
3
Serious
Lost-time accident
2
Minor
Medical treatment
1
Negligible
No injury
Source: Emerson Process Management
legislation. Over the last 20 years, since Bhopal, there are increasing concerns and a resurgence of public interest.
Root-causes for accidents. Major contributory factors to
accidental releases in the hydrocarbon/chemical industries are
mechanical failures and operator error. Today, the petrochemical industry uses a predictive maintenance strategy based on
equipment-condition monitoring to overcome shortcomings
from preventive maintenance. It is also possible to satisfactorily
assess the integrity of equipment and structures with modern
inspection tools and methods; these tools can predict likely failure situations well in advance so that effective remedial action
can be taken.
Recent developments in ultrasonic technology can eliminate
using hazardous chemicals associated with radiographic examinations that are commonly used for flaw detection. Better training,
simplified procedures and work practices, and ready access to vital
information can help reduce human error and enable operators
to spot exact plant locations where problems have a higher probability of occurring and to take corrective actions early. With the
currently available technology and skill, it is possible to operate
and maintain hazardous installations with a very high degree of
safety and environmental protection standards.
Case history. The following case study illustrates the success from
the discussed methods and approach. The Willington Island Ammonia import terminal belongs to a major fertilizer producer and state
company, Fertilizers And Chemicals Travancore (FACT) Ltd. This
facility came under suspicion that it posed a serious safety threat to the
local community of Cochin. A Public Interest Litigation (PIL) was
initiated by a local non-government organization (NGO) presented
before the High Court. The facts under judicial scrutiny are:
• In the case of a catastrophic accident to the storage tank,
resulting in a major crack or rupture, it would lead to disastrous
and devastating consequences from loss of life to all inhabitants
of Cochin.
• Catastrophic failure of the tank is not an unreal or remote
possibility; it is a credible and contingent possibility due to reasonably anticipated facts.
• Although the catastrophic event is only a possibility and
when it would happen is unpredictable, it is unwise to ignore this
72
I APRIL 2009 HYDROCARBON PROCESSING
The process. Liquid ammonia at –33°C is moved by rail cars
to the plant. The tank terminal is a self-contained facility with
provisions for emergency supplies and it is guarded around the
clock by security personnel. The terminal is operated and maintained by competent personnel with all mandatory inspections,
tests and certifications.
Based on its finding that “the catastrophic failure of the tank is
not a remote possibility but a credible and contingent possibility
to be reasonably anticipated on the facts unfolded in the case,”
the High Court ordered decommissioning and shutdown operations of this installation. Against the verdict FACT appealed to
the Supreme Court of India for reconsideration of the case. The
PETROCHEMICAL DEVELOPMENTS
Supreme Court appointed a consulting group with international
repute to re-examine the issues and submit a report.
Following the Supreme Court directive, extensive inspection
and tests were to ascertain the tank’s present condition. The report
included:
• Visual examination
• Non-destructive test (NDT) methods on the piles, beams
and slabs to assess strength of concrete
• Ultrasonic pulse velocity test to assess the condition of structures such as cracks, voids, etc.
• Carbonation test for assessing alkaline protection of reinforcement steel
• Test of compressive strength for concrete (IS 456:2000)
• Half-cell potentiometer test to assess corrosion levels of steel
reinforcements
• Chemical analysis of soil samples.
From the listed analyses, inspectors inferred that the tank’s
foundation was in a sound condition. The inspectors also evaluated
the health and integrity of the tank through visual inspections and
with a series of NDT methods. These methods involved using:
• Wet fluorescent magnetic particle testing (WFMPT) to
ensure that weld joints are free from cracks and discontinuities
• Liquid penetrate testing (LPT) for weld joints in the annular
area not accessible to WFMPT
• Ultrasonic thickness measurement (UTT) of shell, plates,
piping and nozzles
• Ultrasonic flaw detection (UFD) to detect subsurface defects
in T joints of shell plates of the inner cup
• Hardness testing of weld heat affected zones to detect degradation of parent material
• In-situ metallurgical examination by advanced replication
techniques
• Vacuum box leak test to ensure that there are no leaks
through bottom plates of inner cup and annular plates of inner
and outer tanks
• Water load test at 10,000 mton
• Hydro pneumatic test by pressurizing to 1,000 mm WG for
1 hour to detect any settlement and then maintaining a vacuum
of 50 mm WG for 30 minutes.
All of the tests provided satisfactory results. Thus, the tank was
considered to be in sound condition. The inspection contractor
further evaluated the probabilities of leaks and other failures from
accessories and connected systems. Reviewing the history of leaks
from the installation, it was determined that the leaks had developed outside the storage tank and could be handled effectively by
proper monitoring and maintenance.
Safety audit. FACT conducted a full fledged safety audit and
hazard and operability (HAZOP) study in 1988, engaging specialists in the field. The idea was to identify potential hazards involved
in the plant, their likelihood of occurring and possible effects on
the local population. The safety specialists reviewed the site’s safety
policies, safety responsibilities, design standards and guidelines,
operating procedures, safety checks, inspection and maintenance,
modifications, detection systems, disaster management plans,
training facilities, fire fighting procedures, emergency shutdown
systems, etc. Also, they identified areas of concern.
Results of this study showed that, generally speaking, plant
leaks would not potentially affect the surrounding population to
a significant extent. However, reducing potential effects stemming
from several release cases can be achieved by installing automatic
SPECIALREPORT
shut-off facilities. Additionally, containment of the spill, and
hence, boil-off rate will reduce the distance that the vapor cloud
could travel and further mitigate risks to the local population.
Comprehensive inspection, testing and maintenance routines
would help in minimizing the likelihood of any failures leading
to an ammonia release. Therefore, these procedures should be
continued on a regular schedule with a periodic review of maintenance frequencies. Following the report, FACT implemented
the recommendations.
Safety inspectors concluded that “management and organization structure appears to be well-balanced and efficient with
good backup from technical services, maintenance and inspection
groups. Due to the sensitive siting of the tank, management has
taken every effort to ensure that the integrity of the facility is not
undermined and it is operated by well-trained, competent staff.
Everyone interviewed at the site had a strong working knowledge
of the plant and how to react in an emergency situation. All senior
operations staff were qualified engineers and had extensive experience in the operation of a chemical plant.”
Expert opinion. During the course of the hearing, the High
Court sought the opinion of Dr. John M. Campbell of CHERRYROSE Ltd., in the UK, to review the merits of the safety audit/
inspection. Dr. Campbell, after studying documents made available, suggested that the issue is not limited to leakages that can be
contained and which may not cause major hazards. He was of the
opinion that worst-case scenarios including tank rupture, terrorist attack, aircraft crash, extreme high speed wind or cyclone and
4IBQJOHUIFGVUVSF
3FTQPOTJCMFUBOLDMFBOJOH
JOUBOLDMFBOJOH
BMM
BOE1 )
UTU
7JTJUVTB
B
"DIFN
FSNBOZ
OLGVSU (
Z 'SB
.B
4DBOKFUUIFXPSMETMFBEJOHQSPEVDFS
PGUBOLDMFBOJOHFRVJQNFOUGPSBOZ
*OEVTUSJBMBQQMJDBUJPO
1IPOF
&NBJMJOGP!TDBOKFUTZTUFNTDPN
XXXTDBOKFUTZTUFNTDPN
Select 172 at www.HydrocarbonProcessing.com/RS
73
SPECIALREPORT
PETROCHEMICAL DEVELOPMENTS
earthquakes should have been considered. These events were not
addressed. Later, a separate HAZOP study and quantitative risk
analysis covering all these issues were conducted.
TABLE 2. Paradigms of inherently safe designs
Intensification
Risk assessment study. Another contractor conducted an
additional HAZOP study and quantitative risk assessment (QRA)
covering the tank, ammonia-ship unloading facilities, barge and
rail-loading facilities, storage tank and associated facilities, and
flare and other utilities. The recommendations from the earlier
studies intended to improve safety during operation. The QRA
identified hazard types that could emanate from the facilities,
along with the most probable failure scenarios and then evaluated the potential hazards, damage effects and risks posed to the
surrounding population from unforeseen ammonia release. The
likelihood of a catastrophic failure from an air crash on the facility
was also evaluated. Certain mitigation measures were suggested
to reduce this hazard and risk potentials. Major observations and
recommendations from the study are:
• Catastrophic failure of the tank can be considered as a
remote possibility. This storage tank has double-containment
construction.
• The failure frequency associated with the catastrophic
failure of such storage tanks indicates that this event may be classified as an unforeseeable scenario. Possible causes that could lead
to this remote scenario are earthquakes because of terrorism or
air crash on to the tank. Latest prevalent seismic data has already
been considered during the design of the tank.
• Sabotage is an issue that cannot be predicted, and it can
cause a disaster at any time even under the best of safety measures.
Reduce the quantity in use of hazardous and toxic input
chemicals, reduce reactor volumes
Example: Development of batch processing into continuous
ones (integration of ammonia and urea plants to avoid
storage of ammonia), online reaction (nitration, etc.), pipe
reactors and static mixers (for nitrogenous fertilizers by
ammoniation), improvements in process chemistry (partial
oxidation of hydrocarbons to reforming in the case of
synthesis gas making in ammonia plants) and use of more
efficient catalysts (ruthenium instead of iron for ammonia
process)
Substitution
Shift to use of less hazardous materials as raw material
such as:
Change of solvent medium of reactions (ethylene dichloride
to n-hexane), use water as solvent (aqueous latex emulsions
in place of solvent-based paints)
Attenuation
Storage and use of materials under in less hazardous states
and low energy level such as:
Storage of toxic and inflammable material (ammonia,
chlorine, methyl amine, butadiene, etc.) in refrigerated state
as opposed to pressurized storages, bullets, etc., under
ambient conditions Operate process under less extreme
conditions—temperature and pressure,
Limitation
Minimize the impact of harmful effects in terms of release
of energy and hazardous material.
Example: Avoid overheating by limiting the temperature of
hot fluids rather than relying on instrumentation interlocks.
Simplification
Design for known error tolerances, such as:
Use of wide tolerance limits for reactivity, inflammability,
etc. Consider reasonable deviations from designers’
intentions for safe operations.
A proper tight security and surveillance installation is the answer
to this cause.
• Air crashes. The study also assessed the air-crash rates and
compared the assessed crash rates with that of the inherent failure
frequencies associated with such failures. It is observed that the
assessed crash rate to the tank with respect to one of the runways is
1.36 per million years, which is of the same magnitude as that due
to inherent failures. The assessed crash rate due to second runway
is estimated about 0.67 times that due to inherent failures. Thus,
the possibility of air crash on the tank can be considered remote
and pose a low risk level.
• Catastrophic tank failure. In the case of a catastrophic
tank failure, fatalities to 1% of the exposed population can be
expected to reach about 1.5 m from the storage facilities under
stable weather conditions. It is the plant control room and personnel who are most vulnerable. To mitigate risks from this event,
it was recommended to pressurize the control room, making it
air tight. Ammonia detectors and alternate breathing air systems
should be installed at vulnerable points and an effective personnel
evacuation system should be in place.
• Rupture of the ship-unloading arm could be caused by
roughness of the sea and cause undue stresses subjected to the
arm. A quick connecting/disconnecting coupling could alleviate
this situation. A provision for emergency relief system for the
Select 173 at www.HydrocarbonProcessing.com/RS
74
PETROCHEMICAL DEVELOPMENTS
loading/unloading arms, automatic shutdown facilities for loading and unloading operations and installing ammonia detectors
at strategic locations, etc., would radically improve safety level
at the site.
• Thermal radiation effects at ground level during flaring of ammonia vapors were studied. It was found that the
maximum ground-level thermal radiation intensity is 0.2 kW/
m2 and can be considered safe for operating personnel and the
general population. The thermal radiation intensity at the height
level of the tank was determined to be 3.8 kW/m2, which is also
considered acceptable. Discharge from safety valves should be
disposed carefully by routing to the flare. Pilot burners of the
flare should be kept lit.
• A well coordinated emergency management plan should
be developed that addresses detailed onsite and off-site action plans
that need be initiated in the event of any release from the tank.
After the above exhaustive review, it was concluded that the
tank could continue in service under present conditions subject
to certain measures being taken by the company (FACT), as suggested to further enhance safety of the operations.
Final verdict. Based on this report, the Supreme Court held
that, “On both these issues (structural integrity of the tank and
its operations), the inspection company has recommended continuance of the tank in its present condition subject to certain
measures being taken by the operating company (FACT). The
company has taken those steps. We must find a balance between
existing utilities, which exist in public interest and human safety
conditions. It is not in dispute that such plants are needed for
the welfare of society. In modern times, we have nuclear plants,
which generate electricity. Their structural integrity and operations are vulnerable to certain risk. However, electricity generation is equally important, and within the prescribed limits,
society will have to tolerate existence of such facilities. It is for
this reason that we called for a report so that these facilities can
examine the structural integrity of the tank, and its operations
and then determine the steps to be taken to minimize risk factors.
If arguments of the original petitioner are accepted, then no such
utility can exist, no power plant can exist, no reservoir can exist
and no nuclear reactor can exist. We do not discount such risks,
but we have to live with such risks, which are counterbalanced by
services and amenities provided by these utilities.” The appellate
court set aside the order of the High Court.
Thus, process hazard analysis (PHA) tools have become successful in logically assessing risk emanating from installations. The
assessments are credible and have been successful in quieting the
public’s fear increasing public acceptability.
Second study. In a similar event, the US Environmental Pro-
tection Agency (EPA) commissioned a detailed study in 1995
entitled, “Innovative high risk/high priority anhydrous ammonia
study.” This study investigated the various safety aspects for the
storage of a liquid ammonia installation at Tampa Bay, Florida.
In this part of Florida, three major storage facilities belonging to
CF Industries, IMC-Agro and Farmland Hydro are located; all are
major fertilizer producers. The combined maximum storage facility
is just over 100,000 mton of ammonia, and, annually, 2.5 million
mton to 3 million mton of material are handled by these installations. The main focus of the study was to examine the risk level
posed to the local community of half a million people. The risk
assessment was done by addressing the severity of consequences
SPECIALREPORT
from any harmful occurrence coupled with the likelihood of such
an event. The report also considered the other location-specific
problems of the Tampa Bay area and includes:
• Presence of a small air field only 1.1 km from one of the
storage tanks
• Proximate scrap metal yard
• Possibility of a terrorist attack or earthquake.
The major findings of the exhaustive study were:
• Risk posed by the ammonia storage tanks to the local community is relatively small due to the low probability of a release.
• The ammonia industry in the Tampa Bay area has shown
itself to be a model for other industries with regard to safety and
concern for community welfare.
• Each of the companies continually improve operations to
provide the highest degree of safety possible for their employees
and the surrounding community.
New directions in hazard management. At present, petrochemical industries are addressing more descriptive approaches
to tackle human error, which are the prime cause for accidents.
At the technology level, there are several recent advancements,
which culminate in standard practices, occasional audits and
adherence to practice codes in design, operation and maintenance,
which were prevalent earlier. Process safety management (PSM)
is a fully developed engineering program, and it supports the
processing industry with a reliable safety management program.
PSM provides well-defined objectives and goals, clear documentation of systems and procedures, mechanism for checking projects
BOLTING PROBLEMS?
Meet the solution:
Fast, safe,and easy
bolting solution!
Superbolt® Multi-Jackbolt
Tensioners eliminate
unsafe and time consuming
bolting methods. Only
hand/air tools required for
any size tensioner!
Request FREE DVD
or catalog today!
1-412-279-1149
1-800-345-BOLT (USA)
www.superbolt.com
Select 174 at www.HydrocarbonProcessing.com/RS
75
S T E A M
U T I L I TY
SOLUTIONS
http://www.armstronginternational.com/HPI
In the face of rising energy costs, let Armstrong optimize your facility’s steam utility system.
For more than 100 years, Armstrong International has provided utility optimization for our global partners.
We’ve solved problems, conserved energy and improved efficiency in countless applications.
We can do the same for your petrochemical facility with our complete prefabricated piping solutions. Designed
to simplify and supply all the components necessary for your drip and tracer line applications, Armstrong’s steam
distribution manifolds, condensate collection manifolds and trap valve stations bring everything together. You’ll
enjoy lower installation costs and a compact, easy-to-access, centrally located assembly.
We also offer complete steam system asset management. Our professionals can conduct trap audits, deliver
a system analysis and recommend ways you can optimize. To reduce energy costs while ensuring best-of-class
performance, contact your Armstrong representative or visit armstronginternational.com/HPI.
Select 65
68 at
at www.HydrocarbonProcessing.com/RS
www.HydrocarbonProcessing.com/RS
Select
© 2008 Armstrong International, Inc.
PETROCHEMICAL DEVELOPMENTS
and designs, risk management program, efforts to bring cultural
changes into the organization, mechanisms to ensure process
equipment and integrity, procedures for instant investigation,
and provisions for training employees to update their knowledge
and understanding.
Definitions. The degree of the havoc has been assessed in
terms of:
• Most likely release scenario, e.g., leaks from a pump seal
or relief valve
• Most probable worst-case scenario, e.g., truck crash or
movement of a ship severing a pipeline during unloading
• Absolute worst-case scenario, e.g., total release of tank
contents due to an aircraft crashing into the facility
• Nightmare scenario, e.g., simultaneous release of contents
from all neighboring storage tanks due to earthquake or terrorist
actions.
More inherent safety aspects are being integrated into the
design of projects and processes coupled with adequate risk reduction strategies and risk-management plans. Inter-disciplinary
exercises must apply creative thinking among team experts to
find hidden situations that can crop up and culminate into a
disaster. The HAZOP and HAZAN exercises are examples of
such actions.
Most major accident industries have reasonable estimates for
releases, hazard distance and evacuation, and environment management plans. They also ensure neighborhood hospital preparedness to support victims, and to effectively coordinate with
civic administrations, government departments and neighboring
institutions.
The two risk levels that are usually encountered are individual
and societal. The maximum permissible level for individual risk
that is accepted worldwide is one in one million per year (1x10–6/
man/yr). Most studies have shown that the risk to life for the
public from industrial activities is less than 1 in 10x10–6/man/
yr, and this level is considered acceptable for the community.
The accuracy of QRA heavily depends on the data’s authenticity,
model reliability and human error. The risk is often estimated
very high when compared with real-life accident situations that
can occur in the industrial environment.
Cut field connections
and potential leak
points – tenfold.
Process design: Changing trends. Major changes have
occurred in the design concepts that include safety and loss prevention considerations. Equipment reliability and efficient operations
are the corner stone of safety and long-term profitability. With
plant capacities becoming increasingly larger, concerns over safety
and economic losses stemming from short production outages are
very large. Remaining life assessment of equipment, redundancy
of instruments and software support operations have all contributed to maintain a better safety environment. Recent advances
for online performance monitoring (OPM), which is based on a
rigorous engineering model, is capable of detecting performance
deterioration well before mechanical collapse. Such dynamic systems are developed to suit individual installations and incorporate
thermodynamic efficiencies and process changes—ambient conditions, stream composition and operating parameters.
Armstrong’s modular steam tracing systems will:
• Lower your installation costs
• Reduce time spent in design and construction
• Lower long-term maintenance and operating costs
• Provide advanced piston sealing technology,
reducing overall life-cycle costs
Safety standards and regulatory compliance. The
regulatory and social requirements for safety and reliability have
initiated a revolution in the safety technologies. There is increased
dependence on “smart” instruments, integrated controls and a
With Armstrong’s compact manifold
system for steam distribution and
condensate collection.
Contact your Armstrong representative or visit
armstronginternational.com/HPI.
© 2008 Armstrong International, Inc.
Select 68 at www.HydrocarbonProcessing.com/RS
77
SPECIALREPORT
PETROCHEMICAL DEVELOPMENTS
variety of system architectures. Although, any new development
towards attaining an increased safety level is welcome, it is also
necessary that the whole must be done with in an overall safety
framework that maintains an appropriate safety level and provides
confidence that this goal is being achieved.
For example, such a framework is under the development
in the UK. This system is the Conformity Assessment of Safety
related Systems (CASS); it certifies safety related systems. It is a
conformity assessment scheme that recognizes compliance with
the requirements of the international standards IEC 61508 and
IEC 61511. These standards define the safety integrity level
(SIL)—the protection level needed for a particular safety instrumented system. There are four possible discrete SILs determined
by multiplying the risk level factors based on frequency and severity. If the product is less than 6, the risk is low and only SIL 1
protection is needed. If the risk factor is between 7 and 15, then
the risk is moderate and SIL 2 protection is needed. For a product
between 16 and 25, the risk is considered high and SIL 3 protection is necessary.
Creating awareness and preparedness. A major initiative in the public interest with regard to hazardous installations
called Awareness and Preparedness for Emergencies at the Local
Level (APELL) was developed by the United Nations Environment Program, in partnership with industry associations, communities and governments, following several major industrial
accidents that had serious impacts on health and the environment. APELL is now being implemented in nearly 30 countries
globally. APELL is a tool for bringing people together to allow
effective communication about risks and emergency response
by reducing risk through improved effectiveness of response to
accidents and allowing ordinary people to react appropriately
during emergencies.
APELL was originally developed to cover risks arising from fixed
installations, but it has also been adapted for specific applications.
Launched in 1988, APELL sets out a 10-step process to develop an
integrated and functional emergency response plan involving local
communities, governments, emergency responders and others.
This process creates awareness of hazards within communities close
to industrial facilities, encourages risk reduction and mitigation,
and develops preparedness for emergency response.
Communication is often among the three main groups of
stakeholders—the operating company, the local community and
local authorities. Discussion on hazards usually leads to identifying
risk reduction measures, thus making the area safer than before.
Structured communication between emergency response bodies
(public and operating company) results in a better-organized
overall emergency response effort. APELL can apply to any risk
situation, whether industrial or natural. Any party can initiate it,
although companies can be expected to take the lead. It can be
facilitated by governments or by industry associations.
Although things are fine and well coordinated in most countries, the public has little awareness of such strengths associated
with the industry. Even in countries where the “community right
to know” legislation is in effect, most people do not believe what
the industry communicates to them. Thus, there is a need to
regularly explain in clear terms what risks are possible from the
operating facility and how safe are the neighboring industrial
environments. The community has been told that there is an
acceptable level of risk; however, the operating company is pursuing new developments and is committed to maintaining their
78
I APRIL 2009 HYDROCARBON PROCESSING
operations within acceptable limits. Industry’s preparedness to
handle abnormal situations, real-time monitoring of systems and
equipment, and programs to mitigate human error should be well
publicized. Socially speaking, operating companies must justify
the risk level and continuously raise the effectiveness of process
safety tools and programs.
Even in the best-designed and operated plants, accidents can
happen. The question that is often asked is, how safe is “safe
enough” when it comes to managing potentially risky processes
in chemical plants? Here comes the relevance of workable environment management plans. Industries are capable of developing
such plans. But the most important point is that these plans are to
be updated very frequently, tested and kept ready so that they can
be pressed into operation when such situations arise. HP
BIBLIOGRAPHY
“A New World of Safety, Emerson Process Management,” Austin, Texas, 2003,
www.PlantWeb.com
Andrews, J. D. and T. R. Moss, Reliability and Risk Assessment, Professional Engineering
Publishing Ltd., London, UK, 2002.
Awareness and Preparedness for Emergencies at Local Level (APELL) Handbook, A Process for
Responding to Technological Accidents, Industry And Environment office, United Nations
Environment Programme (UNEP), 1988.
Bwonder, B., Industrial Hazard Management, Administrative Staff College of India, Hyderabad, India, 1986.
“Code of Practice for Liquid Ammonia Storage Vessels, Projects and Developments,” India
Ltd. (PDIL), Sindri, India, 1988
Englund, S.M., “Design and operate plants for inherent safety,” Chemical Engineering Progress,
March 1991.
Environmental Protection Agency, “Innovative High Risk/High Priority Anhydrous Ammonia
Study: Tampa Bay,” Washington, D.C., June 1995.
Lemkowitz. S. M., G. Korevaar. G. J. Marmsen, and H. J. Pasman, “Sustainability as the
Ultimate Form of Loss Prevention: Implications for Process Design and Education,”
Proceedings of the 10th International Symposium on Loss Prevention and Safety Promotion in the Process Industries, European Federation of Chemical Engineering, Stockholm,
Sweden, 2001.
Lytollis, B., MTL Ltd., “Safety Instrumentation Systems: How Much is Enough?,” Chemical
Engineering, December 2002.
Major Hazard Control—A Practical Manual, International Labour Organisation, Geneva,
1988.
Mallett, R., “Rate your risk management plans,” Hydrocarbon Processing, August 1992,
pp.111–115.
Nair, M. P. Sukumaran, “Hazard identification and management—an overview,” Hydrocarbon
Processing, July 2002, pp. 63–67.
Ozog, H., and M. Bendixen, “Hazard identification and quantification,” Chemical Engineering Progress, 1987.
“Premises for Risk Management,” Dutch National Environment Policy Plan, Publication of
the Directorate General for Environmental Protection at the Ministry of Housing, Physical
Planning and Environment, The Hague, 1988–89.
“Prevention of Major Industrial Accidents,” International Labour Organization (ILO) Office,
Geneva, 1991.
“Recommendations for the Safe and Reliable Inspection of Atmospheric Refrigerated Ammonia Storage Tanks,” European Fertilizer Manufacturing Association (EFMA), Brussels,
Belgium, 2002.
“Reducing costs with PlantWeb digital plant architecture: Safety, Health, & Environment,”
Emerson Process Management, Austin, Texas, 2003.
Seiving, J. and S. Kemp, “The road to zero accidents,” Chemical Engineering, June 2003.
Smith. K. E., and D. K. Whittle, “Six steps to effectively update and revalidate PHAs,” Chemical Engineering Progress, January 2001.
“Technical Guidance for Hazard Analysis—Emergency Planning for Extremely Hazardous
Substances,” US Environment Protection Agency, Washington, 1987.
“Techniques for Assessing industrial Hazards—A Manual,” World Bank Technical Paper No
55, The World Bank, Washington, 1988.
“The CASS Scheme, Accredited Certification to IEC 61508,” The CASS Secretariat, Kent,
UK, 2004.
Wilson, S., “Develop an effective crisis management strategy,” Chemical Engineering, September 2003
Withers, J., Major Industrial Hazards—Their Appraisal and Control, Gower Technical Press,
Hunts, UK, 1998.
Dr. M. P. Sukumaran Nair is managing director of the
state-owned chlor alkali major Travancore-Cochin Chemicals Ltd.,
Cochin, India. Earlier, he was with the fertilizers and chemicals
travancore (FACT) Ltd., India’s pioneer fertilizer and chemicals
manufacturing, engineering design and consultancy organization.
He has over 35 years of experience in process plant design, operation, troubleshooting and management in the chemical processing industry. Dr. Nair is a Fellow of the
Institution of Engineers (India), was chairman of its Cochin center and is a member of
the AIChE and EFCE. He serves on several expert advisory committees to the central
and state governments in India and has published over 80 papers on management
and technology at various national, as well as international, journals. Dr. Nair is listed
in the Marquis’ Who’s Who in the World and by the International Biographical Centre
in Cambridge, England.
PROCESS INSIGHT
Selecting the Best Solvent for Gas Treating
Selecting the best amine/solvent for gas treating is not a
trivial task. There are a number of amines available to
remove contaminants such as CO2, H2S and organic sulfur
compounds from sour gas streams. The most commonly used
amines are methanolamine (MEA), diethanolamine (DEA),
and methyldiethanolamine (MDEA). Other amines include
diglycolamine® (DGA), diisopropanolamine (DIPA), and
triethanolamine (TEA). Mixtures of amines can also be used
to customize or optimize the acid gas recovery. Temperature,
pressure, sour gas composition, and purity requirements for
the treated gas must all be considered when choosing the most
appropriate amine for a given application.
Tertiary Amines
A tertiary amine such as MDEA is often used to selectively
remove H2S, especially for cases with a high CO2 to H2S ratio
in the sour gas. One benefit of selective absorption of H2S is a
Claus feed rich in H2S. MDEA can remove H2S to 4 ppm while
maintaining 2% or less CO2 in the treated gas using relatively
less energy for regeneration than that for DEA. Higher weight
percent amine and less CO2 absorbed results in lower circulation
rates as well. Typical solution strengths are 40-50 weight % with
a maximum rich loading of 0.55 mole/mole. Because MDEA
is not prone to degradation, corrosion is low and a reclaimer is
unnecessary. Operating pressure can range from atmospheric,
typical of tail gas treating units, to over 1,000 psia.
Mixed Solvents
In certain situations, the solvent can be “customized” to
optimize the sweetening process. For example, adding a
primary or secondary amine to MDEA can increase the rate
of CO2 absorption without compromising the advantages of
MDEA. Another less obvious application is adding MDEA to
an existing DEA unit to increase the effective weight % amine
to absorb more acid gas without increasing circulation rate or
reboiler duty. Many plants utilize a mixture of amine with
physical solvents. SULFINOL® is a licensed product from
Shell Oil Products that combines an amine with a physical
solvent. Advantages of this solvent are increased mercaptan
pickup, lower regeneration energy, and selectivity to H2S.
Primary Amines
The primary amine MEA removes both CO2 and H2S from
sour gas and is effective at low pressure. Depending on
the conditions, MEA can remove H2S to less than 4 ppmv
while removing CO2 to less than 100 ppmv. MEA systems
generally require a reclaimer to remove degraded products
from circulation. Typical solution strength ranges from 10 to
20 weight % with a maximum rich loading of 0.35 mole acid
gas/mole MEA. DGA® is another primary amine that removes
CO2, H2S, COS, and mercaptans. Typical solution strengths are
50-60 weight %, which result in lower circulation rates and less
energy required for stripping as compared with MEA. DGA
also requires reclaiming to remove the degradation products.
Secondary Amines
The secondary amine DEA removes both CO2 and H2S but
generally requires higher pressure than MEA to meet overhead
specifications. Because DEA is a weaker amine than MEA, it
requires less energy for stripping. Typical solution strength
ranges from 25 to 35 weight % with a maximum rich loading
of 0.35 mole/mole. DIPA is a secondary amine that exhibits
some selectivity for H2S although it is not as pronounced as for
tertiary amines. DIPA also removes COS. Solutions are low
in corrosion and require relatively low energy for regeneration.
The most common applications for DIPA are in the ADIP® and
SULFINOL® processes.
BR&E
Choosing the Best Alternative
Given the wide variety of gas treating
options, a process simulator that
can accurately predict sweetening
results is a necessity when attempting
to determine the best option.
ProMax® has been proven to accurately
predict results for numerous process
schemes. Additionally, ProMax can
utilize a scenario tool to perform
feasibility studies. The scenario
tool may be used to systematically
vary selected parameters in an
effort to determine the optimum operating conditions and the
appropriate solvent. These studies can determine rich loading,
reboiler duty, acid gas content of the sweet gas, amine losses,
required circulation rate, type of amine or physical solvent,
weight percent of amine, and other parameters. ProMax can
model virtually any flow process or configuration including
multiple columns, liquid hydrocarbon treating, and split flow
processes. In addition, ProMax can accurately model caustic
treating applications as well as physical solvent sweetening
with solvents such as Coastal AGR®, methanol, and NMP. For
more information about ProMax and its ability to determine the
appropriate solvent for a given set of conditions, contact Bryan
Research & Engineering.
Bryan Research & Engineering, Inc.
P.O. Box 4747 • Bryan, Texas USA • 77805
979-776-5220 • www.bre.com • sales@bre.com
Select 113 at www.HydrocarbonProcessing.com/RS
“Advertisement”
ReactoGard® V
The Ultimate Protection
for Fixed Bed Catalytic
Reactors from Eaton.
Using refinery-proven
AccuFlux™ media,
ReactoGard V automated
backwashing systems offer
significant advantages in all
types of refinery feedstocks.
ReactoGard V systems are engineered to
operate cleaner, more efficient low flux
sizing. This is achieved through improved
media materials and AccuFlux element
designs that increase filtration area by as
much as 300% over previous standards. In
addition, a new multi-bank system and controls approach eliminates the headers and
reduces the number of valves by up to 85%.
The ReactoGard V provides:
•
Improved filter productivity
•
Complete media cleaning
•
Superior mechanical integrity for enhanced
serviceability and reduced maintenance
•
Reduced product loss through less
frequent backwashing
•
Reduced cost of installed filtration capacity
•
Reduced space requirements
ClearAmineTM
A Safe, Green and Economical Solution from
Eaton for the Filtration of Amine Gasses.
With the ClearAmine™ automated self-cleaning
system there are no bags or cartridges to purchase,
no material to inventory and track, no hazardous
waste landfill fees and greatly reduced maintenance
and handling costs. Over a ten year period, you
can expect nearly a 60% savings compared to
a disposable media system. Plus, with no cartridges or bags to change out, employee
exposure to hydrogen sulfide is minimized or eliminated. Amine filtration is a key factor
for trouble-free sulfur removal. Pipe scale, corrosion, iron sulfide, sand and other solids
build-up in closed-loop amine systems. They foul flash drums, heat exchangers, strippers,
re-boilers and carbon filters and also attract hydrocarbons – which cause system foaming.
ClearAmine™ provides an efficient method of removing harmful solids to protect your
investment, extend equipment life, and maximize your amine system’s effectiveness.
For more information, call Eaton at 888-309-6648.
Select 119 at www.HydrocarbonProcessing.com/RS
Your complete source for
Oil & Gas Liquid Filtration
•
•
•
•
For more information, call Eaton
at 888-309-6648.
ReactoGard® V
ClearAmineTM
Strainers
Bags & Housings
Select 118 at www.HydrocarbonProcessing.com/RS
Model 2596
Automatic SelfCleaning Strainer
This automatic
self-cleaning
strainer is designed
for the continuous
removal of entrained
solids from liquids in
pipeline and process
water systems.
With an auto control system monitoring the
strainer operation, cleaning is accomplished
by an integral backwash system. A small
portion of the screen element is isolated
and cleaned by reverse flow. The remaining
screen area continues to strain – providing
an uninterrupted process. Also included is
the idLTM shaft seal that positively prevents
leakage from the backwash shaft at the top
of the strainer. Eaton automatic strainers
are ideal replacements for both simplex and
duplex manual strainers because of their
reliability and low maintenance.
Sustainable. Economical. Environmental.
Eaton provides complete refinery and petrochemical liquid filtration solutions
with installations in thousands of applications worldwide. We stand behind
our products with comprehensive parts and service programs, plus innovative
purchase/lease options. Count on Eaton to provide complete solutions that are
sustainable economically and environmentally while protecting the safety of
your workforce. At almost any point in your refinery, effective, efficient filtration
can deliver tremendous benefits including:
„
„
„
Longer equipment life
Reduced downtime
Improved safety
„
„
„
Protection of costly process materials
Extended runtime between turnarounds
Enhanced environmental stewardship
For more information, visit www.filtration.eaton.com.
Or, call 888-309-6648 to speak with an Eaton Oil & Gas Specialist.
For more information, call Eaton
at 888-309-6648.
Select 117 at www.HydrocarbonProcessing.com/RS
Select 116 at www.HydrocarbonProcessing.com/RS
PETROCHEMICAL DEVELOPMENTS
SPECIALREPORT
Update catalyst technology
for syngas production
Changes in bed support maintain lower pressure drop across
shift reactor in ammonia processes
W. KHALID, Engro Chemicals Pakistan, Pakistan
L
ow pressure drop in the front end of an ammonia plant saves
energy needed to compress synthesis gas. Such operations
conditions can remove major processing bottlenecks when
increasing plant capacity. In this case history, a forced shutdown
enabled a catalyst retrofit reconfiguration of the media support
system. This decision improved unit operations and plant energy
efficiency.
Ammonia plant. Several processes are commercially available
to produce synthesis gas for ammonia (NH3) production. Steam/
air reforming of natural gas is the dominant processing method
used for NH3 synthesis. Fig. 1 is a simplified process flow diagram
of NH3 production.
Sulfur removal or feed gas purification. The first stage
of the NH3 process is the preliminary purification section, where
impurities, primarily sulfur compounds, are removed from the
gas stream. The desulfurization vessel contains a catalyst that
hydrogenates organic sulfur to hydrogen sulfide (H2S), which is
then absorbed in ZnO-based catalyst:
ZnO + H 2 S ZnS + H2 O
Sulfur and sulfur containing compounds
must be efficiently removed from the feed
gas to prevent poisoning of the nickel-based
reforming catalyst in the primary reformer
and other downstream catalysts. Chlorine,
if present in the feedstock, is also removed
via the feed purification section.
Process steam
C n Hm + nH2 O nCO + (n + m/2)H2
CO + H 2 O CO2 + H 2
In the secondary reformer, the necessary reaction heat is provided by internal combustion using air. The stiochiometric quantity of preheated process air is injected to introduce the required
nitrogen (N2) amount needed for NH3 synthesis.
Shift conversion section. Two-step shift conversion consists of
a high-temperature shift converter (HTSC) and a low-temperature
shift converter (LTSC). The reaction is:
CO + H 2 O CO2 + H 2
The performance of the carbon monoxide (CO) conversion section strongly impacts the total energy efficiency of the NH3 plant,
as unconverted CO will consume H2 and form methane (CH4) in
the downstream methanator, thereby reducing available H2 and
increasing the inert level/pressure within the synthesis loop.
CO2 removal and methanation section. The gas stream is
sent to the absorber column, where an activated hot potassium
Prereforming
Sec reforming
HT shift
LT shift
Feed purification
Natural gas
Process air
Primary reforming
Reforming section. Steam reforming is
a well-established process for the manufacturing of hydrogen (H2) and synthesis gas.
This process is done in two steps namely
1) adiabatic pre-reforming, which allows
using of higher preheat temperature and
reduces the size of the primary reformer)
and 2) primary reformer. The reforming reaction(s) occurs place over a nickel
(Ni) catalyst loaded in vertical tubes. The
required reaction heat is supplied by combusting fuel gas. The endothermic steam
reforming reactions are:
CH 4 + H 2 O CO + 3H2
WHB
WHB
Purge gas
Ammonia
product
CO2
CO2
removal
WHB
Ammonia synthesis
Methanation
Process
condensate
Source: www.topsoe.com
FIG. 1
Simplified NH3 process flow diagram.
HYDROCARBON PROCESSING APRIL 2009
I 81
SPECIALREPORT
7 ft 10 in.
17 ft 1 in.
9 in.
rashing
rings
Sample
cages
6 ft 9 in.
24 ft 7 in.
6 ft
5 in.
Inlet nozzle
22 ft
Thermocouple
shaft
18 ft 9.5 in.
SK-202-2
1,500 ft3
6 in. TI 126
3 in. 5%
21 ft
6 in. TI 125
43.2%
3 in.
Side man
way
MI
3 in.
6 in. TI 127
77.7%
5 ft 5 in.
Catalyst dumping nozzle
FIG. 2
6 in.
22 in.
23 ft 4 in.
¼ in. AI balls, 100 ft3
½ in. AI balls, 100 ft3
¾ in. AI balls, 450 ft3
Outlet nozzle
FIG. 3
Visual of spent HTSC catalyst loading.
Schematic details of previous catalyst loading.
24
22
20
18 142%
FEL
16
14
12
HTSC ΔP from SOR
154% FEL
147%
FEL
152% FEL
147% FEL
153% FEL
18-Nov-02
16-Dec-02
20-Jan-03
24-Feb-03
17-Mar-03
17-Jun-03
25-Nov-03
03-Feb-04
02-Nov-04
08-Feb-05
16-Aug-05
11-Oct-05
13-Dec-05
14-Feb-06
14-Mar-06
13-Jun-06
29-Aug-06
26-Sep-06
31-Oct-06
19-Dec-06
09-Jan-07
20-Nov-07
carbonate solution is used to absorb carbon dioxide (CO2) from
the gas, and is sent to the stripper where it is regenerated and the
CO2 is stripped off with steam. The CO2 is forwarded along with
NH3 for urea production.
CO and CO2 are poisons to the NH3 synthesis catalyst and
must be removed (below 5 ppm) before the gas is fed to the syn-
HTSC, ΔP
25 ft 10.5 in.
Perforated plate
vapor distributor
PETROCHEMICAL DEVELOPMENTS
Date
FIG. 4
Pressure-drop profile of previous catalyst charge.
thesis section. This is achieved by converting the CO to CO2 in
the shift reaction and removing the CO2; finally, traces of CO2
and CO are converted back to CH4 in the methanator via these
reactions:
CO + 3H 2 CH 4 + H 2 O
CO2 + 4H 2 CH 4 + 2H 2 O
Syngas compression and synthesis sections. The gas is
cooled, and excess steam is condensed before the feed enters the
synthesis section. The compressed gas is pre-heated with hot
outlet gas from the ammonia converter. The exothermic reaction
takes place in a three-bed radial flow converter:
N 2 + 3H 2 2NH3
The formed NH3 is condensed and removed via a separator.
Initial catalyst and support media loading. The hightemperature shift converter (HTSC) at the Engro Chemicals
Pakistan (ECPL) site is a cylindrical vessel with an inner diameter
of 16 ft. The loaded reactor holds 1,500 ft3 of catalyst. The vessel
internals included a perforated plate vapor inlet distributor, an
elephant stool type outlet gas collector, a catalyst unloading nozzle
(protruding into the vessel) and a thermocouple shaft. The 22-in.
diameter inlet flange on top of the HTSC is used as a manway
for catalyst loading and a side manway can be used for catalyst
unloading. New catalyst was loaded in October 2002 (see Figs. 2
Select 176 at www.HydrocarbonProcessing.com/RS
82
PETROCHEMICAL DEVELOPMENTS
SPECIALREPORT
8 ft 1 in.
Reclaimed
Sample
rashing rings cages
22 ft
3 in.
6 in. TI 126
5%
New catalyst
1,625 ft3
of SK-2001-2
6 in.
2 in.
3⁄8 in.
Catalyst dumping nozzle
Thermocouple
shaft
18 ft 9.5 in.
21 ft
23 ft 4 in.
16 ft 7 in.
Inlet nozzle
Perforated plate
vapor distributor
6 in. TI 125
43.2%
3 in.
Side man way
3 in.
6 in. TI 127
77.7%
MI-22 in.
6 in.
FIG. 5
6 in.
Outlet nozzle
½ in. AI balls
¾ in. AI balls
1 in. AI balls
2 in. AI balls
22 in.
Schematic details of new catalyst loading.
and 3) was at the end of catalysts’ service life:
Age
56 Months
Loaded volume of catalyst
1,500 ft3
Bottom inert support media
650 ft3
(¾-in., ½-in. and ¼-in. alumina balls)
The start-of-run (SOR) pressure drop was 14 psi at front-end
load (FEL) of 142%. The pressure drop of the catalyst bed at
these initial conditions was only 3 psi, and the remainder was
contributed by 650 ft3 of the ¾-in. and smaller sized alumina
balls loaded at the bottom as support media. Over time, the time
FIG. 6
Visual of new HTSC catalyst loading.
pressure drop increased to 24 psi—end-of-run (EOR)—due to
aging of catalyst.
New loading scheme. Due to a forced plant outage from an
air compressor problem, ECPL engineers decided to replace the
HTSC charge. The plant loading had increased and, now with
154% FEL, the SOR pressure drop was estimated at 17 psi when
using the original catalyst loading scheme. This pressure drop was
expected to reach 25 psi by the end of catalyst service life.
Helping you keep your cool under
any circumstances 24/7/365.
Aggreko Cooling Tower Services (ACTS)
is the world’s largest provider of rental
cooling tower solutions. For over
20 years, we have successfully helped
customers solve their cooling water
limitations - under any circumstances.
From the planning stages to the turnkey
installation of convenient modular cooling
towers, ACTS has the solutions to help
you keep your cool, 24/7/365.
ACTS provides proven rental cooling
tower solutions to:
• Maintain cooling capacity during
partial or complete tower repair
• Reduce cooling water temperatures
during peak summer conditions
• Minimize post-disaster downtime
• Add cooling water capacity with no
capital commitment
Contact Aggreko today for all your
rental cooling tower needs.
Performance Certified by
Cooling Technology Institute
888.245.6386
888
Select 177 at www.HydrocarbonProcessing.com/RS
www.coolingtowers.com
HYDROCARBON PROCESSING APRIL 2009
I 83
Select 59 at www.HydrocarbonProcessing.com/RS
PETROCHEMICAL DEVELOPMENTS
■ Low-pressure drop in the front end
of an ammonia plant saves energy and
elminates major processing bottlenecks.
The analysis of the loading pattern and the reactor drawings
revealed that “elephant stool” type outlet nozzle with smaller
sized-alumina balls was the bottleneck. Also, the plant and current
loading pattern were of 1960s vintage design where pressure drop
and energy considerations were not so critical. The combination
of decreasing battery-limit pressure from feed gas supplies and
limitations from the gas-booster compressor had limited processing capacity and NH3 production.
At this point, ECPL engineers decided to modify the loading pattern of alumina balls by fabricating new mesh support
and installing larger sized alumina balls. The alumina balls were
arranged locally during the outage. In the new loading pattern,
instead of using ¾-in., ½-in. and ¼-in. alumina balls, larger sized
(2-in. and 1-in.) alumina balls were loaded at bottom portion. To
limit catalyst pellets penetrating to outlet distributor mesh, ¾ in.
alumina balls and a small quantity of ½ in. balls were loaded as a
top layer for the support media (see Figs. 5 and 6):
New loaded catalyst volume
1,625 ft3
2-in. alumina balls
50 ft3
(limited by availability)
1-in. alumina balls
100 ft3
¾-in. alumina balls reclaimed
350 ft3
½-in. alumina balls reclaimed
100 ft3
SPECIALREPORT
Advantages with new loading scheme. With this new
design, several major advantages were realized immediately:
Pressure drop. The results were very encouraging; and pressure drop is only 7 psi at full load vs. the envisaged at 17 psi for
previous loading pattern. This pressure drop is still consistent after
more than a year of service. Also, due to the forced outage, the
project was done earlier and savings started a year ahead of plans.
By calculating the savings in terms of steam used by the synthesis
compressor, the retrofit savings are approximately $600,000/yr
for this part of the world.
Deferring gas-booster compressor revamp. Due to the 17 psi
total margin before and after loading, the retrofit project for the
feed-gas booster compressor was deferred and will be rescheduled
with planned outage.
Low CO slip and higher production. After five years of
operation, CO slip had increased to 3.2% at the HTSC outlet.
Presently, at slightly higher load and lower steam to gas ratio, the
CO slip is 2.2%. Result: Lower inerts present in the back-end
synthesis loop. This, coupled with high suction pressure at the
synthesis compressor (due to lower front-end presser drop) enables
more NH3 production. HP
Waskim Khalid is the head of process engineering for Engro
Chemical Pakistan Ltd. He holds a degree in chemical engineering
from University of Engineering and Technology, Lahore in 1995.
Since then, he has gained experience in design, capacity enhancement, modification, performance monitoring and optimization of
different fertilizer and oil and gas facilities. Also, Mr. Khalid has worked as a lead
process design engineer in a large multinational EPC company.
Select 178 at www.HydrocarbonProcessing.com/RS
HYDROCARBON PROCESSING APRIL 2009
I 85
Real value behind every valve.
Farris Engineering designs and manufacturess superior pressure relief valves.
But sometimes you need more. Like value-added
dded services
servicces and
ork comes in:
support. That’s where our FAST Center Network
t
A global network of Farris Authorized Service
ce
Team (FAST) Centers
t
Factory trained, ASME and VR certified
professionals
t
Local pressure relief valve inventories, plus
a Web-accessible global inventory
t
Total valve replacement, service and repair
any hour, any day: 24/7 – 365
ght
Combined with the worldwide resources of Curtiss-Wright
Flow Control Company, Farris Engineering can deliver asset
management solutions for your pressure protection needs.
“Understanding what the customer wants…making it happen!”
To locate your local FAST Center:
www.farrisengineering.com or 440-838-7690.
Select 84 at www.HydrocarbonProcessing.com/RS
Asset Management
Services & Repairs
RELIABILITY/MAINTENANCE
Extreme failure analysis:
never again a repeat failure
Apply root-cause failure analysis to recurring reliability problems
K. BLOCH, Flint Hills Resources, L.P., Rosemount, Minnesota
T
he ultimate purpose of this article is to significantly reduce
the risk for catastrophic equipment failures. Readers may
believe that having been trained in root-cause failure analysis (RCFA) is enough. Why, then, is some equipment allowed to
repeatedly fail? Are low-consequence repeat failures discretionary
maintenance opportunities, or precursors to more serious reliability and safety problems? What really constitutes effective RCFA?
Let’s consider real life experiences to answer these questions.
For equipment failure analysis to be effective, our beliefs (and
even the most reasonable of assumptions) must align with the
facts. Unfortunately, an extreme failure (an explosion, fire, wreck
or crash) often complicates matters by compromising much
of the information that we would normally use to determine
an accident’s cause. The issue with an extreme failure is that
although limited physical evidence remains, its consequences
are devastating. Indeed, the consequences are so severe that it is
unthinkable to take action without being certain that the problem will be solved.
Latent cause identification is simplified somewhat by recognizing
that a specific sequence of events is shared between many different
extreme failures. The “extreme failure life cycle” shown in Fig. 2
represents the relationship between a failure, a repeat failure and
an extreme failure. Underlying maintenance and design defects
can usually be detected as the probable cause of many controversial failures when this pattern is kept in mind.
Fact-based conclusions ultimately add more value than unproductive conspiracy and sabotage theory debates. Assigning blame
instead of confronting the latent cause is a certain prescription for
repeating the same problem. The extreme-failure life cycle indicates
that when repeat reliability events are disregarded they eventually
become the catalyst for progressively more serious and potentially
highly dangerous equipment failures.
Repeat failures tell an important story. The role that
a “repeat failure” plays in the life cycle of an extreme failure is of
Determining causes with scant physical evidence.
Without physical evidence it can be very difficult to look at an
effect and determine its cause. In contrast, predicting the effect of
an observed cause is a relatively simple task. For example, consider
the simple mental experiment1 shown in Fig. 1. First predict the
outcome of a melting ice cube on hot concrete. Then look at the
photo under it and explain how the water stain got there. Note
that you would be mistaken to believe that an ice cube left behind
this stain. In situations where conclusive physical evidence has
been compromised, it is sometimes easier to pass failures off as
acts of sabotage or conspiracy. Worse yet, events leaving behind
no physical evidence are often dismissed as an “act of God,” and
the case is closed.
In reality, the evidence you need to solve the problem is most
likely available but hidden from plain sight. Therefore, identifying
a probable cause involves knowing where to find this evidence.
Admittedly, resolving who or what left the water behind in Fig. 1
is hardly a matter of great consequence, but in extreme failures the
implications are infinitely higher. Moreover, since there is usually
low confidence in the physical evidence left behind by extreme failures, we must turn our attention to their latent, or hidden causes.
Latent cause identification. Hidden but powerful forces
within our organizations allow incremental mistakes to negatively impact safety and reliability. We must identify these latent
causes to develop an action plan toward assured failure prevention.
FIG. 1
Melting ice cubes leave a stain on concrete, but what left
the other stain behind?
HYDROCARBON PROCESSING APRIL 2009
I 87
RELIABILITY/MAINTENANCE
quence risk takes time away from addressing immediate production constraints that show up on the daily maintenance plan. In
truth, this highly reactive “reliability strategy” is the trademark
of a repair-focused organization. While they might claim to be
reliability-focused, such organizations exhibit few, if any, of the
requisite traits or do so in name only.
Latent cause
Failure
RCFA?
Yes
No
No
Stop
Yes
Latent
cause
removed?
No
Repeat
failure
Interactive
coupling?
Yes
Contributing
Factors
Extreme failures. While we are obviously not condoning repeat
failures, extreme failures are much more offensive. Extreme failures
are “extreme” in every sense of the word and are differentiated as:
• Being of, or having the potential for, the most extreme consequences
• Leaving behind extremely little physical evidence to readily
expose a probable cause
• Statistically, extremely improbable.
Also, because precursor repeat failures leave their tracks in the
maintenance management system, extreme failures, in retrospect,
always appear to be very predictable. Therefore, the maintenance
management system contains not only evidence critical for investigating an extreme failure, but also reproof for not taking preventive action. The following examples illustrate the relationship
between repeat and extreme failures.
The Hindenburg disaster: an extreme failure. The
Unacceptable
consequence
FIG. 2
Extreme
failure
Extreme failure life cycle showing the process a failure
goes through to become an extreme failure. Notice the
repeat failure’s position.
great interest. In a “hindsight is 20/20” world, we often wish we
had acted differently after suffering the painful consequences of
a decision under our control. Since repeat failures are the likely
intermediate step leading up to an extreme failure, they are also
reliable warning signals that precede many catastrophic equipment failures. Taking control over repeat failures to consciously
prevent a catastrophic accident reinforces the precept that we
are in charge of equipment reliability and not victims of their
“unpredictable” behavior.
A repeat failure is simply defined as a recurring equipment
difficulty that prevents it from achieving its anticipated life expectancy. Repeat failures exist because we have perhaps concluded
that a particular failure mechanism is more economical to manage
than to correct. If allowed to persist, a repeat failure will eventually
be perceived as a discretionary, low-risk nuisance with no potential
safety or environmental consequence. This defective risk assessment approach is also known as “normalization of deviance” and
must be resisted.2
Repeat failures build a reactive work order history in our maintenance management systems. More often than not, the entries
abound with useless information such as “bearing replaced” when
the entry “bearing failed due to oil starvation resulting from use of
pressure-unbalanced constant-level lubricator” would have added
real value. Regardless, repeat failure work orders tend to get buried under higher-priority items that represent a more immediate
production constraint. Repeat failures are often addressed only as
time allows and without asking why the failure occurred. Knowing why the failure occurred may require a failure analysis—and
performing a failure analysis on something viewed as a low-conse88
I APRIL 2009 HYDROCARBON PROCESSING
Hindenburg disaster is one of the most identifiable extreme
failures in the history of modern machines. The circumstances
behind this failure still stir considerable controversy and debate,
led by various conspiracy and sabotage assertions that accompany
most extreme failures. The purpose of examining it here is to demonstrate how the pattern shown in Fig. 2 applies to all extreme
failures no matter where they occur. Only by associating the
extreme failure with its adjunct repeat failure can we determine
a fact-based credible scenario that moves us away from accepting
theories fueled by speculation.
The Hindenburg airship was built with a lightweight metal
airframe held rigid by a network of 0.125-in.-diameter steel bracing wires under tension. Its outer covering consisted of cotton
linen painted with a metallic cellulose acetate butyrate “dope” to
repel water and reflect sunlight. Sixteen inflatable bags were filled
with 7 MMscf of hydrogen to lift the airship, since the preferred
medium (helium) was not available.
Like every machine, the Hindenburg had an operating envelope and violating its limits would greatly increase the mechanical
failure risk. Operating procedures were used to mitigate these
failure risks, and the Zeppelin Company’s enviable safety record
was evidence of an effective training program. Top among these
procedures were strict rules governing landing maneuvers to avoid
exceeding the bracing wires’ 1,000-lbs tensile force limit in the
tail-to-fuselage section, which absorbs the energy produced while
turning the massive airship. Regardless, the Hindenburg’s maintenance records contain a history of bracing wire failures in the
tail-to-fuselage section.3
The Hindenburg’s otherwise perfect transatlantic flight was spoiled
by unexpected headwinds that put it 12 hours behind schedule upon
its arrival in Lakehurst, New Jersey. Eager to land the ship without
further delay, the captain ordered a risky sharp left turn after the wind
suddenly changed direction to quickly reorient the airship’s nose
back into the wind. This violated landing procedures that required
aborting the landing attempt if the wind shifted direction. Following
procedures was needed to safely point the airship’s nose back into the
wind without exceeding the bracing wires’ stress limit.
Kobelco Screw Gas Compressors (API 619)
If you thought reciprocating or
centrifugal compressors were the
only options for heavy-duty process
gas service, we have good news.
A Better Answer
for Heavy-Duty
Process Gas
Service
KOBELCO rotary screw gas compressors
are excelling in applications worldwide,
including:
Oil-Injected Compressor Applications:
I Hydrogen for Gasoline & Diesel
Desulfrization and Hydrotreating
I Fuel Gas Boosting
I PP & PE Process Gas
I Gas Pipeline Boosting
I Coke Oven Gas
I Helium
Oil-Free Compressor
Applications:
I Flare Gas Recovery
I Offshore Vapor Recovery Unit (VRU)
I Refinery Off-Gas, Vent Gas, Coker Gas
I Heavy Hydrocarbon Gas
I Dirty Gas
I Petrochemical Process Gas
(Styrene Monomer, Butadiene, LAB, Soda Ash)
… and more
Superior Performance
KOBELCO oil-injected screw compressors
are robust, with discharge pressures up to
1,500 psig (100 barg) and extremely high
compression ratios. Our oil-free screw
compressors handle large capacities up
to 65,000 CFM (110,000 m3/hr)
and difficult gas applications.
Kobelco Screw Compressors —
better technology for
heavy-duty process
gas compression.
Ask KOBELCO!
The Best Solution
for Any Gas
Compression
Tokyo +81-3-5739-6771
Munich +49-89-242-18424
www.kobelco.co.jp/compressor
Kobelco EDTI
Compressors, Inc.
Houston +1-713-655-0015
rotating@kobelcoedti.com
www.kobelcoedti.com
Select 103 at www.HydrocarbonProcessing.com/RS
RELIABILITY/MAINTENANCE
After making the sharp left turn, the captain noticed the Hindenburg suddenly becoming tail-heavy. Since procedures also
required landing the airship horizontally to avoid damaging the
tail fin, the captain released the remaining ton of water from the
ship’s rear ballast tanks (Fig. 3). Several minutes later, the captain
ordered six crewmen to the front of the airship to counterbalance
the continued tail section downward-slope. Next, he dropped the
anchor ropes from the airship’s nose.
On the ground, everything appeared normal. The ground crew
grabbed the anchor ropes and began walking the airship to the
mooring mast. Before they were able to fasten the ropes to the
mast however, a fire broke out in front of the top tail fin, where
evidence of a hydrogen leak (tail-heaviness) existed after the captain deviated from procedures by executing a sharp left turn after
the wind changed direction. The entire airship burned from the
tail forward, destroying all physical evidence within 32 seconds.
Thirty-five of the 97 people on board were killed along with one
ground crew member.
In hindsight, knowing that a repeat failure is somehow involved
makes it easy to understand that a bracing wire probably broke
upon exceeding its stress limit, just as expected. While this failure
had occurred previously, this time the unstable wire penetrated a
hydrogen bag and the airship’s outer skin, which set off a sequence
of events that resulted in one of history’s most famous disasters.
The repeat failure became extreme by an unlikely combination
of contributing factors:
• A very tight schedule, made even tighter by strong headwinds during the flight
• Procedure deviation
• Hydrogen containment was lost
• The failure occurred during a critical phase during the landing procedure
• Light rain was falling, which made the anchor ropes capable
of conducting an electrical charge after becoming adequately
moistened.
Some may wonder why the Zeppelin Company did not address
the Hindenburg’s design risk with something more reliable than
an administrative control procedure, like stress-resistant materials
in the vulnerable tail-to-fin section. But it is important to consider
how the Zeppelin Company’s perfect safety record influenced
its risk tolerance for bracing wire failures. In hindsight, their
maintenance records show that this repeat failure represented a
discretionary maintenance nuisance that could be managed with
little inconvenience. Living with the failure mechanism was,
therefore, a more economical alternative. Would the choice to
sacrifice a wire in the interest of preserving the airship’s remaining
turnaround time have been considered acceptable if the procedure
deviation had not ended in an extreme failure? While the Zeppelin
Company’s safety record was indicative of a reliability-focused
organization it was, in fact, guilty of making decisions associated
with a repair-focused organization.
Inherently safe technology advocates will argue that the use
of hydrogen instead of helium is what caused the accident, while
minimizing the impact of maintenance practices that led to a loss
of containment scenario. Whether or not helium was available
to Germany in the mid 1930s is not the issue here. In modern
times we must operate responsibly because it is not practical to
make similar substitutions. To illustrate, let’s turn our attention
to industries where OSHA’s Process Safety Management (PSM)
Standard (29 CFR 1910.119) applies. The standard’s purpose is to
achieve safe and continuous containment of hazardous substances
inherent to the manufacturing process.
Spent caustic tank explosion. Refineries use caustic
(sodium hydroxide) to purify liquefied petroleum gas (LPG).
As the caustic reacts with LPG contaminants, its concentration
decreases. In other words, it becomes “spent.”
To maintain the minimum caustic concentration needed to
continue the reaction, spent caustic must be periodically removed
and replaced with an equal volume of fresh caustic. In one refinery, the spent caustic batches into a 35,000-gallon intermediate
cone-roof storage tank. From there the caustic slowly drains to
the waste treatment facility (Fig. 4). This disposal strategy absorbs
large slugs of spent caustic that would otherwise upset the biological treatment system.
In 2004, a spent-caustic system hazard and operability (HAZOP)
study concluded that operator error could result in sending a large
volume of LPG directly into the spent-caustic storage tank. Upon
entering the tank, the LPG would vaporize and release a propane
vapor cloud into the refinery. The history of fugitive vapor releases
in refineries is not comforting; vapor releases continue to be responsible for extensive equipment damage and fatalities upon ignition.
Therefore, a HAZOP action item was assigned to mitigate the risk
Flare
To incinerator
RO
Spent-caustic
storage tank
Instrument air
Nitrogen
Waste
treatment
Spent caustic
Degassing
vessel
FIG. 3
90
Rear ballast tanks are emptied to avoid hitting the ground
after the Hindenburg unexpectedly becomes tail-heavy
during landing maneuvers.
I APRIL 2009 HYDROCARBON PROCESSING
FIG. 4
A degassing vessel was installed to vent hydrocarbons
from spent caustic before entering the storage tank.
RELIABILITY/MAINTENANCE
for a vapor cloud release from the atmospheric spent-caustic storage
tank pressure relief system.
A degassing vessel was retrofitted in front of the spent-caustic
storage tank and commissioned on day 1 (actually in 2005). This
system satisfied the HAZOP action item’s purpose for hydrocarbon
removal from the spent caustic entering the tank. For most of the
time the system would operate in “fill” mode, where spent caustic
from the upstream liquid/liquid LPG contact process would stagnate
in the degassing vessel while venting hydrocarbons into the refinery
flare header. After allowing sufficient time to pass, operators would
perform a manual “dump” procedure by opening the discharge valve
under nitrogen pressure to drain its degassed (vented) contents into
the tank. Operators were expected to stand by the transfer valve during this manual procedure, to verify that the liquid seal above the
degassing vessel’s discharge nozzle inlet remained intact.
On day 529 (in 2007) the spent-caustic storage tank failed
a leak detection and repair (LDAR) test, with over 2,000 ppm
hydrocarbon measured exiting the tank’s atmospheric pressure
relief device (PRD). In compliance with refinery policy, a work
order was issued to repair the leaking PRD within 15 days of discovery. The repair involved tightening the bolts around the PRD
to stop the hydrocarbon leak.
After the repair, a second LDAR test was performed to confirm
that the repair was successful so that the work order could be closed.
However, the LDAR test failed again with over 2,000 ppm hydrocarbon being measured exiting the tank after the repair. In response,
the results of the failed repair attempt were logged in the maintenance management system and another repair was scheduled. For
the second repair, the PRD’s sealing gasket was replaced.
FIG. 5
Spent-caustic storage tank after explosion.
The LDAR test failed again after the second repair attempt, with
about 1,000 ppm hydrocarbon detected leaking out of the tank. The
maintenance management system was again updated with the failure
information, and a third repair attempt was scheduled. This repair
was canceled, however, because a final LDAR test conducted before
executing the work showed zero ppm hydrocarbon at the PRD.
Select 179 at www.HydrocarbonProcessing.com/RS
HYDROCARBON PROCESSING APRIL 2009
I 91
RELIABILITY/MAINTENANCE
Minimum liquid height
to prevent vortexing
20
16
Drum level falling
12
8
Drum level constant
4
0
0
2
4
6
Outlet velocity, ft/sec
8
Note: Tangential introduction of feed into a drum may increase the stated
minimum liquid height
FIG. 6
Minimum nozzle submergence requirements (feet) to
prevent vapor entrainment when draining liquid without a
vortex breaker.8
Degassing vessel level, ft
FIG. 8
Degassing vessel operation vs. minimum submergence
18
16
14
12
10
8
6
4
2
0
Minimum submergence (drum level falling)
0
FIG. 7
5
10
15
Bottom drain nozzle velocity, fps
20
25
Actual degassing vessel operation compared with
minimum nozzle submergence requirements shows vapor
entrainment occurring.
On day 621 (2007) two contractors working near the tank
both prematurely shut down their jobs at the same time, after a
foul odor from an unidentified source invaded their work area.
Operators were advised of the situation and they immediately
responded by investigating the problem. However, the source
for the release was not positively identified because the odor had
dissipated by the time they entered the process unit to investigate
the complaints. The contractors were allowed to resume working
in the area and the odor did not return.
On day 628 (2007) the spent-caustic storage tank exploded
suddenly and without warning shortly after operators initiated
the procedure to drain spent caustic from the degassing vessel
into the tank. Because the operator had left the valve to attend
to another part of the process, there were no injuries or fatalities.
However, the accident was severe. It caused the tank to become
airborne, spread fire into the unit, and interrupted spent-caustic
disposal operations. The damage imposed by the accident (Fig.
5) compromised any physical evidence that would expedite rootcause identification.
Only after the incident were the repetitive LDAR failures and
odor complaints recognized as warning signals that hydrocarbon
was leaking through the degassing vessel into the tank. Remembering the ignition triangle, this satisfied the fuel requirement for
an explosion. Although 50 years of reliable spent-caustic storage
system operation had been experienced before the accident, the
refinery was faced with compelling evidence that elements of a
repair-based culture existed. This culture allowed three repeat
92
I APRIL 2009 HYDROCARBON PROCESSING
Typical barrel compressor internal bundle assembly after
casing removal.
failures (hydrocarbon vapor emission events) without investigating why hydrocarbons were entering the tank after commissioning
the degassing vessel.
In the post-accident investigation, it was proven that the spentcaustic interface level did not drop below the degassing vessel’s
drain nozzle at the time of the accident. Therefore, attention
shifted to alternative scenarios that would explain how hydrocarbons could penetrate the degassing vessel’s liquid seal. By chasing
down this thread, the investigation uncovered evidence that an
unintended design condition existed, which allowed flare gas
and LPG in the degassing vessel to contaminate the spent-caustic
storage tank during the draining procedure. Since the degassing
vessel was draining without a vortex breaker, it would have to
operate according to the nozzle submergence requirements shown
in Fig. 6 to avoid entraining hydrocarbon vapor in spent caustic.
Archived process data provided evidence that the degassing vessel
operated outside of these limits (Fig. 7). This means that hydrocarbon vapor was passing into the tank every time a transfer was
made. The investigation uncovered additional systemic defects
that explain how the failure became extreme. These conditions
produced an unlikely combination of contributing factors:
• A procedure deviation that made it possible for operators
to transfer spent caustic without using nitrogen, which greatly
increased the amount of hydrocarbon vapor in the degassing
vessel headspace
• The formation of a pyrophoric iron sulfide ignition source
on the internal tank roof surface
• Oxygen in the tank.
Both examples strongly reinforce repeat failures’ involvement
in extreme failures. In every case, a trustworthy and actionable
cause emerges. It is based on evidence associated with a preceding
repeat failure.
Recall, however, that the goal of a reliability-based organization is to recognize the warning signals and take action before
an extreme failure triggers an accident investigation. The final
example shows how this can be accomplished by taking appropriate intervention steps upon detecting a repeat failure.
Extreme failure avoidance. A five-stage, barrel-type,
hydrogen recycle centrifugal compressor similar to the one shown
in Fig. 8 is in service in a large midwestern refinery’s platformer
Process-gas screw compressors
Gear-type compressors
Axial compressors
High-pressure compressors
Centrifugal compressors
Steam turbines
© Kevin Burke/Corbis | adtention
Expanders
Compressors Turbines Expanders Reactor Systems After Sales Service www.manturbo.com
MAN Turbo inside.
Refinery solutions for the long run.
We provide essential components for the efficient operation
It is our goal to deliver products that perform to the very highest
of a broad range of applications in refineries.
standards of reliability – your standards. Our approach has
made us the world market leader in FCC plants, and has
As key components in fluid catalytic cracking (FCC) units,
earned us the trust of customers like you.
our axial- and centrifugal compressors are designed to
achieve the highest level of availability attainable today. So
Your standards, our goal.
that tomorrow, your plant is running without interruption,
and with very little time devoted to maintenance.
Engineering the Future – since 1758.
MAN Turbo
Select 98 at www.HydrocarbonProcessing.com/RS
From Production Technologies to
Environmental Compliance, Selas Fluid
Is Your Single Source
Selas Fluid has been supplying innovative plant solutions worldwide for more than ļve decades. We have
built a history of service, with thousands of installations worldwide, by providing continuous innovation,
quality products and unmatched customer support.
From concept to reality, Selas Fluid is your full-service partner.
•
•
•
•
Equipment supply
Process design and engineering
Modular construction
Erection services
•
•
•
•
Revamp, retroļt and upgrade
Consultation and feasibility studies
Start-up and operator training
Spare parts and technical services
Selas Fluid
Subsidiary of The Linde Group
Headquarters: Five Sentry Parkway East Blue Bell, PA 19422 USA • Telephone: 610-834-0300 • Facsimile: 610-834-0473
Texas Ofļce: 16225 Park Ten Place, Suite 250 Houston, TX 77084 USA • Telephone: 281-717-9090 • Facsimile: 281-717-9091
www.selasĽuid.com
Select 100 at www.HydrocarbonProcessing.com/RS
RELIABILITY/MAINTENANCE
FIG. 9
Cascade plot showing a troublesome subsynchronous
vibration component “locked-in” at 3,000 cpm along with
expected synchronous (1X) vibration.
unit. The compressor operates at 8,200 rpm and processes a
recycle gas flow of about 97 MMscfd. The suction gas is contaminated with ammonium chloride. This situation is conducive to
depositing salt on the rotor, which has been the presumed source
for a series of recurring vibration events over the compressor’s
30-year history.
Fifteen months into a stable run after overhaul, the compressor
tripped offline and coasted to a stop without lubrication following
an unintended shutdown of both lube-oil supply pumps. After a
warm restart, vibration appeared to be stable and in general very
Elemental Analysis
of Fuels
Determination of Sulfur and other elements
at-line and in the laboratory
similar to conditions before the trip. Stable operation was interrupted a month later when the outboard radial bearing vibration
suddenly jumped to 1.7 mils.
Vibration analysis indicated that subsynchronous vibration had
developed due to a fluid instability problem that produced an “oil
whirl” pattern. Two months later, the vibration profile deteriorated
further into an “oil whip” pattern. This resulted in increasingly
unstable and unpredictable vibration spikes exceeding 2 mils.
Reducing the frequency and severity of the vibration spikes was
possible only by operating the compressor at speeds below 7,600
rpm. The speed curtailment resulted in a significant platformer unit
rate cut. The economics favored shutting down the unit to repair the
compressor rather than continuing to operate the machine below
its normal running speed. The repair plan was limited to replacing
the inboard and outboard floating-ring oil seals and tilt-pad radial
bearings. These components were suspected to have been damaged
by the accidental loss of lube oil. The repair plan also provided a
rationale for the type of vibration experienced soon after, which
indicated a fluid instability problem characterized by oil whip.
When the machine was opened for inspection, the maintenance staff was pleased to find radial-bearing and floating-ring oil
seal damage consistent with their diagnosis. The damaged components were replaced and the compressor restarted. Unfortunately,
the unstable subsynchronous vibration component remained at
speeds above 7,600 rpm upon the compressor’s return to service.
A second repair at considerable expense was scheduled in
response to this unfortunate turn of events. Since the compressor barrel was to be opened for inspection, a complete overhaul
was planned. A comprehensive vibration study was performed
To keep pace with the demanding quality requirements of
modern fuels, advanced, precise and easy to use analytical
technology is required. With a complete range of XRF and ICP
spectrometers, SPECTRO’s unique solutions for at-line and
laboratory elemental analysis are capable of meeting the
most demanding product specification testing requirements.
Measure your fuels
- at sub 10-15 ppm levels of sulfur to ensure federal
government agency compliance
- at trace ppm levels for metal elements such as Cu, Ca, Mg,
Na, K, and P, to ensure low engine emissions as well as
trouble-free motoring
- with reliability, speed and accuracy for any particular
application
- manually or fully automatically
You can find further information
about the SPECTRO solutions for
fuels analysis at
www.spectro.com/fuels
spectro.info@ametek.com and
Tel +49.2821.892-2102.
Select 184 at www.HydrocarbonProcessing.com/RS
HYDROCARBON PROCESSING APRIL 2009
I 95
RELIABILITY/MAINTENANCE
to narrow down the repair scope. An investigation was launched
to determine if a repeat failure could explain this machine’s long
history of what appeared to be unrelated, but persistent unstable
vibration events at high speed.
Although the compressor is armed with an eddy-current type
noncontacting shaft vibration monitoring and shutdown system,
“unstable” and “high speed” are words that do not go well together
in reliability and safety-based organizations. Therefore, refinery
staff wanted to determine if rotor fouling and other discrete events
were somehow related. Among these events the most recent one
was where replacing the damaged components did nothing to
correct unstable vibration.
The vibration study provided evidence needed to determine
both probable cause and, ultimately, avoidance of a repeat failure.
Fig. 9 shows how the subsynchronous component adjusts to maintain a constant fractional relationship with the rotor speed. It is
“locked-in” at a rotating frequency of 3,000 cpm that corresponds
to the rotor’s first natural fundamental frequency (critical speed).
These characteristics apply to flexible rotors that operate above one
or more shaft critical speeds.4 The compressor maintenance file
contains a history of unstable vibration events at speeds above 7,600
rpm. These events date back to 1985 and consistently appeared
within 18 to 24 months after overhaul. References document similar
cases involving the aerodynamic excitation of a rotor’s first natural
fundamental frequency.5 This condition may be experienced with
flexible rotors, due to the gradual deterioration of damping properties associated with normal operation after compressor overhaul.6
Aerodynamic rotor instability was thus identified as the probable cause for the history of compressor vibration events. This
Bartlett-Snow™ Rotary Calciners
Proven for High Temperature Thermal Processing
Custom designed to meet your processing requirements, Bartlett-Snow™ Rotary Calciners provide a
highly effective and efficient means for continuously
processing granular materials and powders at high
temperatures, in oxidizing, inert or reducing atmospheres.
Available in sizes from 6ⴖ to 120ⴖ in diameter with gas,
oil, dual-fuel burners, or electric heating elements.
Special internal flight design promotes gentle tumbling
action and provides for uniform exposure and efficient
heat transfer. Units can be equipped with gas-tight
seals that prevent interchange between the internal
atmosphere and local ambient conditions.
Air Preheater Company
Raymond Operations
4525 Weaver Pkwy, Warrenville, IL 60555
Toll free: 877.661.5509
Tel: 630.393.1000 • Fax: 630.393.1001
Email: info@airpreheaterco.com
www.bartlettsnowcalciners.com
Select 181 at www.HydrocarbonProcessing.com/RS
96
fact-based explanation developed the confidence management
needed to approve the investigation team’s long-term recommendation, i.e., to address the inherent instability by either redesigning or replacing the compressor. Most importantly, it interrupted
an extreme failure’s life cycle that might have resulted in unacceptable consequences, no matter what their relative “improbability.” Bottom line: Tolerating repeat failures is inconsistent with
reliability-focused thinking.
The science of warning signals. As these examples illustrate, rarely will an extreme failure occur simply based on a single,
isolated event. Rather, extreme failures are produced when an
existing repeat failure combines with other factors that are statistically unlikely to coexist. By way of analogy, repeat failures keep
reappearing like bars on a gambling casino slot machine. Repeat
failures are common, predictable events that independently represent low risk. But when all the bars line up, there is a payout.
When certain deviations line up with repeat failures you get negative payout in the form of an extreme failure.
This is the basis for the “coupling” argument introduced by
Charles Perrow in his classic Normal Accidents text. Perrow’s basic
premise is that complex systems are uniquely suited for two or
more independent and innocuous conditions to combine at once
to produce an unexpected catastrophic event.7 This principle is best
reflected in our compressor example, where a flexible rotor (the
latent cause) is no problem at all until it interacts with the contributing factors that align within 18 to 24 months of normal operation.
Likewise, the normal deterioration from start-of-run conditions
expected after 18 to 24 months would have little impact on a rigid
rotor’s aerodynamic stability operating in this specific service.
The benefit of recognizing and controlling a repeat failure is
that eliminating only one of the coupling requirements can mitigate the risk for an extreme failure. For example, the accidents
suffered in the case of the Hindenburg and the spent-caustic
storage tank could have been prevented had the repeat failures
(snapped bracing wires and hydrocarbon leakage, respectively)
been resolved. It is more rewarding to trigger an investigation
that prevents an accident rather than investigating the accident
you could have prevented.
What can you do? Knowledge about the relationship between
repeat failures and extreme failures adds value in two ways. First, it
becomes possible to locate the facts we need to filter our beliefs, so
that a credible probable cause can be identified when physical evidence has been compromised. Second, it promotes confidence that
we control process reliability and safety and will not let it control us.
By recognizing warning signals we can take deliberate actions to prevent extreme failures before suffering unacceptable consequences.
Since failure and accident prevention are the reliability-based
organization’s trademark, here are a few suggestions:
• Recognize repeat failures. Check reactive work orders
and challenge the ones that pop up regularly. Ask yourself, “Do I
know why I’m working on this again?” Perform an RCFA if the
answer is no.
• Follow and enforce procedures. Shortcuts tend to introduce risks that procedures mitigate. Follow procedure steps in
order. Communicate openly when you think there may be a better
way to execute a procedure or if the steps do not make sense or
seem out of order before deviating from them.
• Use good judgment. When changing conditions or circumstances interfere with the plan, don’t be afraid to enter a holding
2
3
4
5
6
7
8
Kenneth Bloch is lead process reliability engineer at Flint
Hills Resources’ Pine Bend Refinery in Rosemount, Minnesota. He
is responsible for mitigating and investigating process-governed
failures on refinery assets. A Certified API 510 Inspector, Mr. Bloch
publishes articles on equipment failure analysis, life cycle extension,
and reliability improvement in Hydrocarbon Processing and Chemical Engineering
magazines, and is a regular participant and speaker at the semiannual API/NPRA
Operating Practices Symposium and annual NPRA National Safety Conference. He
holds a BS degree (honors) from Lamar University in Beaumont, Texas.
Select 182 at www.HydrocarbonProcessing.com/RS 䉴
WORLD LEADER
®
1
LITERATURE CITED
Taleb, N. N., The Black Swan, Random House, New York, New York, p. 196,
(ISBN 978-1-4000-6351-2), 2007.
Bloch, K. and S. Williams, “Normalize Deviance at Your Peril,” Chemical
Engineering, 111, No. 5, pp. 52–56, 2004.
“The Hindenburg Airship,” Seconds From Disaster, Yavar Abbas, The National
Geographic Channel, November 15, 2005.
Eisenmann, Sr., R., and R. Eisenmann, Jr., Machinery Malfunction Diagnosis
and Correction, Prentice-Hall, Inc., Upper Saddle River, New Jersey, p. 436,
(ISBN 0-13-240946-1, out of print), 1998.
Nicholas, J. C. and J. Kocur, “Rotordynamic Design of Centrifugal
Compressors in Accordance with New API Stability Specifications,” Proceedings
of the Thirty-Fourth Turbomachinery Symposium, Turbomachinery Laboratory,
Texas A&M University, College Station, Texas, pp. 25–34, 2005.
Eisenmann, op. cit., p. 436.
Perrow, C., Normal Accidents: Living With High-Risk Technologies, Princeton
University Press, Princeton, New Jersey, p. 7, (ISBN 0-691-00412-9), 1999.
Lieberman, N., Troubleshooting Refinery Processes, Penwell Publishing Co.,
Tulsa, Oklahoma, p. 272, 1981.
w
flo s
to ce
Ro rvi
in e
ts d S
er an
xp rt
e E po
Th Sup
pattern or call time out. Stopping a job makes more sense than
executing it unsafely.
• Operate a near-miss awareness, reporting and investigation program. Ask employees to report things that don’t look,
sound or smell right. Follow up on employee concerns about unresolved problems. Resolve the issue and communicate findings back
to them. Look for trends that indicate a bigger problem looming.
• Develop and apply internal RCFA skills. Our biggest opportunity lies with correcting small failures to avoid the bigger ones.
Ultimately, no time will be saved unless RCFA is performed.
• RCFA triggers must be linked to repeat failures. Many
organizations tier their RCFA levels according to safety, environmental and economic thresholds. Reserve a category for repeat
failures and measure improvement (reduction) over time. The
maintenance staff will appreciate reducing the backlog and their
frustration over experiencing the same problems. You also benefit
in knowing that you are systematically mitigating the risk for an
improbable, yet far too costly, extreme failure (PSM incident).
• Communicate and incorporate lessons learned. Lessons
obtained by investigating repeat failures extend far beyond the
equipment type on which they occur. They will benefit different
units, areas, sites and even industries. Maximizing value from
a single failure involves communicating lessons learned effectively throughout an organization. Lessons learned from outside
resources can be obtained from numerous sources, such as the
annual NPRA Safety Conference (www.npra.org), semiannual
API/NPRA Operating Practices Symposium (www.api.org), the
AIChE Spring National Meeting (www.aiche.org), and the US
Chemical Safety Board (www.csb.gov).
Above all, remember that the machines we build perform
and respond exactly as expected under the conditions to which
they are exposed. Rarely, if ever, is the cause for a failure out of
our control. Be convinced that answers and solutions will come
to those who act on their responsibility to explain unacceptable
equipment performance. HP
In Turboexpander
Technology and Equipment
PRODUCTS:
• NEW EQUIPMENT
• OIL & GAS
• GEOTHERMAL
• AIR SEPARATION
• REDESIGN & UPGRADE
• CONTROL SYSTEMS
• MAGNETIC BEARINGS
SERVICES:
• ENGINEERING SERVICES
• REPAIRS
• FIELD SERVICES
• SPARE PARTS
• ROTOFLOW ® SERVICE
& SUPPORT
CAPABILITIES:
• 60,000 SQ. FT.
FACILITY NORTH OF L.A.
• FULL MACHINE SHOP
CAPABILITIES
• CNC 5-AXIS FOR
WHEEL PRODUCTION
• WORLD-WIDE
REPRESENTATION
FOR A FREE EVALUATION OF YOUR CURRENT
TURBOEXPANDER EQUIPMENT
CALL 661.294.8290 OR EMAIL US
AT SALES@LATURBINE.COM
www.laturbine.com
Tel: +1.661.294.8290 | Fax: +1.661.294.8249
29151 Avenue Penn, Valencia, CA USA
AD: www.gripa.it
© 2009 Costacurta S.p.A.-VICO
SINCE 1921...
AND WE
STILL LOVE IT
For more than eighty years, we at Costacurta have
been constantly and resolutely committed to the
development and manufacture of special steel wire and
plate components used in many different industrial
processes. Every day at Costacurta, we work to
improve the quality of our products and services and the
safety of all our collaborators, paying ever-greater
attention to the protection of the environment.
Within the wide range of Costacurta products you will
also find some, described below, that are used specifically
in the oil, petrochemical and chemical industries:
- RADIAL FLOW AND DOWN FLOW REACTOR INTERNALS;
- GAS-LIQUID AND LIQUID-LIQUID SEPARATORS;
- ARMOURING OF REFRACTORY, ANTI-ABRASIVE AND
ANTI-CORROSIVE LININGS.
For more information visit our website or contact the
division 'C' components for the oil, petrochemical
and chemical industries at tcsc@costacurta.it.
Select 71 at www.HydrocarbonProcessing.com/RS
Costacurta S.p.A.-VICO
via Grazioli, 30
20161 Milano, Italy
tel. +39 02.66.20.20.66
fax: +39 02.66.20.20.99
Management systems
certified by LRQA:
ISO 9001:2000
ISO 14001:2004
OHSAS 18001:1999
Gas-liquid and liquid-liquid separators
www.costacurta.it
COMPUTER TECHNOLOGY/PIPING
Computational fluid dynamics
simulation of solid–liquid slurry flow
The resulting model’s predictions showed reasonably good agreement
with the experimental data
S. K. LAHIRI* and K. C. GHANTA, National Institute of Technology, Durgapur, India
A
comprehensive computational fluid dynamics (CFD) model
was developed in the present study to gain insight into solid–
liquid slurry flow in pipelines. The preliminary simulations
highlighted the need for correct modeling of the interphase drag
force. A two-dimensional model problem was then developed using
CFD to understand the influence of the particle drag coefficient on
the solids concentration profile. The proposed correlation was then
incorporated in a two-fluid model (Euler-Euler) along with the standard k-␧ turbulence model with mixture properties to simulate the
turbulent solid–liquid flow in a pipeline. A computational model was
mapped on to a commercial CFD solver. The model predictions were
compared with the published experimental data of Kaushal et al.1 and
Mukhtar.2 The predicted results show reasonably good agreement
with the experimental data. The computational model and results
discussed in this work would be useful for extending the applications
of CFD models for simulating large slurry pipelines.
Introduction. Transporting slurries through pipelines is com-
mon in the solids handling, mineral and petrochemical industries
and its huge power consumption is drawing attention in recent
years. The need and benefit of accurately predicting the velocity
and concentration profiles and pressure drops of slurry pipelines
during the design phase are enormous since they provide a better
selection of slurry pumps and optimization of power consumption, and help to maximize economic benefits. Despite significant
research efforts, predicting the solids concentration profile in
a slurry pipeline is still an open problem for design engineers.
Slurry pipeline design relies on empirical correlations obtained
from the experimental data. These correlations are prone to great
uncertainty as one departs from the limited database that supports
them. Moreover, for higher values of solids concentration, very
few experimental data on local solids concentration are available
because of the difficulties in the measurement techniques. Considering this, it would be most useful to develop computational
models that will allow “a priori” estimation of the solids concentration profile over the pipe cross-section.
In spite of the inadequate fundamental knowledge required for
formulating and modeling multiphase turbulent flows, the need to
predict slurry behavior handled in various industries has motivated
work aimed at obtaining approximate solutions. Efforts are still
underway to develop a more reasonable correlation-based model for
*Corresponding author
predicting the concentration profile in pipes and in this direction,
the works of Roco and Shook (1983, 1984),3,4 Gillies et al. (1991,
1999, 2000),5–7 Mukhtar (1991)2 and Kaushal et al. (2002)8,1 are
worth mentioning. Most of the equations available in the literature
for predicting vertical solids concentration profiles in slurry pipeline
are empirical and have been developed based on limited data on
materials having equisized or narrow size-range particles and with
very low concentrations. Since the correlations are empirical, their
applicability is limited, e.g., the correlations developed for sand–
water slurry flow do not produce promising results when they are
applied on coal–water slurry flows. An attempt has been made in
the present study to develop a generalized slurry flow model using
CFD and utilize the model to predict the concentration profile.
In recent years, CFD has become a powerful tool for predicting fluid flow, heat/mass transfer, chemical reactions and related
phenomena by solving mathematical equations that govern these
processes using a numerical algorithm on a computer.
A brief review of recent literature shows little progress in simulating flow in slurry pipelines using CFD. For solid–liquid multiphase flows, the complexity of modeling increases considerably
and this remains an area for further research and development.
Due to the inherent complexity of multiphase flows, from a physical as well as a numerical point of view, “general” applicable CFD
codes are nonexistent. The reasons for the lack of fundamental
knowledge on multiphase flows are three-fold:
Multiphase flow is a very complex physical phenomenon where
many flow types can occur (solid–liquid, gas–solid, gas–liquid,
liquid–liquid, etc.) and within each flow type several possible flow
regimes can exist (e.g., in slurry flow four regimes exist namely
homogeneous, heterogeneous, moving bed and saltation).
The complex physical laws and mathematical treatment of
phenomena occurring in the presence of the two phases (interface
dynamics, coalescence, break-up, drag, solid–liquid interaction, .
. . ) are still largely undeveloped. For example, to date there is still
no agreement on the governing equations. In addition, proposed
constitutive models are empirical but often lack experimental
validation for the conditions they are applied under.
The numeric for solving the governing equations and closure
laws of multiphase flows is extremely complex. Very often multiphase flows show inherent oscillatory behavior, requiring costly
transient solution algorithms. Almost all CFD codes apply extensions of single-phase solving procedures, leading to diffusive or
unstable solutions, and require very short time steps.
HYDROCARBON PROCESSING APRIL 2009
I 99
COMPUTER TECHNOLOGY/PIPING
In spite of the major difficulties mentioned, attempts have been
made to simulate the solid–liquid flow in pipelines. Most of these
studies are focused on predicting the solids concentration distribution in the experimental slurry pipelines. Although some degree of
success is reported, a number of limitations are apparent.
Considering the limitations in the published studies, the present
work has been undertaken to systematically develop a CFD-based
model to predict the solids concentration profile in slurry pipeline.
In the present work, the solids suspension in a fully developed pipe
flow was simulated. The two-fluid model based on the EulerianEulerian approach along with a standard k-␧ turbulence model with
mixture properties was used. The computational model developed
in this work was used to simulate solid–liquid flow in the experimental setup used by Kaushal et al. The model predictions were
evaluated by comparing predictions with the experimental data.
where f is defined differently for the different exchange–coefficient models (as described below) and ␶s , the “particulate relaxation time,” is defined as:
d2
s = s s
(4)
18μl
Multiphase CFD model. Many approaches exist for model-
where CD has a form derived by Dalla Valle.17
ing the motion of two-phase mixtures (e.g., solid–liquid), where
one phase is dispersed in the other. They can be divided into
Eulerian-Lagrangian and Eulerian-Eulerian approaches.
Eulerian model. In the former approach, the disperse phase
is treated in terms of individual particles for which the equations
of motion are solved. In the Eulerian-Eulerian approach, the
two phases are considered to be interpenetrating continua. For
the present CFD simulations, the Eulerian-Eulerian multiphase
model implemented in commercial CFD code was used. With
this approach, the continuity and the momentum equations are
solved for each phase and, therefore, determining separate flow
field solutions is allowed.
The Eulerian model is the most complex and computationally intensive among the multiphase models. It solves a set of n
momentum and continuity equations for each phase. Coupling
is achieved through the pressure and interphase exchange coefficients. For granular flows, the properties are obtained from
applying kinetic theory.
Continuity equation. The continuity equations for a generic
phase, q, is:
2
4.8
(6)
C D = 0.63 +
Re s / r ,s This model is based on terminal velocity measurements of
particles in fluidized or settling beds, with correlations that are a
function of the volume fraction and relative Reynolds number:
l d s s l
Re s =
(7)
μl
( ) + ( q q q ) = 0
t q q
(1)
Fluid–solid momentum equations. The conservation of momentum for the s th solid phase is:
( s s s ) + ( s s s s ) = s p ps + t
s + s s g + s s ( Fs + Flift ,s + Fvm,s ) +
(K ls ( l s ) + m ls ls )
N
r ,s s
where ␷r,s is the terminal velocity correlation for the solid phase:
(0.06Re s )2 + 0.12Re s r ,s = 0.5 A 0.06Re s +
(9)
2
(2B
A)
+
A
with
A = l4,14
(10)
B = 0.8 l 1.28 for l 0.85
(11)
and
B = l 2.65 for l > 0.85
(2)
where ps is the s th the solids pressure, K ls = K sl is the momentum
exchange coefficient between fluid phase l and solid phase s and N is
the total number of phases. The lift force, Flift,s , and the virtual mass
force, Fvm,s , have been neglected in the calculations because they give a
minor contribution to the solution with respect to the other terms.
Fluid–solid exchange coefficient. The fluid–solid exchange coefficient, Ksl , is in the following general form:
f
K sl = s s
(3)
s
I APRIL 2009 HYDROCARBON PROCESSING
where the subscript l is for the l th fluid phase, s is for the solid
phase and ds is the diameter of the s th solid phase particles.
The fluid–solid exchange coefficient has the form:
Re 3 K sl = s 2 l l C D s s l
(8)
r ,s 4 d
and
l =1
100
where ds is the diameter of particles of phase s.
All definitions of f include a drag function, CD , that is based
on the relative Reynolds number, Res . CD differs among the
exchange-coefficient models. The following three models found
in the literature are promising and widely used for calculating
solid–liquid interaction in slurry flow.
• Syamlal-O’Brien model.9 For this model f is defined as:
C Re f = D 2s l
(5)
24 r ,s
(12)
This model is appropriate when the solids shear stresses are
defined according to Syamlal et al.10
• Wen and Yu model. For the model of Wen and Yu,11 the
fluid–solid exchange coefficient is of the following form:
l 2.65
3
K sl = C D s l l s
l
(13)
4
ds
where
24 CD =
1+ 0.15( l Re s )0.687 (14)
l Re s and Res is defined by Eq. 7.
This model is appropriate for dilute systems.
• Gidaspow model. The Gidaspow model12 is a combination
COMPUTER TECHNOLOGY/PIPING
of the Wen and Yu model11 and the Ergun equation.13
The fluid–solid exchange coefficient, Ksl , is of the following
form:
l 2.65
3
K sl = C D s l l s
l
(15)
4
ds
where
24 CD =
1+ 0.15( l Re s )0.687 (16)
l Re s when l 0.8,
K sl = 150
s (1 l )μl
l d 2s
+ 1.75
l s s l
ds
(17)
y/D
0.8
0.6
m =
N
i ii
(21)
i=1
N
i i
the turbulent viscosity, μt ,m , is computed from:
μt ,m = mC μ
k2
(22)
and the production of turbulence kinetic energy, Gk,m , is computed from:
Gk,m = μt ,m m + (m )T m
(23)
The model constants C1 ,C 2 ,C μ , k and have the following values:
C1 = 1.44, C 2 = 1.92, C μ = 0.09, k = 1.0, = 1.3
Experimental data. In the present study, 15 sets of Kaushal1
data and 15 sets of Mukhtar2 data with multisized particulate zinc
tailings slurries flowing through 105-mm-diameter pipelines have
been considered. The particle size range used in all these data was
wide enough to cover the range expected in commercial slurries.
The range of experimental data taken is summarized in Table
1. In Kaushal1 and Mukhtar2 data, concentration profiles have
been reported for different efflux concentrations at different flow
velocities. These data are used for proposing the CFD model for
predicting concentration profiles and are shown graphically in
0.1
0.2
0.3
0.4
Volume fraction of solid
(d) Cvf = 18.6%, Vm = 2 m/s
0.6
0.6
0.4
0.4
0.2
0.2
0.0
0.0
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
0.0
0.0
0.3
0.1
0.2
0.4
Volume fraction of solid
(b) Cvf = 8.2%, Vm = 2 m/s
Experimental
Calculated
0.1
0.2
0.3
0.4
Volume fraction of solid
(e) Cvf = 25.5%, Vm = 2 m/s
Experimental
Syamlal model
Wen and Yu model
Calculated
Gidaspow model
0.8
y/D
y/D
Experimental
Syamlal model
Wen and Yu model
Calculated
Gidaspow model
1.0
Experimental
Syamlal model
Wen and Yu model
Calculated
Gidaspow model
0.8
0.1
0.2
0.4
0.3
Volume fraction of solid
(a) Cvf = 4%, Vm = 2 m/s
0.2
FIG. 1
and
1.0
0.4
0.0
0.0
(20)
i=1
y/D
1.0
(19)
Experimental
Calculated
y/D
y/D
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
N
m = i i
i=1
This model is recommended for dense fluidized beds.
Turbulent model. For turbulent multiphase flow, a standard
k-␧ turbulence model was used. In this study, the simplest k-␧
turbulence model was assumed, referred to as the mixture model
where only a couple of k and ␧ equations are solved and the
physical properties of the mixture are adopted.14 The two phases
are assumed to share the same k and ␧ values and, therefore, the
interphase turbulence transfer is not considered.
The k and ␧ equations describing this model are:
μ
( m k ) + ( mm k ) = t ,m k +Gk ,m m (18)
k
t
and
μ
( m ) + ( mm ) = t ,m +
t
k
(C1Gk ,m C 2 m )
where the mixture density and velocity, m and m , are computed from:
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
0.1
0.2
0.3
0.4
Volume fraction of solid
(c) Cvf = 13.5%, Vm = 2 m/s
Experimental
Calculated
0.1
0.2
0.3
0.4
Volume fraction of solid
(f) Cvf = 26%, Vm = 3.5 m/s
Measured (by Kaushal9) and predicted (by present model, Syamlal model,18 Gidaspow model4 and Wen and Yu19 model) concentration
profiles at different efflux concentrations and flow velocity for the flow of zinc tailings slurry through a 105-mm-diameter pipe.
HYDROCARBON PROCESSING APRIL 2009
I 101
FIG. 2
0.2
0.4
Volume fraction of solid
(a) Cvf = 4.09%, Vm = 1.57 m/s
Experimental
Calculated
0.2
0.4
Volume fraction of solid
(d) Cvf = 8.83%, Vm = 2.05 m/s
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
Experimental
Calculated
y/D
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
0.2
0.4
Volume fraction of solid
(b) Cvf = 4.09%, Vm = 1.96 m/s
Experimental
Calculated
y/D
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
Experimental
Calculated
y/D
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
y/D
y/D
y/D
COMPUTER TECHNOLOGY/PIPING
0.2
0.4
Volume fraction of solid
(e) Cvf = 8.83%, Vm = 3.05 m/s
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
Experimental
Calculated
0.2
0.4
Volume fraction of solid
(c) Cvf = 4.09%, Vm = 2.89 m/s
Experimental
Calculated
0.2
0.4
Volume fraction of solid
(f) Cvf = 10.52%, Vm = 3.05 m/s
Measured (by Mukhtar11) and predicted (by present model) concentration profiles at different efflux concentrations and flow velocity for
the flow of zinc tailings slurry through a 105-mm-diameter pipe.
102
I APRIL 2009 HYDROCARBON PROCESSING
y/D
y/D
coupled by phases, but in a segregated fashion.
The block algebraic multigrid scheme used
by the coupled solver solves a vector equation formed by the velocity components of
all phases simultaneously. Then, a pressurecorrection equation is built based on total volume continuity rather than mass continuity.
Pressure and velocities are then corrected to
Experimental
Experimental
satisfy the continuity constraint.
Calculated
Calculated
The structured grid composed of 50,000
0.2
0.4
0.2
0.4
rectangular cells (1,000 × 500) was created in
Volume fraction of solid
Volume fraction of solid
a GAMBIT 2.2 pre-processor. A dense com(a) Cvf = 25.8%, Vm = 1.76 m/s
(b) Cvf = 25.8%, Vm = 2.90 m/s
putational grid was used because of the pilotscale pipe dimensions. The initial conditions
FIG. 3 Measured (by Mukhtar11) and predicted (by present model) concentration profiles at
different flow velocity for the flow of zinc tailings slurry through a 105-mm-diameter
were: a uniform fully developed velocity propipe.
file at the pipe inlet and the solid particles are
uniformly distributed at the pipe inlet. The
TABLE 1. Experimental data used in the present study
second-order upwind discretization scheme
was used for the momentum equations, turMean particle
Flow
Pressure
Specific
Pipe
dia. of efflux Efflux conc.
velocity
drop range, bulence kinetic energy, k, and turbulence disAuthor
Material gravity dia., mm sample, ␮m
range, %
range, m/s
m/mwc
sipation rate, ␧. The QUICK discretization
1
Zinc
2.82
105
34.95
3.8–26
2–3.5
0.062–0.214 scheme was used for the volume fraction. All
Kaushal
tailings
the simulations were performed in doubleMukhtar2
Zinc
2.597
105
69.24
4.09–25.8
1.48–3.08
0.036–0.147 precision and a user-defined function (UDF)
tailings
was used for fixing the total volume fraction in
the pipe. A total number of 20,000 iterations
Figs. 1–4. Details of the experimental setup and the experimental
was found to be sufficient to achieve a fully converged solution.
data collection method can be found in reference 1.
To improve the convergence behaviour, the flow for only one
phase was first computed (by deselecting the volume fraction
CFD simulations and results. For Eulerian multiphase calculaequations). Once the initial solution for the primary phase was
tions, we use the phase-coupled SIMPLE (PC-SIMPLE) algorithm15
obtained, the volume fraction equations were turned back on and
for the pressure-velocity coupling. PC-SIMPLE is an extension of
the calculation continued with all phases. Finally, low under-relaxthe SIMPLE algorithm to multiphase flows. The velocities are solved
ation factors were used to increase the convergence behaviour.
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
FIG. 4
Experimental
Calculated
0.2
0.4
Volume fraction of solid
(a) Cvf = 3.8%, Vm = 2.75 m/s
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
Experimental
Calculated
y/D
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
y/D
y/D
COMPUTER TECHNOLOGY/PIPING
0.2
0.4
Volume fraction of solid
(b) Cvf = 8.75%, Vm = 2.75 m/s
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.0
Experimental
Calculated
0.2
0.4
Volume fraction of solid
(c) Cvf = 12.2%, Vm = 2.75 m/s
Measured (by Kaushal9) and predicted (by present model) concentration profiles at different efflux concentrations for the flow of zinc
tailings slurry through a 105-mm-diameter pipe with a velocity of 2.75 m/s.
Comparisons between measured and predicted concentration
profiles based on the Syamlal-O’Brien9 model, Wen and Yu11
and Gidaspow models.12 CFD simulations were done for all the
30 cases of Kaushal1 and Mukhtar2 data for all the three models and
some typical concentration profiles are shown in Figs. 1–4. These
figures present the comparison between measured and predicted
concentration profiles for Kaushal1 and Mukhtar2 data, where y/D
is the reduced vertical coordinate from the pipe bottom, Cv ( y/D)
the concentration by volume at y/D and Vm the slurry flow velocity.
It is seen that for almost all the data, the three models fail to predict
the concentration profile accurately. All three models predicted the
concentration profile as flat and homogeneous. However, the experimental concentration profile is not flat and more solids concentrate
at the bottom. From the experimental solids concentration profiles
(Figs. 1–4) it is clear that the settling tendency leads to a significant
gradation in the slurry solids concentration. The solids concentration is higher in the lower sections of the horizontal pipe. The extent
of the solids accumulation in the lower section depends strongly
on the slurry velocity in the pipeline. The higher the velocity, the
higher the turbulence level and the greater the ability of the carrier
fluid to keep the particles in suspension. Upward motion of eddy
currents transverse to the main direction of slurry flow is responsible
for maintaining the particles in suspension. At very high turbulence
levels the suspension is almost homogeneous with very good solids
dispersion while at low turbulence levels the particles settle toward
the channel floor and can, in fact, remain in contact with the flow
and are transported as a sliding bed under the influence of the pressure gradient in the fluid. When the turbulence level is not high
enough to prevent any deposition of particles on the channel floor,
the flow regime is described as being heterogeneous suspension.
From the quantitative comparison, it is clear that these three
models do not take into consideration the changes in fluid and
flow properties that occur with an increase in solids concentration
at the pipe bottom. All three models could not capture the variations of drag coefficients with the increase in solids concentration
at the pipe bottom. In light of these shortcomings, an effort was
made in the present study to modify the existing models to incorporate the effect of solids concentration at drag coefficients.
Modified model description. As discussed earlier, estimating
drag is critical for accurate prediction of a solids concentration
distribution. In a solid–liquid pipeline, the interphase drag coefficient, CD, is a complex function of a drag coefficient in a stagnant
liquid, CD 0 , and the prevailing turbulence level. In the present
work, we have critically examined the available information to
select the appropriate interphase drag formulation. A computer
program (user-defined function) was developed based on the fol-
lowing steps to implement the modified model:
1. The particle Reynolds number for size fraction was calculated as:
d p s Vm
Re p =
(24)
μs
2. The drag coefficient was calculated using the Turton-Levenspiel equation:
24
0.413
CD =
(1+ 0.173Re p0.657 )
(25)
Re p
1+ 1.163104 Re 1.09
p
This equation is chosen purposefully from the literature
because it accurately predicts the experimental drag coefficient
value in the range of Rep < 2!10 5.
3. Terminal velocity, Vto , was calculated using the following
equation:
4( s l )gd p
Vto =
(26)
3l C d
4. If the surrounding liquid is turbulent, as in the case of
a slurry pipeline, the prevailing turbulence and solid particles
are expected to influence the effective particle settling velocity.
However, unhindered settling velocity in the calculations does not
account for the effect of concentration, particle size distribution
and pipe walls. Richardson and Zaki16 have already given a correlation for hindered settling velocity by taking into consideration
these factors.
Richardson and Zaki’s coefficient, Z, was calculated as:
d
p
0.002 < Re p 0.2
Z = 4.65 +1.95
(27)
D
d
p
Z = 4.35 +17.5 Re 0.03
p
D
d
p
1.0 Re p
Z = 4.45 +18.0 Re p0.1
D
5. Hindered settling velocity was determined by:
0.2 Re p 1.0
Vt = Vto (1C v f )Z
(28)
6. The fluid–solid exchange coefficient is calculated from:
3 s l C D Re p μl
K sl =
(29)
4Vt 2 d 2
HYDROCARBON PROCESSING APRIL 2009
I 103
COMPUTER TECHNOLOGY/PIPING
The above user-defined
putational model and results disfunction was coupled in the
cussed in this work would be useCFD solver.
ful for extending the applications
Comparison between meaof CFD models for simulating
sured and predicted concentralarge slurry pipelines. HP
tion profiles based on modified
LITERATURE CITED
model. The overall concentra1 Kaushal, D. R., Tomita, Y. and R. R.
tion profiles are predicted by
Dighade, “Concentration at the pipe
the modified model for 30 sets
bottom at deposition velocity for
transportation of commercial slurries
of experimental data reported
through pipeline,” Powder Technology,
by Kaushal1 and Mukhtar2 and
Vol. 125, pp. 89–101, 2002.
some of them are shown in Figs.
FIG. 5 Concentration profile at the end of the pipe (Cvf ) = 8.83%,
2 Mukhtar, A., “Investigations of the
Vm = 2.05 m/s).
1–4. It is observed that for almost
flow of multisized heterogeneous
slurries in straight pipe and pipe
all the data, the modified model
bends,” Ph.D. thesis, IIT, Delhi, 1991.
gives an almost exact fit between the measured and predicted
3 Roco, M. C. and C. A. Shook, “Modelling of slurry flow, the effect of particle
overall concentration profiles. In the earlier predictions by the
size,” The Canadian Journal of Chemical Engineering, Vol. 61, pp. 494–503,
Syamlal-O’Brien, Wen and Yu and Gidaspow models (Fig. 1), the
1983.
4 Roco, M. C. and C. A. Shook, “Computational methods for coal slurry
predicted concentration profiles were flat and large deviations were
pipeline with heterogeneous size distribution,” Powder Technology, Vol. 39,
observed from experimental profile. This shows that the predicpp. 159–176, 1984.
tions by the modified model for overall concentration profile are
5 Gillies, R. G. and C. A. Shook, “Modelling high concentration settling slurry
better than the predictions by the three models. The modified
flows,” The Canadian Journal of Chemical Engineering, Vol. 78, pp. 709–716,
model actually takes care of the change of settling velocity and drag
2000.
6 Gillies, R. G., Shook, C. A. and K. C. Wilson, “An improved two-layer
coeffient with the solids concentration at the bottom of the pipe.
model for horizontal slurry pipeline flow,” The Canadian Journal of Chemical
Actually, when we plotted the concentration profile contours (Fig.
Engineering, Vol. 69, pp. 173–178, 1991.
7 Gillies, R. G., Hill, K. B., McKibben, M. J. and C. A. Shook, “Solids
5) in CFD we found that solids concentration is very low at the
top of the pipe and settled at the bottom of the pipe as expected.
transport by laminar Newtonian flows,” Powder Technology, Vol. 104, pp.
269–277, 1999.
Due to this difference, the drag coefficient and settling velocity
8 Kaushal, D. R., and Y. Tomita, “Solid concentration profiles and pressure
are not constant throughout the pipe cross-section and they vary
drop in pipeline flow of multisized particulate slurries,” International Journal
along with the concentration. This nonuniform drag coefficient
of Multiphase Flow, Vol. 28, pp. 1697–1717, 2002.
9 Syamlal, M. and T. J. O’Brien, “Computer Simulation of Bubbles in a
and settling velocity give rise to different solid–liquid exchange
Fluidized Bed,” AIChE Symp. Series, Vol. 85, pp. 22–31, 1989.
coefficients across the pipe cross-section as per Eq. 29. The com10
Syamlal, M., Rogers, W. and T. J. O’Brien, MFIX Documentation, Volume 1,
Theory Guide, National Technical Information Service, Springfield, Virginai,
1993.
11 Wen, C. Y. and Y. H. Yu, “Mechanics of Fluidization,” Chem. Eng. Prog.
Symp. Series, Vol. 62, pp. 100–111, 1966.
12 Gidaspow, D., Bezburuah, R. and J. Ding, “Hydrodynamics of Circulating
Fluidized Beds, Kinetic Theory Approach,” Fluidization VII, Proceedings of the
7th Engineering Foundation Conference on Fluidization, pp. 75–82, 1992.
13 Ergun, “Fluid Flow through Packed Columns,” Chem. Eng. Prog., Vol. 48,
No. 2, pp. 89–94, 1952.
14 Launder, B. E. and D. B. Spalding, Lectures in Mathematical Models of
Turbulence, Academic Press, London, England, 1972.
15 Vasquez, S. A. and V. A. Ivanov, “A Phase Coupled Method for Solving
Multiphase Problems on Unstructured Meshes,” Proceedings of ASME
FEDSM’00, ASME 2000 Fluids Engineering Division Summer Meeting,
Boston, June 2000.
16 Richardson, J. R. and W. N. Zaki, “Sedimentation and Fluidization: Part I.,”
Trans. Inst. Chem. Eng., Vol. 32, pp. 35–53, 1954.
17 Dalla Valle, J. M., Micromeritics, Pitman, London, 1948.
18 Seshadri, V., Malhotra, R. C. and K. S. Sundar, “Concentration and size distribution of solids in slurry pipeline,” Proc. 11th National Conference on Fluid
Mechanics and Fluid Power, BHEL, Hyderabad, India, pp. 110–123, 1982.
Sandip Kumar Lahiri has 15 years’ technical services and
operation experience in petrochemical industries across the globe. He
has an M.Tech qualification in chemical engineering and is currently
doing research on multiphase flow and CFD. Mr. Lahiri’s interests
include simulation, optimization, APC and soft sensor development.
Dr. Kartik Chandra Ghanta is a professor in the Department of Chemical Engineering of the National Institute of Technology, Durgapur, India. He has 16 years of teaching and research experience. Dr. Ghanta’s fields of interest are slurry flow and modeling.
Select 179 at www.HydrocarbonProcessing.com/RS
104
© 2009 Thermo Fisher Scientific Inc. All rights reserved. All tradesmarks are the property
of Thermo Fisher Scientific Inc. and its subsidiaries.
To optimize plant production, decipher this simple equation.
Looking for a proven formula to speed plant optimization
and fuel profits? We have the answer: PMS (Process Mass
Spectrometry) plus MPC (Model Predictive Control) equals
ROI (Return on Investment).
The Thermo Scientific Prima bB and Sentinel bB process mass
spectrometers deliver the fast, precise, stable online analysis
you need to reduce the need for predictive approximations—
and monitor fugitive VOC emissions. Add MPC to the equation
to build more robust hybrid control models and improve
process metrics.
Thermo Scientific Prima bB–
Find out how our low-maintenance PMS solutions can help
you reduce energy use, boost yield, and improve profits.
The online process mass
spectrometer for increased product
yield and greater profits.
Call 1 (713) 272–0404 or 1 (800) 437–7979. Or visit
www.thermo.com/PMS.
Part of Thermo Fisher Scientific
Select
Select103
104at
atwww.HydrocarbonProcessing.com/RS
www.HydrocarbonProcessing.com/RS
Select 110 at www.HydrocarbonProcessing.com/RS
SAFETY
Apply new trends for
safety-instrumented systems
Take a closer look at advancements for emergency shutdown designs
P. GRUHN, ICS Triplex, a Rockwell Automation Company, Houston, Texas
P
rior to 1968, most safety-instrumented systems, also known
Flexible redundancy. As mentioned earlier, the first popular
as emergency shutdown systems, were implemented using
safety PLC was triplicated. The early Model T automobiles came
relays. The advent of the programmable logic controller
in any color you wanted, as long as it was black—you could also
(PLC) changed all that. Hard-wired solid-state systems—designed
receive an early PLC system in any configuration you wanted, as
to replace relays without using software—were also popular for
long as it was triplicated. These were some of the first systems to
several decades. Software-based systems pose the majority of
be independently certified. The dual vendors had their systems
safety-instrumented systems installed today.
certified to compete with the triplicated systems. The dual-sysGeneral purpose PLCs have a variety of weaknesses in safety
tem vendors also offered non-redundant configurations. When
applications that have been recognized for many years, primarily
triplicated-system vendors manufactured new systems, they were
the lack of thorough diagnostics.1 Users, vendors and integrators
still triplicated. However, when single- and dual-system vendors
have understood these weaknesses and some have engineered
designed new systems, they were still single and dual.
customized solutions to overcome many
Three different vendors released new
such weaknesses. Such a customized
safety PLCs in 2008 that could be con■ Specialized PLCs
general-purpose PLC engineered and
figured single, dual or triplicate systems.
configured for safety is referred to as a designed from the ground up, One vendor also offers a quad system. At
“safety-configured PLC.” 2 Specialized
least one offers flexible redundancy, i.e., in
PLCs designed from the ground up, spe- specifically for critical safety
one system some modules can be single,
cifically for critical safety applications,
others dual, and others triplicated. Flexare referred to as “safety PLCs.” Safety applications, are referred to as ible redundancy allows the system to more
PLCs have been available since the early
closely match the safety and reliability
1980s. Over time, more vendors have “safety PLCs.”
requirements in a cost-effective manner.
entered the market. Changes in technology have led to a variety of recent developments. Many vendors
Integrated control and safety from one vendor. The
have released new systems that are a considerable departure from
traditional approach for control and safety systems has been to
past systems. So, just what are the latest safety-instrumented
provide two separate platforms from two separate vendors. Consystem trends?
trol and safety systems communicate with each other using either
The following information pertains primarily to safety PLCs,
an industry standard protocol (e.g., MODBUS, OPC) or using
not safety configured PLCs, used in the process industries.
the same proprietary highway as the control system (often using
some form of gateway). While major control system companies
Smaller, distributed systems. The first popular safety
usually offer safety systems, many systems were either acquired
PLC introduced in the mid-1980s was triplicated. These systems
from different companies or supplied through some form of
were naturally much more expensive than non-redundant general
partnership with a different company.
purpose PLCs. They were often considered too expensive to have
The traditional approach has the advantage of allowing the user
multiple distributed systems scattered around a facility. The most
to purchase what they believe to be the best of both worlds, i.e., a
economical implementation of such systems was often one large,
control system from one company and a safety system from another.
centralized system. One large 1,000-input/output (I/O) system
However, this means that the user must deal with two different
was cheaper than 10 or more 100-I/O systems.
vendors, learn two different hardware and software platforms, send
However, not all systems are classified as 1,000-I/O systems or
people to more training courses, experience the frustration of gethigher. Therefore, some vendors developed safety PLCs targeted
ting both systems to communicate together effectively, etc.
for small I/O applications. But, using one system for small appliSince control system vendors saw no need to give the safety
cations, and a completely different system for large applications
system business away to another company, many decided to
in the same facility, is hardly an ideal solution (even though they
develop their own systems. The trend now is to have one venmay be from the same vendor). A number of vendors have recently
dor supply both systems. The control and safety systems often
released systems that can be small and stand-alone, as well as large
look very similar (although they are not interchangeable). Users
and distributed, all using the same hardware.
only have to attend one training class and the systems are usually
HYDROCARBON PROCESSING APRIL 2009
I 107
SAFETY
programmed using the same software. Communication between
systems is effortless, and there is no more finger pointing when
problems occur.
2 and 3 applications. One-out-of-two or two-out-of-three sensor
configurations and one-out-of-two final element configurations are
generally required for SIL 2. The total installed cost of a sensor has
been reported as high as $10,000—redundant final elements are
Field busses. Field busses are digital networks for sensors and final
often more expensive.
elements that allow multiple field devices to be connected on a single
However, the standard does acknowledge cases where the fault
pair of wires. Commonly cited features and benefits include reduced
tolerance numbers may be reduced. One such instance is to use field
wiring, higher levels of internal diagdevices that are designed and analyzed
nostics, and lower total costs. Field
according to the IEC 61508 standard.
busses have been available for gen- ■ The primary benefit touted by
The first safety certified transmitter
eral process control applications for a
released around 1998, the secsafety fieldbus manufacturers and was
number of years, but their use in safety
ond a few years later. Initially, vendor
was considered questionable by many. consortia is diagnostics: being able interest in developing and certifying
The concern with safety is whether a
such devices was not strong. Recent
digital message has been corrupted in to predict problems before they
standards and end-user demands have
some manner. Safety standards state have an impact on the process.
prompted many vendors to develop
that busses are acceptable only if they
new field devices that are certified for
meet the integrity-level requirements.
use in safety applications. There are
No busses could meet such requirements in the past when the stannow dozens of safety-certified field devices on the market. The main
dards were written, but this is changing.
difference with these devices is their much higher level of internal
PROFIsafe is a safety protocol used along with PROFIBUS
diagnostics. Redundancy is not always the magic answer for safety;
and PROFINET. It has been certified for use in Safety Integrated
diagnostics is an important factor. Some sensors have achieved this
Level 3 (SIL 3) applications for a number of years. Its initial use
with diverse, redundant electronics. There are many valve manufacwas primarily in the machinery industry, but there have been
turers that offer partial stroke solutions. Partial stroking assures that
recent releases of PROFIsafe devices in the process industry. At
the valve is not stuck. The main point of certified devices is simpler
least one safety PLC is able to incorporate PROFIsafe devices.
designs with less hardware, therefore, lower total cost for users. Single
Foundation Fieldbus is the only bus that allows control in the
devices with high levels of diagnostics usually offer similar safety
field (i.e., a master controller such as a PLC or DCS is not necesperformance to redundant standard devices, at a much lower cost.
sary). However, standard Foundation Fieldbus is not suitable for
safety applications. The Fieldbus Foundation has been working
Personnel with certifications. Most safety PLCs are certion safety standards (Foundation Fieldbus SIF) for several years
fied by independent third parties for use in critical safety applicawith safety PLCs and field device manufactures as part of the
tions according to international standards. Unfortunately, many
consortium. Early field device products were demonstrated in the
systems do not work effectively because they were either specified,
summer of 2008 and final products (both field devices and logic
designed, installed, operated or maintained incorrectly. Using a
solvers) are expected to be released by 2010.
certified system does not automatically make a facility safe. People
The primary benefit touted by safety fieldbus manufacturmust implement them properly. The standards state that everyone
ers and consortia is diagnostics: being able to predict problems
involved must be “competent” to do their assigned tasks. How
before they have an impact on the process, such as problems that
does one evaluate competency?
may lead to a shutdown. In fact, increased device diagnostics has
Three different groups have tackled this matter over the last
nothing to do with bus technology itself; it is simply additional
decade by issuing certifications/certificates based on either expecapabilities built into field devices so they can detect a higher
rience, coursework, examination or a combination of all three.
percentage of failures. Such devices have been available for many
The first was the Certified Functional Safety Expert and Certified
years and they have nothing to do with busses. Sensors certified
Functional Safety Professional (CFSE/CSFP) program in 2001.
for use in SILs 2 and 3 have been available for many years and
TÜV Rhineland set up their Functional Safety Expert and Funchave nothing to do with bus technology. Valves that implement
tional Safety Engineer (FSExp/FSEng) program a few years later.
partial stroking have also been available for many years and also
International Society of Automation (ISA) developed a three-part
have nothing to do with bus technology.
safety system certificate program in 2008. HP
How can a sensor communicate extensive diagnostic informaLITERATURE CITED
tion on a standard 4-20mA signal? One such method is using
1 Martel, J. T., “PLCs and safety PLCs: Lessons from pucker events”, ISA
highway addressable remote transducer (HART), which combines
InTech, June 2008.
additional information such as device diagnostics along with a
2 Functional Safety: Safety Instrumented Systems for the Process Industry
standard 4-20mA signal. HART devices have been available for
Sector, ANSI/ISA-84.00.01-2004, Parts 1–3 (IEC 61511-1 Mod), 2004.
decades, but it has only been recently that some safety PLCs have
started to incorporate HART information.
Field device diagnostics. Using a safety PLC certified for
use in SIL 3 does not provide a system with SIL 3 performance. A
chain is only as strong as the weakest link. Field devices are the
typical weak link in most safety-instrumented systems.
Fault tolerance tables in the safety standards clearly show the
level of redundancy of field devices that will be required to meet SIL
108
I APRIL 2009 HYDROCARBON PROCESSING
Paul Gruhn is a training manager at ICS Triplex, a Rockwell
Automation company, in Houston, Texas. ICS Triplex manufactures
and integrates safety instrumented systems. Mr. Gruhn is an ISA
Fellow, ISA 84 standard committee member, developer and ISA
instructor on safety systems, and the co-author of an ISA textbook
on safety systems. He has a BS degree in mechanical engineering from the Illinois
Institute of Technology and is a licensed professional engineer (PE) in Texas and a
certified functional safety expert (CFSE).
When the right
reaction matters ...
Trust BASF Process Catalysts
and Technologies
At crucial moments, the right reaction matters. When you are looking
for the right reaction from your process catalyst, turn to BASF. Our
technical experts will recommend the right catalyst from our innovative
product line that will achieve the desired reaction. The end results
may also include greater yield and better end product properties.
When the catalyst is right, the reaction will be right. Trust BASF.
Adsorbents
Polyolefin catalysts
Chemical catalysts
Refining catalysts
Custom catalysts
For more information, please visit www.catalysts.basf.com/process
Select 67 at www.HydrocarbonProcessing.com/RS
Select 99 at www.HydrocarbonProcessing.com/RS
SAFETY
Maximize uptime for sulfur testing
New analyzer determines trace level amounts quickly
R. VAN DER WINDT and A. VAN STRIEN, Thermo Fisher Scientific, The Netherlands
T
he total sulfur content of petroleum products is of great
importance as it may interfere with refinery processes and
have a negative impact on human health and the environment. Total sulfur contained in process feeds may damage the
catalysts used in refinery processes, decreasing their efficiency
and the overall profitability. When extracting gasoline from oil or
burning fuel with a high total sulfur concentration, dangerous sulfur dioxide (SO2) gas emissions are produced, causing respiratory
illnesses, a decline in existing heart disease, visibility impairment
and acid rain.1 In response, regulations have been enforced to
monitor the total sulfur content in petroleum products.
Regulations. The US Environmental Protection Agency has
introduced the ultra-low-sulfur diesel (ULSD) regulations with
the aim to reduce emissions from diesel-powered vehicles.2 Legislation mandates that a minimum of 80% diesel fuel produced for
highway vehicles must be ULSD with a maximum 15 ppm sulfur
content. The remaining 20% may be low-sulfur diesel (LSD) fuel
with a maximum 500 ppm of sulfur content. The 80% ULSD
fuel production requirement is intended to ensure that ULSD is
available for use in 2007 models along with newer diesel vehicles.
According to the regulation, ULSD fuel will become mandatory
for all highway vehicles by June 2010.
To comply with regulations for ULSD motor fuels and ensure
high product quality, catalyst protection and consequently optimization of production, the petroleum industry will need to have
a test method capable of measuring the total sulfur content in
automotive fuels with high precision. The American Standardization of Testing Methods (ASTM) has published D54533 specifying ultraviolet fluorescence (UVF) use for total sulfur content
determination in light hydrocarbons, spark-ignition engine fuel,
diesel engine fuel and engine oil.
The ASTM D5453 test method can be used to determine total
sulfur content both in process feeds and in finished products. It
covers the analysis of total sulfur in liquid petroleum products
containing less than 0.35% (m/m) of halogen(s) and boiling in
the range from approximately 25°C to 400°C with viscosities
between 0.2 cSt (mm2/S) and 20 cSt (mm2/S) at room temperature. The test method is applicable to naphtha, distillates, engine
oil, ethanol, fatty acid methyl esters and engine fuel such as gasoline, oxygen-enriched gasoline, diesel, biodiesel, diesel/biodiesel
blends and jet fuel. Samples containing 1.0 mg/kg to 8,000 mg/
kg of total sulfur can be analyzed. Nevertheless, traditional total
sulfur analyzers are associated with some disadvantages that affect
the method’s overall efficiency.
Traditional system limitations. Traditional total sulfur analyzer operation is based on full evaporation of injected
samples, thus requiring a minimum temperature of 400°C for the
quartz glass injection port and needle. Samples cannot be allowed
to combust in this part of the injector, necessitating argon use as
an inert carrier gas. The main downfall of this injection technique
is that the needle’s high temperature could result in deposition
of cracking products within the needle, causing it to block. An
alternative is to inject samples directly in the combustion tube,
but this may result in droplets of sample combusting vigorously
in the oxygen atmosphere, generating local hotspots and undesirable combustion products. In addition, the carbon dioxide
produced by this reaction would form a blanket around the
droplets, leading to a local oxygen deficiency that would then
promote soot formation.
Conventional total sulfur analyzers also feature horizontally
orientated turbo combustion tubes with inlet and outlet positioned on opposite sides. This results in an elongated system
that uses substantial laboratory space. Another disadvantage of
these traditional turbo combustion tubes is that it does not have
efficient mixing of carrier gas, oxygen and sample limiting combustion control and extending evacuation time. Additionally, the
gas velocity is not high enough to create sufficient turbulence,
while the horizontal orientation of the combustion tube results
in the carrier gas/oxygen mixture segregating from the combustion gases that sink toward the tube bottom. When using conventional combustion tubes, alkaline metals in the combustion
product settle on the tube surface creating areas with a lowered
melting point. As the tube cools down, these areas form separate
crystals causing the tube to become brittle, thus necessitating
complete replacement.
These shortcomings have triggered further research to develop
a more efficient solution. This has led to a range of technological
advancements being incorporated in modern UVF-based total sulfur
analyzers in full compliance with the ASTM D5453 test method.
Technological innovation. Based on nebulizing the sample
with gas flow, new injection technology eliminates the need for
an inert carrier gas. In addition, the novel technique facilitates
complete sample introduction into the inner combustion tube
and optimal mixing with oxygen. The needle and the injector are
constantly kept at the lowest possible temperature, making the
system suitable for a wide range of liquid applications, regardless of their final boiling point. Even very heavy products can be
injected as long as they can be dissolved in a solvent (Fig. 1).
New total sulfur analyzers are equipped with advanced folded
turbo combustion tubes consisting of primary and turbo compartments that fold back over the outside of the primary compartment
and include a number of separate tube-shaped cavities. Since the
primary compartment is separated from the folded turbo comHYDROCARBON PROCESSING APRIL 2009
I 111
SAFETY
Oxygen
Makeup gas
4,000
Combustion tube
Area
Sample
FIG. 1
y = 455.55x + 286.09
R2 = 0.9993
5,000
Heat-sink
Heat flow
Cooling device
Cal line 1, 0-10 ppm
6,000
3,000
2,000
Sample
supply tube Spray head
1,000
Simplified spray injector layout.
0
0
2
4
6
8
10
ppm TS
Effluence
FIG. 3
Cal line 1: blank, 0,5; 1,0; 5 and 10 mg S/L.
Turbo cavities
Sample and
oxygen
Primary compartment
Oxygen
FIG. 2
Simplified cross-section of the “folded turbo tube.”
partment, it is only the inner tube that requires replacing, which
results in considerable maintenance savings. The new tubes follow
the high-level laminar-plug flow principle and they are fitted with
up to nine static mixers in the cavities of the turbo compartment,
allowing for enhanced mixing performance. Gas flows can be
directed in both vertical directions, meaning that both the injection port and the outlet to the detectors can be located on the
tube’s top side while the bottom side remains closed (Fig. 2).
The gas conditioning module of total sulfur analyzers consists
of mass flow controllers and pressure control and regulation
devices, monitoring argon and oxygen pressure injected in the
unit. The system is preconfigured to prohibit sample injections
in case the inlet pressures are below 2 bar. In traditional analyzers, the gas flow through the detector is pulled by the vacuum
pump and regulated by a capillary whereas the make-up gas
flow is pulled from an open connection located at the back of
the instrument.
ASSET VIRTUALIZATION from INOVx connects asset information from across the enterprise
with a precise and up-to-date virtual plant model.
By integrating asset information and 3-D models into role specific environments, INOVx is
transforming the way plant operators manage safety, compliance, inspection, operations,
engineering and maintenance.
Contact us at +1-949-341-1620 or by email at info@inovx.com
www.inovx.com
112
I APRIL 2009 HYDROCARBON PROCESSING
Select 180 at www.HydrocarbonProcessing.com/RS
SAFETY
The new systems have been designed to TABLE 1. Standard set used for
allow for the make-up gas flow to be provided calibration lines
by the oxygen supply and regulated by the
Cal line 2 (mg/kg)
pressure control valve. The valve offers imme- Cal line 1 (mg/kg)
diate reaction to pressure drops and rises, addBlank
Blank
ing or reducing extra oxygen flow. Follow0,5
5
ing injection, the make-up gas flow passes
1,0
25
through the flow exchange module where it is
5
50
measured accurately enough to enable analysts
10
100
to observe the formation of combustion gases
and water removal by using dryers.
The total sulfur detector module of the TABLE 2. System settings
newly designed analyzers consists of a pulsed Parameter
Setting
UVF lamp for SO2 (SO2*) excitation and a
Injection temperature
80°C
photomultiplier tube for the detection of
Furnace
1
temperature
1,000°C
light emitted by SO2* returning to its ground
1,000°C
state. An automatic gain control tool estab- Furnace 2 temperature
3 uL/sec
lishes a constant energy level for the UVF Injection speed
lamp, ensuring superior long-term stability Injection volume
25 uL
and reducing the need for calibration.
Gasflow oxygen
800 mL/min
Experiment. A total sulfur analyzer was
calibrated using two sets of calibration standards based on dibutyl
sulfide in isooctane as specified by the ASTM D5453 method
(Table 1). Each standard was analyzed four times to verify the
repeatability. Table 2 details the system settings that were selected
to run the calibration lines and test the quality control (QC) and
practical samples on total sulfur analysis.
Analysis. After running the calibration curves, a diesel QC
ULSD sample was analyzed nine times to demonstrate the repeatability. An injection volume of 25 uL was implemented. Following
the diesel QC ULSD sample analysis, general hydrocarbon sample
sets were also analyzed. The total sulfur content was measured in
triplicate to confirm that the method’s application coverage was
in full compliance with the ASTM D5453 standard.
Results. Figs. 3 and 4 illustrate the two individual calibration
curves obtained from the total sulfur analyzer and demonstrate the
system’s linearity. The results obtained from the general hydrocarbon sample analysis for total sulfur content are listed in Table 4.
The advanced injection and combustion technologies
employed in this experiment resulted in a considerable reduction
Cal line 2, 0-10 ppm
45,000
Area
30,000
25,000
1
4,25
2
4,23
3
4,17
4
4,26
5
4,30
6
4,14
7
4,21
8
4,28
9
4,33
Average
4,24
RSD (%)
1,6
in the analysis time for an individual sample
to less than three minutes. Fig. 5 shows the
triplicate of a 10-ppm sulfur sample and
illustrates the short analysis time of 3 mins. per sample injection.
This means that within 9 mins., the user achieves a triplicate fully
automated process resulting in optimal repeatability.
The advanced injection port and folded turbo combustion
tubes incorporated in the innovative UVF-based total sulfur
analyzers ensure fast and reliable analysis of trace level sulfur in
liquid petroleum products within any boiling point range. The
M3
M3 Technology
SIMTO™
Advanced Scheduling, Planning
and Optimization Solutions
www.m3tch.com
X SIMTO Scheduling
Oil Refining
Petrochemical
LNG (liquefaction & regasification)
Terminals
X SIMTO Dock Manager
20,000
Jetty/berth scheduling
15,000
X SIMTO Distribution
10,000
Supply & distribution optimization
5,000
20
40
60
ppm TS
FIG. 4
Total Sulfur
Conc (mg S/kg)
Multi blend recipe optimization
Gasoline, Crude, Fuels, Asphalt
Naphtha olefin plant feedstock
35,000
0
0
Sample
X SIMTO M-Blend
y = 407.82x + 244.93
R2 = 0.9993
40,000
TABLE 3. Results derived from the
QC ULSD sample analysis
Cal line 2 : blank; 5; 25; 50 and 100 mg S/L.
80
100
X SIMTO Planning Workspace
Sales and operation planning
10850 Richmond Ave., Suite 290, Houston, TX 77042
Tel: +1.713.784.8285 • Fax: +1.832.553.1893
Select 185 at www.HydrocarbonProcessing.com/RS
113
SAFETY
400.00
358.63
317.26
275.89
234.52
193.15
151.78
110.41
69.04
27.67
3
Signal
01:45
FIG. 5
03:30
05:15
TABLE 4. Total sulfur analysis
test data
Sample
Conc (mg S/kg)
Naphtha
0,15
5,1
Ethanol
1,5
2,1
Gasoline
8,3
0,6
Biodiesel
2,6
1,3
Biodiesel FAME
3,9
0,8
1
2
07:00
08:45
Total sulfur sample peaks at 10 ppm.
RSD (%)
remote-assess capabilities
of the new systems help
analysts achieve a maximum up-time. Overall,
good repeatability is
ensured, productivity
is improved and at the
same time being ASTM
D5453 compliant. HP
LITERATURE CITED
Environmental Protection Agency, “Air and Radiation, Six Common
Pollutants, Sulfur Dioxide, Health and Environmental Impacts of SO2,”
http://www.epa.gov/air/urbanair/so2/hlth1.html.
Environmental Protection Agency, “Compliance and Enforcement, Civil
Enforcement, Clean Air Act, Clean Air Act National Enforcement Priority,
Ultra-Low-Sulfur Diesel Fuel,” http://epa.gov/compliance/civil/caa/ultralow-
sulfurdieselfuel.html.
ASTM Standard D5453, 2008b, “Standard Test Method for Determination of
Total Sulfur in Light Hydrocarbons, Spark-Ignition Engine Fuel, Diesel Engine
Fuel, and Engine Oil by Ultraviolet Fluorescence,” ASTM International, West
Conshohocken, Pennsylvania, www.astm.org.
René van der Windt is the product manager for Thermo Scientific Combustion
EA products at Thermo Fisher Scientific Delft B.V., the Netherlands. He graduated with
an HBO-O level degree in analytical chemistry from Van Leeuwenhoek Institute. Mr.
van der Windt started the laboratory of Caleb Brett Continental B.V. in Rotterdam,
now known as Intertek Netherlands B.V. The company offers inspection and testing
services on a wide scope of petrochemical and refinery products. His main expertise
was gas and liquid chromatography along with mass spectrometry. Mr. van der Windt
moved to the position of laboratory manager for BSI Inspectorate Netherlands B.V.
where he was responsible for laboratories in Rotterdam and Amsterdam. In 2005,
he took a new position with M&I-Labtech in Rotterdam as the installation and commissioning manager and later as the QA manager. M&I-Labtech is an engineering
company focused on the engineering, procurement and commissioning of turnkey
laboratories. Mr. van der Windt is currently responsible for the introduction and further product development of the new TITAN combustion analyzer and supports the
research and development and sales organizations.
Arthur Van Strien is the product marketing manager for the Thermo Scientific
Combustion EA products in Delft B.V. Netherlands. He began his career as an application specialist at the former company Euroglas B.V., and was involved in product and
application development for the analysis of Organic Halogens (TOX/AOX), Total Sulfur
and chlorine analysis in a variety of environmental and industrial applications. Mr. Van
Strien moved into the position of product manager after spending five years in the
application laboratory. He was responsible for the commercial support and marketing
of laboratory analyzers for the determination of Absorbable Organic Halogens (AOX/
EOX) and Total Organic Carbon (TOC). Mr. Van Strien was also an area sales manager
for the Asia Pacific region and then moved to his current position. He studied at the
Van Leeuwenhoek institute in Delft, The Netherlands and graduated with an analytical
chemistry degree. Mr. Van Strien also studied business administration on international
export and industrial marketing at the Rotterdam High Economic School.
EVERY TECHNOLOGY HAS ITS ERA – CANNED MOTOR PUMPS
Visit us:
A C H E M A 2009, 11.–15.05.2009
Hall 8.0, Stand O48-P51
Customer benefits with canned motor pumps
114
■
absolute no leakage
■
horizontal or vertical installation
■
low temperature applications
up to –160 °C and high temperature
applications up to +450 °C
■
low life-cycle-costs
■
low noise level
■
standard or special design –
matched to the requirements
of customers process
■
pressure ratings PN 16 to PN 1000
■
single- or multistage design
I APRIL 2009 HYDROCARBON PROCESSING
Select 186 at www.HydrocarbonProcessing.com/RS
HERMETIC-Pumpen GmbH
info.hp@lederle-hermetic.com
www.lederle-hermetic.com
2009
In its seventh edition, the Gulf Coast Turnaround & Maintenance
Services Directory gives companies a unique opportunity to target
the United States Gulf Coast, which has the largest collection of
refineries, petrochemical/chemical plants and gas processing
facilities in the world. In this day of high operating rates and the need
to keep facilities in operation, downtime is extremely expensive and
maintenance services are more critical than ever.
Reach Decision Makers
Reaches decision makers and the buyers of your products and
services because the Directory provides the information that plant
managers and maintenance service managers are looking for and
need. The 2009 Gulf Coast Turnaround & Maintenance Services
Directory will be distributed to over 6,0001 decision makers in Texas,
Mississippi, Arkansas, Oklahoma, Alabama and Louisiana. There will
also be bonus distribution at the NPRA’s Maintenance Conference
and Exhibition, International Liquid Terminals Association Meeting
and the Texas A&M Turbo Machinery Symposium.
24 Hour Access
Your presence in the Gulf Coast Turnaround & Maintenance Services
Directory is enhanced through a year long presence on PetroPages.
com, an online directory, as well as HydrocarbonProcessing.com—
both providing 24/7 access.
Two Ways to Participate
1. Directory Listing
• Five product category listings.
2. Full Page Advertisement *BEST BUY*
• 10 product listings
• Full year’s listing on PetroPages.com
• Frequency discounts for Hydrocarbon Processing advertisers
• 15% Agency Discounts where applicable
Publish Date: May 2009
Closing Date: April 15, 2009
1
June 2008 BPA Statement.
Published by Hydrocarbon Processing
in cooperation with PetroPages.com
2009
advertising
For more details on how you can participate
in this exciting new opportunity to reach the
Gulf Coast refining and petrochemical market,
contact Mark Peters at +1 (713) 520-4421 or
e-mail at Mark.Peters@GulfPub.com.
ARE YOU A
SUBSCRIBER?
Order online by May 15 to receive
these items in the coming months.
CLICK
ENEW
/R
BSCRIBE
SU
As a paid
subscriber,
in addition to your
12 monthly issues, in print or digital:
• Online access to the current issue
and all the latest Process Handbooks
• Online access to the world’s most
powerful archive of HPI information
containing eight years of back issues
• Online subject/author index of print
articles with links to articles currently
available online.
• Monthly e-newsletters providing
an early preview of upcoming special
editorial features, which provide
operational and technical insights.
HYDROCARBON PROCESSING is
the leading monthly magazine for
staying connected to the hydrocarbon
processing industry. Published since 1922,
HYDROCARBON PROCESSING provides
operational and technical information to
improve plant reliability, profitability, safety
and end-product quality. The editors of
HYDROCARBON PROCESSING bring you firsthand knowledge on the latest advances in
technologies and technical articles to help
you do your job more effectively.
2
simple ways
to subscribe:
• Visit www.HydrocarbonProcessing.com
• Call +1 (713) 520-4440
Receive Monthly e-newsletters providing
an early preview of upcoming special
editorial features, which provide
operational and technical insights:
June 2009: Process/Plant Optimization
• Process control technology,
real-time optimization
• Distillation/trays/packing
• New licensed technology
• Better maintenance, reliability programs
July 2009: Liquified Natural Gas (LNG)
• Energy management, heat exchangers,
refrigeration
• LNG catalyst advances
• Products, ultra-clean transportation fuels
• Compressor technology
August 2009: Fluid Flow and Rotating
Equipment
• Pumps, valves and compressors
• Level gauging
• Custody transfer systems–flow meters,
process analyzers
• Tankfarm management
SAFETY
Rethink your overpressure systems
Consider multiple relief valve designs
S. RAHIMI MOFRAD, Petrofac Engineering & Construction, Sharjah, UAE
I
nstalling a single relief valve to handle the relieving rate of particular
equipment during emergency conditions is a normal practice in the
hydrocarbon processing industry. Relief valves are primarily sized
using equations presented in API-520 sections 3.6 through 3.101 as
appropriate for vapor, gases, liquid, steam or two-phase fluids. API5262 is used to select a standard orifice size, orifice designation, inlet
and outlet flange sizes, material, pressure/temperature limits and
other specifications. This preliminary relief valve sizing and selection
is verified by manufacturers, using the valve’s effective coefficient of
discharge, back pressure correction factor and other parameters.
Installing multiple relief valves for a very large relief rate is also a
well-known situation for all process designers. Some cases in which
considering a multiple safety device is helpful or sometimes essential
are introduced below. However, using multiple safety devices when it
is not mandatory by code is usually approved by the project’s owner.
Multiple-device installation may be considered when:
1. The calculated orifice area is greater than the maximum
available standard orifice size. The magnitudes of some large
releases may be greater than the largest single relief valve capacity
that is commercially available, necessitating the use of two or more
valves. The standard orifice size is illustrated in Table 1.
2. The particular orifice designation cannot be used due to
its limitation on the inlet flange rating. Table 2, extracted from
API-526, shows the limitation of each orifice designation on the
inlet flange rating.
For example, if the calculated area for the particular springloaded relief valve is 10.1 in.2, the selected orifice will be a Q desigTABLE 1. Standard effective orifice areas2
Orifice
designation
API standard orifice
(in.2)
(cm2)
D
0.710
0.110
E
1.265
0.196
F
1.981
0.307
G
3.245
0.503
H
5.065
0.785
J
8.303
1.287
K
11.854
1.838
L
18.406
2.853
M
23.226
3.60
N
28.000
4.34
P
41.161
6.38
Q
71.290
11.05
R
103.226
16.0
T
167.742
26.0
nation with the effective area of 11.05 in.2, (Table 1). If the required
inlet flange rating, with respect to inlet pressure and temperature, is
900#, this additional requirement will conduct the valve selection to
multiple smaller orifices. In this case, two orifices with a P designation (with the total area of 12.76 in.2) may be appropriate.
The pressure temperature ranges for piping classes in Table
2 depend on orifice designation, nozzle size, body, bonnet and
spring materials. An example, for spring loaded relief valves with
an R or T designation, the maximum inlet flange ratings are 600#
and 300#, respectively. If valve body, bonnet, and spring selected
materials is carbon steel, the relief valve maximum pressure (set
pressure) in relieving temperature range of –20°F to 450°F will
be limited to 300 psig. This pressure is much lower than what is
known as a piping class pressure limit for 600# or 300# ratings.
For a pilot-operated valve with the same orifice designation, material and temperature range; the pressure limit is about 900 psig.
For other orifice designations, materials and temperature ranges,
the standard or vendor catalogue should be returned.
3. There is a significant difference between relieving rates of
various applicable contingencies, to avoid a pressure relief device
chattering at a lower relieving rate. The chattering likelihood is
higher when the fluid quantity discharged is less than 25% maximum capacity of the relief valve. If relief loads of two emergency
cases are 1,000 lb/hr and 10,000 lb/hr, it is advised to use two
pressure relief valves: one with 1,000 lb/hr capacity and the other at
9,000 lb/hr minimum capacity. The lower capacity valve is usually
TABLE 2. Relief valve inlet flange rating limitations
Orifice
designation
ANSI inlet flange rating
Spring-loaded relief valve
Pilot-operated relief valve
D
150,300,600,900,1500,2500
150,300,600,900,1500,2500
E
150,300,600,900,1500,2500
150,300,600,900,1500,2500
F
150,300,600,900,1500,2500
150,300,600,900,1500,2500
G
150,300,600,900,1500,2500
150,300,600,900,1500,2500
H
150,300,600,900,1500
150,300,600,900,1500,2500
J
150,300,600,900,1500
150,300,600,900,1500,2500*
K
150,300,600,900,1500
150,300,600,900,1500
L
150,300,600,900,1500
150,300,600,900,1500
M
150,300,600,900
150,300,600,900,1500
N
150,300,600,900
150,300,600,900,1500
P
150,300,600,900
150,300,600,900,1500
Q
150,300,600
150,300,600
R
150,300,600
150,300,600
T
150,300
150,300,600
*2,500# rating is only available for a 2 in. inlet flange size (2 J 3) not for 3 J 4.
HYDROCARBON PROCESSING APRIL 2009
I 117
SAFETY
Italian design
A masterpiece
Creativity is the art we apply
to achieve superior design
and developments in technology. For over 70 years we
have designed and supplied
cost-effective technology, process plants and equipment
for the oil & gas industry around the world. With our expertise we provide tailor-made solutions from studies
and revamps to skid-mounted units and complete turnkey
plants. Our own technologies are complemented by alliances with renowned licensors such as BOC, BP Amoco,
IUT, WorleyParsons and UOP to provide state-of-the-art
answers to design issues.
Oil & gas production facilities:
separation, filtration, NGL and LPG recovery, stabilisation
Gas & liquids treatment:
amines, physical solvents, molecular sieves,
iron oxide, glycol, silica gel, Merox™, sour water stripping
Sulphur recovery:
Claus, ammonia Claus, oxygen-enriched Claus,
tail gas clean-up, Thiopaq™, redox, sulphur degassing, sulphur
forming, advanced process controls
Flue gas treatment:
De-SOx, De-NOx & De-Dioxin, ammonia production
Gas manufacture:
low pressure gasification
Special process equipment
SIIRTEC NIGI Engineering Contractors
Via Algardi, 2 – 20148, Milan (Italy)
Tel: +39-0239223.1 – Fax: +39-0239223.010 – E-mail: sinimail@sini.it – Web: www.sini.it
Contact: marketing@sini.it
Select 187 at www.HydrocarbonProcessing.com/RS
118
set at a lower set pressure than a larger one. Another alternative is to
use a single modulating-action pilot-operated relief valve.
4. API-520 section 3.5.3.4 calls for a supplemental device
to provide relieving capacity for an additional hazard created by
exposure to fire or other unexpected external heat sources. In fact,
a supplemental device is used in addition to devices sized for nonfire (operating) contingencies.
When a fire contingency is the largest contingency and the
next contingency is less than 1% of the fire relieving rate, multiple
(supplemental) relief valves with staggered settings should always be
used. However, when the fire contingency has a smaller load, it is
generally ignored. This is because fire is a remote event, hence, there
is no significant concern of chattering under the conditions.3
5. Multiple installations decrease the area overdesign of a pressure safety device in comparison with single installations. The relief
valve orifice size is selected among standard sizes; hence, the selected
orifice size is sometimes more than 70% larger than the required
area. Accordingly, the rated (actual) relief valve flowrate is also
70% higher than the required flowrate. This unavoidable flowrate
overdesign may not be acceptable, especially if:
• This flowrate is the design flow of flare network. Limiting
overdesign will cause reduction in the flare system components
size and cost
• Loss of valuable, toxic or noxious materials is a major issue
• Environmental aspect is not tolerated
• Process operation upset or equipment destruction occurs.
For example, installing an over-sized safety device on a tower
may lead to top tray blow off, packing lifting and crushing, tower
flooding or excessive liquid carry-over.
If the required orifice area is much smaller than the smallest available standard orifice, an alternative design to reduce the
overdesign would be a nonstandard orifice. Another option is to use
a rupture disc, especially when downtime for changing a rupture
disc is tolerable. For instance, the required relief rate is often very
low in pilot plants, but, if the calculated area is 0.02 in.2, selecting
the D designation will provide huge overdesign on the area. Considering this matter that production is not the major purpose of
pilot plants, using a rupture disc is the ultimate solution. Rupture
discs are usually available in nominal sizes of ½-in. or larger with
some manufacturers supplying a ¼-in. as a nominal size.
The main focus of other techniques is to reduce the required orifice area to match it with the lower standard size so that the equipment safety is not compromised. A list of these techniques which
are mainly applicable to fractionation columns is as follows:
• Increase the mechanical design pressure which makes the
required relief area smaller (refer to relief valve sizing formulas)
and also lowers the required relief rate in some cases when a temperature pinch happens.4
• Install a restricting orifice on a heat medium line to a column reboiler which restricts the hot stream flowrate in case the
control valve is fully opened.
• Use fire-proof insulation, and elevate the vessel above fire
height, place it below grade or earth covered. Providing adequate
drainage and firefighting facilities are also effective ways for reducing the relief load and relief valve size in case of an external fire.
• Provide a turbine-driven spare for cooling water, reflux or
feed pumps which is automatically put into service in case of an
electric power failure.
• Use three or more (redundant) cutoff pressure switches with
a voting system to remove the source of overpressure, for example,
a heat input to the column.
SAFETY
TABLE 3. Relief valve sizing parameters for unfired
pressure vessels
Installation type
Maximum
Maximum accumulated
set pressure, MAWP % pressure (MAWP %) (Note 1)
First valve
100
Additional valve(s)
105 (Note 2)
Supplemental valve
110
Notes:
Non-fire cases:
Fire cases:
116
121
(1) The maximum accumulated pressure is not more than 4 psi (28
kPa) when the MAWP is between 15 psig to 30 psig (103 kPa to
207 kPa).
(2) For set pressures below 150 psig, staggering the set pressure
becomes impracticable because the difference between the set
pressure tolerance of 3% and the value of 5% of the MAWP
becomes too small.
TABLE 4. Relief valve sizing parameters for fired
pressure vessel
Installation type
Maximum set pressure
(MAWP %)
First valve
100
Additional valve(s)
103
Maximum accumulated
pressure (MAWP %)
106
6. The relative cost of a multiple valve installation is lower
than a single installation. Above a certain size (typically a 12-in.
discharge size), structural and piping engineering considerations,
such as space-limitation and pipe-supporting difficulties associated
with the large piping and valves, may result in a lower installed cost
for two smaller relief valves. Refer to the standard, sections 4.3 and
4.4, to study the different types of forces and stresses transmitted
to relief valves and the associated piping and minimum standard
requirements for relief valve inlet and outlet pipe support.5
Another concern with large discharge pipes is fatigue failures
resulting from acoustically induced vibration. This occurs in piping
systems when upstream valves and/or restriction orifices have high gas
flowrates and large pressure drops. The relief valves with downstream
piping 10 in. or larger are potentially susceptible to mechanical failure
due to this phenomenon. If the sound power level calculated from
Eq. 1 for these relief valves exceeds 155 dB, the detailed screening of
the piping downstream of the safety device is carried out to highlight
any welded connections likely to be an acoustic fatigue failure risk.
Based on the results of this analysis, some remedial actions, including
changes in piping and support reinforcement, piping layout modifications and changing piping schedule as well as using more relief
valves with smaller capacities are recommended.
3.6
1.2
2 P T + 55
L w = 10 log W (1)
P1 MW 7. When the revamping of an existing plant is a design concern,
the installation of a new relief valve next to the existing one may
be the most cost-effective way. In this way, reviewing the existing
system’s configuration and problems accompanied with dismantling
of existing facilities and new relief valve installation is removed.
Moreover, it is possible to connect the new relief valve to the atmosphere (where acceptable) or a new closed disposal system instead of
an existing disposal system. If it is decided to connect the new relief
Select 188 at www.HydrocarbonProcessing.com/RS
SAFETY
valve to an existing disposal system, the ability of the existing system
to handle the additional flowrate shall be thoroughly checked.
8. When the bare-tube water-heating surface of a boiler is more
than 500 ft2 (47 m2) or when electric boiler input power is more
than 1,100 kW, the boiler should be equipped with two or more
relief valves. For a boiler with combined bare tube and an extended
water-heating surface exceeding 500 ft2 (47 m2), two or more relief
valves are required only if the boiler’s design steam generation
exceeds 4,000 lb/hr (1,800 kg/hr). The minimum required relieving capacity of each relief valve for all types of boilers shall not be
less than the maximum designed steaming capacity, as determined
by the manufacturer, and shall be based on the capacity of all fuelburning equipment as limited by other boiler functions.6
Installation rules. The following criteria should be followed
when dealing with designing a multiple safety device.
From a relief valve sizing point, according to ASME VIII Div.
1, relief valves installed on an unfired pressure vessel in multiple
arrangements should have a staggered set pressure. This is so that
the set pressure of the first device is equal to the maximum allowable working pressure (MAWP) of the vessel, and the set pressure
of additional device(s) is 105% of the vessel’s MAWP. If the supplemental device installation is justified, its set pressure shall not
exceed 110% of the MAWP. Tables 3 and 4 summarize multiple
device sizing rules for vessels designed according to ASME code
for unfired and fired pressure vessel design.
From an installation point, the inlet piping to multiple relief
valves in a common section for all relief valves must have a flow
area that is at least equal to the combined inlet areas of the mul-
Build your foundation
with these petrochemical
must-haves
tiple relief valves connected to it. This is likely to cause a common
header size too large than is really practicable. It is preferred to
install all safety devices directly on or near the overpressure source.
Like single installations, the total non-recoverable pressure loss
between protected equipment and the relief valves, using the rated
valve relief capacity, should not exceed 3% of the set pressure of
the valve except for pilot-operated types.
Example. The example given in API-520, section 3.6.2.2, with
higher flowrate is used with the following specifications:
• Required hydrocarbon vapor flow caused by an operational
upset is 391,800 lb/hr
• The hydrocarbon mixture molecular weight, compressibility
factor and Cp/Cv of 65.0, 0.84 and 1.09, respectively
• Relieving temperature of 627R
• Relief valve set at 75 psig, which is the equipment’s design
pressure
• Total back pressure of 14.7 psia.
Substituting the above data into equation 3.2 of API-520, gives
36.10 in.2 as required orifice area, which is larger than the maximum available standard size in Table 1. Accordingly, several relief
valves should be installed. Since the relief valve inlet nozzle flange
rating is 150#, three reasonable options are envisaged for this case:
1. Two T-type orifices with a total area of 52.0 (26 + 26).
2. One T-type and one R-type orifice with a total area of 42.0
(26 + 16).
3. One R-type and two Q-type orifices with a total area of
38.10 (16 + 11.05 + 11.05).
The author prefers the second choice due to relatively lower
overdesign on the orifice area as well as a minimum number of safety
devices. Keep in mind, that better fitting may be possible with numerous smaller orifices, but is not practical. It is better to set the smaller
valve at MAWP and the larger one at 105% of MAWP. HP
1
2
3
4
5
6
LITERATURE CITED
“Sizing, Selection and Installation of Pressure Relieving Devices in Refineries,
Part I—Sizing and Selection,” American Petroleum Institute, API RP 520,
Seventh Edition, January 2000.
“Flanged Steel Pressure Relief Valves,” American Petroleum Institute, API RP
526, Fifth Edition, June 2002.
Cheremisinoff, N. P., “Pressure Safety Design Practices for Refinery and
Chemical Operations,” 1998.
S. Rahimi Mofrad, “Tower pressure relief calculation,” Hydrocarbon Processing,
pp. 149–159, September 2008.
“Sizing, Selection and Installation of Pressure Relieving Devices in Refineries,
Part II—Installation,” American Petroleum Institute, API RP 520, Fifth
Edition, August 2002.
ASME I, “Boiler and Pressure Vessel Code—Rules for Construction of Power
Boilers,” 2004.
Lw
MW
W
P1
⌬P
T
NOMENCLATURE
Sound power level, dB
Gas molecular weight
Relief rate, kg/hr
Upstream pressure, bara
Pressure drop, bar
Gas temperature, K
Saeid Rahimi Mofrad is a process engineer at Petrofac Engi-
Gulf Publishing Company
+1-713-520-4428 l +1-800-231-6275
Email: svb@GulfPub.com
www.GulfPub.com
Select 189 at www.HydrocarbonProcessing.com/RS
120
neering & Construction. His experience includes process equipment
sizing and selection, relief rate and depressuring calculation and
flare system design. Mr. Rahimi Mofrad’s personal interest is visual
basic programming. He has developed a user-friendly process engineering software called “Chemwork Collection” for performing process equipment
sizing and calculations. Mr. Rahimi Mofrad has an MS degree in chemical engineering
from Sharif University of Technology and a BS degree in chemical engineering from
Shiraz University, Iran.
ASSET MANAGEMENT
Transforming refining best practices
with 3D virtual models
The technology, from laser scanning to management of change,
is mature, functional, cost-effective and proven
K. M. RENNER, Chevron Global Manufacturing, San Ramon, California,
and C. LANZA, INOVx Solutions, Irvine, California
F
or every type of business, there are certain techniques, methods, processes or activities that are more effective than others.
They deliver optimal outcomes with fewer problems and a
minimum of unforeseen complications. This is the concept of
“best practices;” it is simple and powerful. Best practices are based
on efficient and repeatable procedures that have proven themselves
over time for large numbers of people.
Technologies that support these best practices have a history of
steady evolution punctuated by discrete step changes. Computing
technologies have resulted in a new level of efficiency and effectiveness within the refining and processing industries. For example,
today we take e-mail and information sharing over networks for
granted, however, imagine the regression in current work processes
if we had to suddenly revert to voice messages and physical mail.
Such technological step changes or breakthroughs play a dual
role in the progression of a company’s best practices. Not only
do they provide better ways to execute existing work practices,
these breakthroughs are often significant and strong enough to
loosen the natural tendency of established practices to persist
unchallenged. This allows practices and methodologies to be
re-examined, re-defined and improved. Therefore, it is doubly
important that technological breakthroughs be embraced as soon
as they are viable and cost-effective.
For plant operations and asset management, the “next big
thing” in support of best practices may be a surprise, because
much of the underlying technology has been in use in product
design and entertainment arenas for years. This technology—
involving 3D virtual models of production facilities and assets—is
transforming the way we work, replacing 2D abstract representations such as isometric drawings that are more difficult to read
and can diverge from reality.
In this article, we take a look at the role of 3D virtual models
in best practices, where visualizations that precisely match a plant’s
actual facilities and assets are presented and navigated on computers in your offices, in the field or over the Internet. This article
starts by describing some actual applications in refining and then
discusses how 3D virtual models are constructed, maintained and
applied in support of plant engineering, turnarounds, maintenance, inspection and operations.
3D virtual models in engineering. The process industries
(CAD) systems for initial plant design and engineering. However,
the models and documentation created in these processes do not
serve operating and maintenance tasks over the productive life of
the assets. This is because the “as-designed” CAD representations
often deviate from “as built” or field conditions and, over time,
become less representative of the actual plant and equipment.
(The 3D virtual models typically are not updated as modifications
are made to process equipment, nor is it cost-effective to maintain
these CAD models.)
A refinery requiring a major upgrade of its blending and shipping facilities recently faced a similar situation. Documentation
for the tank farm, marine terminal, product blending area and
other facilities was out of date. To support the upgrade project,
a high-fidelity, location-accurate 3D model of the facilities and
equipment was created by onsite laser scanning and subsequent
modeling that identified and labeled every object in accordance
with the actual plant. This model served the project in many
important ways:
• Engineers “walked” the scanned images of the as-built model
and identified discrepancies in existing process and instrumentation diagrams (P&IDs). The P&IDs were then corrected and
made suitable for engineering work at a fraction of the labor
otherwise required for field inspection, redlining and updating.
Reducing staff exposure to the operating plant was an additional
important safety benefit.
FIG. 1
Taking field measurements using a 3D virtual model.
have completely adopted 3D technology in computer-aided design
HYDROCARBON PROCESSING APRIL 2009
I 121
ASSET MANAGEMENT
• Documentation for the tank farm was also out of date.
Using the 3D virtual model, engineers were able to identify and
accurately number all piping and equipment for clearer communications in the upgrade process.
• The blending and shipping upgrade project required upgrading manual valves to motor-operated valves. This meant identifying and locating all the power lines, power poles and junction boxes that fed them. These were captured in the 3D model,
enabling very efficient planning and design. The 3D virtual model
was also used to achieve similar benefits of accuracy, reduced manhours and quicker completion for line-ups, crossovers and other
required piping improvements.
• When it came time to configure the automation system, the
virtual plant model was found to be of tremendous assistance in
determining optimal lineups, sequencing of actions, back-flushing
volumes, etc.
With accurate 3D virtual models, many engineering tasks
were transformed from a field exercise with paper and pencil
to an office task where field conditions can be explored, accurate measurements taken and general productivity dramatically
improved. Fig. 1 depicts taking field measurements using the 3D
virtual model.
Turnaround planning and execution. Plant turnarounds
are distinct projects that often involve significant numbers of
internal staff, contractors and suppliers. A typical turnaround consists of many work packages that have to be planned, coordinated
and executed on a tight schedule.
Turnaround planners must take into account many considerations when developing work packages that provide clear documentation and instructions to each responsible team. The 3D
virtual model of the affected facilities provided tremendous value
by enhancing communications and ensuring team familiarity with
tasks and their environment. Time-consuming walkthroughs were
only taken as a final confirmation of the plans. This saved many
hours in preparation while improving the quality of the plans and
minimizing plant exposure.
Specific views to support and inform each individual work
package can be easily isolated from the clutter of the real world
FIG. 2
122
and the full 3D virtual model. These are shared with the turnaround staff, supporting workers and contractors. We refer to
these as “knowledge views” as they capture and share knowledge
about the plant and planned work tasks. These views are used in
combination for added perspective. For example, structural steel
views were combined with piping views so that proper access and
routing could be planned and communicated to turnaround staff.
Figs. 2 and 3 are examples of documented work packages, keeping
in mind that each of these views are not static but full 3D screens
that can be panned, zoomed and navigated to gain a full perspective. When needed, scaffolding plans can be overlaid on the views
to ensure suitability.
Plant maintenance. In one refinery project, the issue of
temporary leak repairs was addressed. Specifically, the question
was: “How to assure that the permanent leak repairs would be
completed in the most efficient manner by taking full advantage
of both planned and unplanned shutdowns?” Before having a
virtual model, it was very challenging to identify all eligible leak
repairs in every situation in a timely manner. With a virtual model
that is dynamically connected to the temporary repair database,
opportunities were immediately identified for permanent repair
within the physical boundaries of any turnaround activity or work
order involving a shutdown.
Applications of the 3D virtual model for plant maintenance are
many and varied, and the impact on best practices is significant.
Maintenance personnel are able to quickly locate lines, equipment
and instrumentation, and familiarize themselves with the location
before going to the field to perform their work. Work orders are
precisely linked to the target equipment or system and, through
that connection, to the most current asset data. The model is a
natural tool for organizing and visualizing maintenance history,
operational data, test results and analysis.
Work order planning is greatly facilitated by the 3D virtual
model. Maintenance planners can develop libraries of work packages for routine maintenance tasks, supported by their respective
knowledge views of the 3D virtual model. Physical conditions can be
readily assessed and necessary support equipment scheduled for the
task, such as a fork lift or scaffolding. Work crews can be assigned so
that they do not interfere with each other. Even the seemingly simple
Pipe inspection, isolated and in context. Work package views are not static.
I APRIL 2009 HYDROCARBON PROCESSING
ASSET MANAGEMENT
FIG. 3
Pipe replacement, isolated and in context. Views can be panned, zoomed and navigated.
FIG. 4
Legacy 2D method contrasted with new 3D document of the inspection circuit.
task of locating the equipment becomes easier and unambiguous.
The net result is greater productivity and quicker repairs, resulting
in shorter downtimes and greater plant utilization.
Inspection and plant integrity. A common practice in
refineries is to document inspection circuits using 2D isometric
drawings with manual placement of the thickness monitoring
locations (TMLs). In parallel, an “inspection” database is kept
with corrosion rates, inspection dates, and other data for each
circuit and TML. The challenges in coordinating and maintaining
accuracy under this system should be obvious. In contrast, inspection circuits documented in a 3D virtual model can be subset
into individual views with TMLs clearly called out in their exact
geospatial location while linked dynamically to the source data.
With such “active isometrics,” personnel can virtually walk
the area before inspections, adding or subtracting detail to understand what they are dealing with. The model accuracy enables
scaffolding design and other preliminary set-up work. And since
the 3D virtual model always shows true placement and measurements, so do the isometric circuits. This avoids the possible and
time-consuming inconvenience of inaccurate inspection circuit
documentation. Fig. 4 shows the legacy 2D method contrasted
with the new 3D document of the inspection circuit.
In a bitumen upgrading facility, the focus was on identifying and
monitoring locations and conditions that could adversely affect plant
integrity and reliability, especially vessels and pipes under pressure.
The plant staff used the 3D virtual model to identify the physical
boundaries and components for all corrosion inspection circuits. Seeing the “big picture” in 3D enabled them to select the best locations
based on access and corrosion potential. The model became the organizing tool for all the TMLs and linked with the inspection software
to display their baseline readings, test schedules and results.
The virtual model provides inspection planners with access to
actual field conditions without actually having to go there. Inspectors can use the 3D virtual model to determine scaffolding needs,
access limitations and safety requirements. Also, the model can be
used to effectively communicate and coordinate with technicians
and maintenance staff. Corrosion histories, kept in the inspection
software, are accessed from the 3D virtual model for analysis, root
cause determination and communication with subject-matter
HYDROCARBON PROCESSING APRIL 2009
I 123
ASSET MANAGEMENT
FIG. 5
Section of a process unit as captured by a laser scanner, and the same unit fully modeled as 3D objects.
experts. As one inspector put it, “One hour using the 3D virtual
model saves me eight hours in the plant.”
Plant operations. There are many opportunities to utilize
the 3D virtual model in the operations department. For example,
in the offsite area, determining the optimal routing for an ad hoc
oil movement had relied on memory and potentially lengthy
multiday site walks and investigation. With the 3D virtual model,
routings are easily defined and, more importantly, the routings can
often be optimally lined up and determined in just minutes.
Operating procedures can be more easily created and reviewed
because the model provides a true “in plant” perspective at the
user’s desktop. Familiarizing personnel with facilities and procedures is greatly simplified. Procedures and training materials can
be linked and accessed from within the 3D virtual model and an
isolated view can be shown.
Safety procedures, including isolation device locations, can be
documented in full 3D and full context. HAZOP analysis can be
Take Control of Your Refinery with These Products
PetroChem Toolkit
WinHeat 4
CPPAC
An invaluable tool for refining and
petrochemical engineers
Put control back into the hands
of the process engineer
Centrifugal Pump Design and Analysis
To learn more, visit
Get your upgraded version today!
www.GulfPub.com/PetChemToolkit
To learn more, visit
To learn more, visit
www.GulfPub.com/CPPAC
www.GulfPub.com/WinHeat
Gulf Publishing Company
+1-713-520-4428 l +1-800-231-6275 l Email: svb@GulfPub.com I www.GulfPub.com
124
I APRIL 2009 HYDROCARBON PROCESSING
Select 190 at www.HydrocarbonProcessing.com/RS
ASSET MANAGEMENT
performed with greater clarity and
structures, circuits and subsystems,
■ 3D virtual models introduce a
with accurate asset documentation.
the model shapes gain context and
Location of persistent alarms can be fundamental and significant change— can be used for searching, sorting and
visualized in their physical context.
linking to relevant data from all other
Creating work orders is a much a breakthrough—in the way people
plant information systems. The result
more precise activity because the
is an asset management environment
virtual model provides an easy way perform work.
that we call “asset virtualization.”
to tie the work order to the equipManagement of change is a very
ment piece of interest instead of at the process unit level. The virimportant aspect of any 3D virtual model because much of the
tual model also provides a 3D common basis for communication
model’s benefit results from model precision and it representing
between operations and maintenance.
the actual production assets and facilities. Therefore, the 3D
virtual model software must be capable of accepting updates at
How the model is created. The path to an “as-built” 3D
any time via new laser scans, altered CAD information and direct
virtual model of plant facilities and assets is surprisingly easy. If a
model changes to reflect field conditions. Furthermore, changes
3D design model does not already exist, laser scanning technology
must be automatically propagated (or inherited) to views, docuis used. The scanning services are widely available. The process
ments and integrated systems to ensure that all asset information
is similar to conventional surveying in that scans are taken from
and the 3D virtual model accurately reflect the plant.
multiple perspectives, each from known coordinates.
Modeling software can combine the scans into a coherent
Features, functions to consider. Despite the seemingly
“as-is” model or point cloud. Where CAD data exist for equipcomplex services provided by such software, the users should
ment and systems, it can be imported and integrated into the
find the application as intuitive and as easy to use as a video
model. Otherwise, software is used to convert the point cloud
game. Training for nonpower users should require only one or
data derived from laser scanning into 3D objects. The end result
two hours, not days. It should run on standard office computing
is a visual, navigable, multiperspective 3D virtual model that
platforms. The software should understand roles and be able to
accurately and precisely reflects the actual facilities. Fig. 5 depicts
assign and manage authorizations, permissions and security based
a section of a process unit as captured by a laser scanner, and the
on the organization structure, command and control levels, and
same unit fully modeled as 3D objects.
plant security policies.
The next step is to “intelligize” the model by adding identifying
The model should represent the actual plant with detailed pretags and other asset information. By tagging objects, components,
cision and dimensions. Equipment is not always perfectly vertical;
Rotary Lobe Pumps
Macerating Technology
Innovation.
Not for all. One for you:
The compact design combined with the variety of sizes and
rotor options gives the best optimum solution for almost
any targeted application of solid laden liquids.Thanks to
the elaborated engineering combined with outstanding
construction quality and the maintenance-in-place
principles we achieve best life cycle cost-effectiveness.
Makes our pump, your first choice.
9
00
MA 2
T21
ACHE nd T20-
8·
Hall
Sta
Select 191 at www.HydrocarbonProcessing.com/RS
… optimal process-integrated systems
to generate and maintain vacuum in
evaporators, dryers, in distillation and
rectification plants, for lyophilization,
polycondensation, degassing and
desodorization.
… more than 80 years of experience
in the development, design, and
construction of vacuum systems.
… thousands of references in
numerous industrial sectors all over
the world.
Convince yourself.
GJP4e09
The Boerger
Rotary Lobe Pump.
Börger GmbH I Benningsweg 24 I 46325 Borken-Weseke / Germany I www.boerger-pumps.com
Vacuum Systems
ACHEMA,
11-15 May 2009
in Frankfurt/Main, Germany,
Halle 4.0, Stand D13-G22
Process Engineering
GEA Wiegand GmbH
Einsteinstrasse 9-15, 76275 Ettlingen, Germany
Telefon: +49 7243 705-0, Telefax: +49 7243 705-330
E-Mail: info.gewi.de@geagroup.com, Internet: www.gea-wiegand.com
Select 192 at www.HydrocarbonProcessing.com/RS
125
ASSET MANAGEMENT
piping is not always orthogonal; valves and other devices rarely
end up precisely where they were designed. In the 3D virtual
model, it is reasonable to expect and demand accuracy tolerances
of all details to within 5 mm (3/16 in.).
The 3D virtual model should support the creation of any number of subviews that isolate and emphasize individual processes,
equipment and work tasks. It should be possible to layer these
views (show two or more together) for more precise planning,
documentation and communication of work tasks in the appropriate detail and context. Also, look for the ability to incorporate
3D views of dynamic assets such as cranes and scaffolding that
may be temporarily deployed in the plant.
In addition to providing true graphical representation of
the plant on the desktop, the 3D virtual model must be easily
integrated with the various systems of record for plant and asset
data so that operations data, maintenance records, asset documentation, safety data, etc., can all be accessed quickly without
awkward searches or time-consuming requests and responses.
Information should not be replicated but instead directly accessed
as needed from native sources and put into appropriate context
for the user and task at hand. For example, it should support
a query—pulling the required data from several databases—
requesting to see all pipes containing sour gas, having a corrosion
rate greater than 5 mils/yr, and an operating temperature greater
than 260°C (500°F).
Also very useful would be simulation and playback functions that
create movie-like depictions of scenarios and events. These would
help support training, learning and reviews of upsets and recovery
processes. The model also should allow user annotations that persist
in context for developing procedures and advancing best practices.
3D virtual models are a perfect foundation for collaboration,
coordination and collective knowledge capture that extends across
plant disciplines and to the plant’s network of service and product
suppliers. In the future, look for exciting developments that meld
these 3D virtual models with Web-accessible virtual meeting
rooms, forums, subject-matter wikis and other emerging Web/
Enterprise 2.0 and 3.0 concepts.
Upgrade your pipe design
with products from
Gulf Publishing Company
BIBLIOGRAPHY
Ayral, T., D. Reinhart and C. Lanza, “Quantifying the benefits of virtual plant modeling,”
Hydrocarbon Processing, May 2008, pp. 131–134.
Baker, James A. III, et al., The Report of the BP U.S. Refineries Independent Safety Review
Panel, January 2007.
Renner, K., “Working Smarter, 3D & The Virtual Refinery,” keynote address to SPAR 2008
5th Annual Conference, Houston, Texas, March 3–5, 2008.
Renner, K. and C. Lanza, “Working Smarter in a 3D Virtual World,” keynote address to
NPRA Technology Conference, Orlando, Florida, Oct. 6, 2008.
“Virtualization – The Natural Way to Work,” a white paper from INOVx Solutions.
!
ELLER
BEST S
Value proposition. There is no shortage of software prod-
ucts that propose to save time and money, reduce downtime
and increase plant utilization. The 3D virtual models, however,
do this by introducing a fundamental and significant change (a
breakthrough) in the way people perform work.
Because the industry workforce is aging, the capture, documentation and transfer of their know-how using asset virtualization is
essential. Future plant workers will greatly benefit from this knowledge and thrive in a more modern 3D virtual model environment.
Plant owners and operators also must consider that environmental issues and corporate responsibility are in the governmental
spotlight. Sarbanes-Oxley requires internal awareness and proper
controls over information and processes that relate to the business’s financial health, including asset documentation. The 2007
investigative report commonly referred to as the “Baker Report”
draws attention to leadership’s role in making safety in industrial
processes and equipment “a core value” of any company. OSHA
1910 calls on companies to meet standards of safety for workers
and the local environment. 3D virtual models facilitate these
efforts in important arenas while delivering the operational excellence that distinguishes world-class companies. HP
Kevyn Renner, as a senior technology consultant, drives innovative application of control and information systems for Chevron
Global Manufacturing, based in San Ramon, California. He has
a chemical engineering and technology marketing background
with more than 25 years combined experience in chemical process
design and operations, advanced control and instrument systems, vertical industry
marketing and information systems—with companies including PetroCorp., Mobil
Oil, Foxboro, Emerson and Sun Microsystems. Mr. Renner is widely published on
automation and information systems topics and has delivered numerous keynote
presentations in international forums. He is presently focused on the integral use of
refining system automation and information systems, within an interoperable infrastructure, as well as new visualization techniques, to drive enhanced value from the
petroleum value chain. He holds an engineering honors degree from the University of
Canterbury, New Zealand, with majors in chemical engineering and chemistry.
Constantino (Tino) Lanza is the CEO of INOVx Solutions,
Gulf Publishing Company
+1-713-520-4428 l +1-800-231-6275
Email: svb@GulfPub.com
www.GulfPub.com
Select 193 at www.HydrocarbonProcessing.com/RS
126
where he has lad the company through three years of rapid growth.
He comes to this position with a strong and broad base of experience in technology and business development, and has worked in
most regions of the world as a management consultant and business leader. Mr. Lanza started his career with Exxon Corp., where he had a number
of responsibilities. He also spent about half of his career with Honeywell, where he
was the company’s representative on the NPRA Computing Committee. He holds BS
and MS degrees in chemical engineering from Columbia University.
2 5 – 2 8 M AY 2 0 0 9
Abu Dhabi National Exhibition Centre • UAE
WHERE THE COMMERCIAL AND TECHNICAL GAS WORLDS MEET
THE LARGEST INTERNATIONAL CONFERENCE AND EXHIBITION FOR
THE LNG, LPG AND NATURAL GAS INDUSTRIES IN 2009
● A must-attend conference for anyone operating in the global gas industry, with the theme
‘Gas: A time of change – a time for challenges, solutions and alternatives’
● Unrivalled networking for a global gas audience
● Latest innovations and products displayed at the Gastech exhibition
● The exhibition features 300 exhibiting companies, attracting thousands of visitors from
58 countries
View the full conference programme at
AT
Y
A
OD p
T
www.gastech.co.uk
CE k/h
A
L
u
R P .co.
U
YO tech
R
TE .gas
S
I
G
RE www
HOSTED BY
ORGANISED BY
www.wglnetwork.com
www.gastech.co.uk/hp
Select 108 at www.HydrocarbonProcessing.com/RS
Platinum sponsor:
Gold sponsor:
Silver sponsor:
In-Kind Media Sponsor:
O2 Marketing
Communications
Ó{Ê>ÞÊÓää™ÊUÊՓiˆÀ> Ê
i>V ʜÌiÊUÊÊ
ÕL>ˆ]Ê1˜ˆÌi`ÊÀ>LÊ “ˆÀ>ÌiÃ
KNOW.LEAD.CHANGE.
2 0 0 9 W o m e n ’ s G l o b a l L e a d e r s h i p C o n f e r e n c e i n E n e r g y & Te c h n o l o g y
The Women’s Global Leadership Conference in Energy & Technology is the only conference that focuses on
women in the Energy & Technology Industry and covers topics in both professional development and critical
industry issues. Listen to presentations from international speakers who will share their thoughts on the
industry in this turbulent economy. Panel discussions will focus on the following issues:
· Hydrocarbons vs. Alternatives – Where Do We Stand?
· The Changing Relationship between Independent and National Oil Companies
· The Energy Industry and the Global Economy – The Financial Crisis, The Price of Oil, Human Capital
and Other Complex Issues
· Adapting to a Changing Workforce – Company Success Stories and Tools for Success
· Understanding Cultural Differences: International Business Etiquette, Negotiation and Norms
· Ensuring the Recruitment and Retention of Young Talent in Tough Economic Times
View the agenda and learn more by visiting www.WGLNetwork.com
REGISTER TODAY!
Single attendee:
Team of 2:
Leadership Pack of 10:
$775
$1,400
$6,000
Register Online: www.WGLNetwork.com
Supporting Organizations (additional discounts for members available through the organizations):
·
·
·
·
Arab International Women’s Forum
Association for Women Geoscientists
British American Business Council
Dubai Department of Tourism
and Commerce Marketing
· GASTECH*
· Multinational Development of
Women in Technology
·
·
·
·
Reflex Publishing ME
Sister Cities of Houston
The Petroleum Institute, Abu Dhabi
UK Trade and Investment,
British Consulate General
· Young Professionals in Energy
*Additional discounts to attend both GASTECH and WGLC by registering for both at www.GASTECH.co.uk
2009 WOMEN’S
CONFERENCE IN ENERGY & TECHNOLOGY
DUBAI
Ask about Speaking and Sponsorship Opportunities:
Events@GulfPub.com or +1 (713) 520-4450
ENGINEERING CASE STUDIES
Case 49: Isolating foundations
from machinery vibrating forces
Vibration can be detrimental to nearby equipment
T. SOFRONAS, Consulting Engineer, Houston, Texas
A
roof fan that had been rebuilt
and balanced was causing excessive noise and was shaking nearby
equipment. The rubber isolators on which
the fan was originally mounted had been
discarded during disassembly. With no
information on the type of mounts the
maintenance team installed some they had
obtained from an idle piece of equipment.
Most equipment is rigidly mounted and
so, this type of vibration problem does not
occur often. The following analysis was
done to see if these isolators were the cause
of the higher vibration levels. It’s a good
case history because it also explains some
important vibration principles.
Ff
4Ff
C/Cc
FIG. 1
k
Vibrating machine and simplified
system.
10.0
Fig. 1 shows the simplified fan along
with a support point that will be analyzed.
Notice that the load is evenly divided over
the four mounts (springs), meaning each
mount supports one-fourth of the total
load. If the loads were unequal, more extensive calculations would be required, since
moments would also be present.
The ratio of damping constants, C/Cc ,
is a measure of the internal damping in the
isolator; for well-designed rubber mounts
its value is about 0.05. The amount of load,
w, divided by the spring deflection, ␦, is the
spring constant, k, lb/in.
Fig. 2 is a graph of the transmissibility
ratio, TR, and the frequency ratio, FR:
force transmitted to the foundation
TR =
force transmitted by the machine
FR =
machine vibration frequency, f f
machine natural frequency, f n
Notice that for frequency ratios below
√2 there is no isolation but a magnification
of the force. Isolation only occurs at ratios
higher than √2.
Before determining
TR, some simple calculations are required.1
C/Cc = 0.05
1.0
fn = 188 (k/w)1/2,
cycles/min
k = w/␦, lb/in.
TR
C/Cc = 0.3
0.1
0.01
0.1
FIG. 2
1.0 2.0
ff /fn
Transmissibility ratio curve.
10.0
In this particular case the machine
weighs 300 lb and
each of the four
mounts support
75 lb. Each mount
deflected 0.01 in.
under this load.
The vibrating force
occurs at a frequency
that equals the rotor
speed, 2,700 rpm.
fn = 188 (7,500/75)1/2 = 1,880 cpm
ff /fn = 2,700/1,880 = 1.44
From Fig. 2, this shows TR ≈ 0.8.
The percent isolation = (1–TR ) 100 =
20%.
This is less isolation than desirable since
80% of the vibratory force is reacting on
the foundation. The fabricated mounts
should be resized.
Notice that C/C c does not, in this
range, have much effect on the isolation
because it is not very different from the 0.3
heavily damped case. Damping becomes
quite important for controlling the peak
amplitude if the equipment will operate
through resonance, as will many variablespeed drives.
Changing the spring constant of the
mount will be of more benefit. For example, selecting a mount with k = 2,000 lb/
in. changes the FR to 2.5 and TR drops
to 0.15 or 85% isolation. However, due
to the softer springs more motion can be
expected and this eventuality should not
be overlooked.
Isolation-mount suppliers can offer
valuable assistance in determining if elastomer or coil spring-type mounts should be
used. Heavy equipment, shock, chemicals,
damping, large displacements and high
temperatures need to be considered. HP
1
LITERATURE CITED
Sofronas, A., Analytical Troubleshooting of Process
Machinery and Pressure Vessels: Including RealWorld Case Studies, p. 117, ISBN: 0-471-73211-7,
John Wiley & Sons.
Dr. Tony Sofronas, P.E., was
worldwide lead mechanical engineer
for ExxonMobil before his retirement.
The case studies are from companies
the writer has consulted for. Information
on his books, seminars and consulting is available at the
Website http://www.mechanicalengineeringhelp.com.
HYDROCARBON PROCESSING APRIL 2009
I 129
HPI MARKETPLACE
HPI M
ARKETPLACE
PROCESS
PROCESS
EQUIPMENT
EQUIPMENT
AND
AND
MMATERIALS
ATERIALS
7!"!3( 3%,,3 2%.43
"/),%23 $)%3%, '%.%2!4/23
-/Ê ,
9Ê- ,6
nää‡Çä{‡ÓääÓ
ÜÜÜ°Ü>L>à «œÜiÀ°Vœ“
8\Ê n{LJx{£‡£ÓǙ
Ê
n{LJx{£‡xÈää
Select 201 at www.HydrocarbonProcessing.com/RS
Wedge-Wire Screen Manufacturer:
filtration screens, resin traps, strainer
baskets, hub and header laterals, media
retention nozzels, and custom filtration
products manufactured with stainless
steel and special alloys.
Contact: Jan or Steve
18102 E. Hardy Rd., Houston, TX 77073
Ph: (281) 233-0214; Fax: (281) 233-0487
Toll free: (800) 577-5068
www.alloyscreenworks.com
Select 202 at www.HydrocarbonProcessing.com/RS
Select 204 at www.HydrocarbonProcessing.com/RS
Custom Article
Reprints
SURPLUS GAS PROCESSING/REFINING EQUIPMENT
NGL/LPG PLANTS:
10 – 600 MMCFD
AMINE PLANTS:
60 – 5,000 GPM
SULFUR PLANTS:
10 – 1,200 TPD
FRACTIONATION:
1,000 – 15,000 BPD
HELIUM RECOVERY:
75 & 80 MMCFD
NITROGEN REJECTION: 25 – 80 MMCFD
ALSO OTHER REFINING UNITS
We offer engineered surplus equipment solutions.
Bexar Energy Holdings, Inc.
Phone 210 342-7106
Fax 210 223-0018
www.bexarenergy.com
Email: info@bexarenergy.com
Select 205 at www.HydrocarbonProcessing.com/RS
&MJNJOBUF
7BMWF$BWJUBUJPO
s 0LACE ONE OR MORE DIFFUSERS DOWNSTREAM
OF A VALVE TO ELIMINATE CAVITATION
s %LIMINATE NOISE
s %LIMINATE PIPE VIBRATION
s 2EDUCE VALVE lRST COSTS
s 2EDUCE VALVE MAINTENANCE
Gulf Publishing Company’s
low-cost reprint program
makes it easy and affordable
to receive additional copies
of advertisements, news
releases and articles appearing
in HYDROCARBON
PROCESSING ® magazine
and supplements.
For samples and
a price quote, contact:
Gulf Publishing Company
Attn: Cheryl Willis
2 Greenway Plaza, Suite 1020
Houston, Texas 77046 USA
Phone: 713-520-4449
E-mail: cheryl .willis@gulfpub.com
#5 3ERVICES ,,#
0ARKVIEW #IR %LK 'ROVE 6LG ), 0HONE s RCRONFEL CUSERVICESNET
WWWCUSERVICESNET
Select 206 at www.HydrocarbonProcessing.com/RS
Select 203 at www.HydrocarbonProcessing.com/RS
WORLD’S LARGEST INVENTORY OF LPG STORAGE TANKS
ASME Tank Sales
ASME Fabrication & Alteration
10,000 to 120,000 gallons
Separator Tanks
Slug Catchers
Knock Out Drums
Propane
Butane
Ammonia
CO2 & O2
Nitrogen
LNG
Any Size - Any Quantity
®
“ENERGY PRODUCTS & SERVICES WORLDWIDE”
Total Energy
130
I APRIL 2009 HYDROCARBON PROCESSING
BUY - SELL - DISMANTLE
www.totalenergy.com
Select 207 at www.HydrocarbonProcessing.com/RS
USED & RECONDITIONED
PROCESS EQUIPMENT
1.800.682.0181
MARKETPLACE
SHPI
OFTWARE
AND INSTRUMENTATION
HPI MARKETPLACE
CA
Co PE-O
mp PE
lian N
t!
HTRI Xchanger Suite® – an integrated, easy-to-use suite of tools that
delivers accurate design calculations for
• shell-and-tube heat exchangers
• jacketed-pipe heat exchangers
• hairpin heat exchangers
• plate-and-frame heat exchangers
• spiral plate heat exchangers
• fired heaters
• air coolers
• economizers
• tube layouts
• vibration analysis
Interfaces with many process simulator and physical property
packages either directly or via CAPE-OPEN.
Heat Transfer Research, Inc.
150 Venture Drive
College Station, Texas 77845, USA
HTRI@HTRI.net
www.HTRI.net
Select 209 at www.HydrocarbonProcessing.com/RS
Select 208 at www.HydrocarbonProcessing.com/RS
BUSINESS AND TECHNICAL SERVICES
Select 210 at www.HydrocarbonProcessing.com/RS
NOISE
0IPE 3TRESS
0ROCESS 3IMULATION
0ELLETIZING $IE $ESIGN
(EAT 4RANSFER !NALYSIS
&INITE %LEMENT !NALYSIS
#OMPUTATIONAL &LUID $YNAMICS
6ESSEL%XCHANGER-ACHINE $ESIGN
2OTOR $YNAMICS3TRUCTURAL $YNAMICS
3PECIALISTS IN DESIGN FAILURE
ANALYSIS AND TROUBLESHOOTING OF
STATIC AND ROTATING EQUIPMENT
WWWKNIGHTHAWKCOM
CONTROL ENGINEERING
HFP Acoustical Consultants
Houston TX
(888) 789-9400
(713) 789-9400
Calgary AB
(888) 259-3600
(403) 259-6600
E-mail: info@hfpacoustical.com
Internet: www.hfpacoustical.com
Select 213 at www.HydrocarbonProcessing.com/RS
Select 212 at www.HydrocarbonProcessing.com/RS
(OUSTON 4EXAS
4EL ss
&AX ss
Select 211 at www.HydrocarbonProcessing.com/RS
NOW HIRING
WANTED:
MANUFACTURER’S
REPS
Dorf Ketal Chemicals seeks
Manufacturer’s Reps to represent
our process control chemicals
in the Refinery market and the
Ethylene sector. Ideal candidates
will have significant experience and
live near such plants. Contact:
wloven@dorfketalusa.com
Call 713/520-4449
for details about
Hydrocarbon Processing’s
Recruitment
Advertising Program
Use a combination of print, recruitment e-newsletter, plus Website to reach our
total audience circulation of more than 100,000 !
Visit our Website at
www.HydrocarbonProcessing.com
Select 214 at www.HydrocarbonProcessing.com/RS
HYDROCARBON PROCESSING APRIL 2009
I 131
PROCESS EQUIPMENT AND MATERIALS
KAMAL
AIR PREHEATERS
(CAST & GLASS)
!
An ISO 9001:2000 Company
!
World class design & manufacturing facility with technical
backup from ENGINEERS INDIA LTD (EIL).
!
KAMAL Air Preheaters (APH) approved by various
international inspection agencies such as LLOYDS, MOODY,
TUV, BV, DNV, UHDE, SGS and TOYO.
!
More than 180 Air Preheaters supplied to Oil Refineries,
Petro Chemical, Fertilizer and Steel Plants are in operation
and giving satisfactory performance.
!
LO W N O X B O I L E R S
HPI MARKETPLACE
>LARGE MOBILE FLEET
Trailer-mounted to 120K PPH
Skid-mounted to 250K PPH
Mobile Boiler Rooms to 650 HP


>LOW NOX PERFORMANCE
Ultra Low NOx Units in Stock
Sp App
ec lic
i f i at
E a s i l y M e e t 5 p p m o r L e s s Su
p e I n cl c B o i o n
rh ud
e a i n g i l e rs
tS
ys
tem
>AUXILIARY EQUIPMENT
s!
EconoStak Economizers
CataStak SCR Systems
Complete Feedwater Systems
Heat Recovery Systems
International Clients served:
KTI Rome, Foster Wheeler-UK, JNK Korea, Heurtey France
for overseas supplies of APH to Qatar, Indonesia, Egypt,
Korea, Kuwait, Russia, Thailand, Myanmar and Poland.
Numerous international enquires under consideration.
!
Most competitive prices & on time deliveries.
Call 1-800-227-1966
www.nationwideboiler.com
6th Floor, Antriksh Bhawan, 22, K.G.Marg, New Delhi -110001 (India)
Phone : +91 11 23357598 / 23311693
Fax
: +91 11 23721656 / 23721657
Mail
: kamal@kecindustries.com
Web
: www.kecindustries.com

San Francisco | Baton Rouge | Birmingham | Calgary
Charlotte | Chicago | Cleveland
Hamilton, Ont | Houston | Philadelphia | Seattle
Representative Offices: Kuwait, France, USA
(Soliciting sales rep. for South East, Middle East Asia & China)
Select 216 at www.HydrocarbonProcessing.com/RS
Select 215 at www.HydrocarbonProcessing.com/RS
2 Greenway Plaza, Suite 1020
Houston, Texas, 77046 USA
Houston, Texas 77252-2608 USA
Phone: +1 (713) 529-4301, Fax: +1 (713) 520-4433
www.HydrocarbonProcessing.com
Mark Peters, Publisher
SALES OFFICES—NORTH AMERICA
AR, KS, LA, MO, OK, TX
Josh Mayer
5930 Royal Lane, Suite 201, Dallas, TX 75230
Phone: +1 (972) 816-6745, Fax: +1 (972) 767-4442
E-mail: Josh.Mayer@GulfPub.com
AK, AR, AZ, CA, CO, ID, KS, LA, MO, MT, NM, NV,
OK, OR, TX, UT, WA, WY, WESTERN CANADA
Laura Kane
2 Greenway Plaza, Suite 1020, Houston, Texas, 77046
Phone: +1 (713) 520-4449, Fax: +1 (713) 520-4459
E-mail: Laura.Kane@GulfPub.com
CT, MA, ME, NH, NJ, NY, PA, RI, VT,
EASTERN CANADA
Merrie Lynch
20 Park Plaza, Suite 517, Boston, MA 02116
Phone: +1 (617) 357-8190, Fax: +1 (617) 357-8194
E-mail: Merrie.Lynch@GulfPub.com
IA, IL, IN, KY, MI, MN, ND, NE, OH, SD, WI
Janis Mason
3711 Ravenswood Ave., Unit 146, Chicago, IL 60613
Phone: +1 (773) 325-1804, Fax +1 (773) 325-9406
E-mail: Janis.Mason@GulfPub.com
AL, DC, DE, FL, GA, MD, MS, NC, SC, TN, VA, WV
Lee Nichols
2 Greenway Plaza, Suite 1020, Houston, Texas, 77046
Phone: +1 (713) 525-4626, Fax: +1 (713) 520-4433
E-mail: Lee.Nichols@GulfPub.com
132
I APRIL 2009 HYDROCARBON PROCESSING
SALES OFFICES—EUROPE
SALES OFFICES—OTHER AREAS
FRANCE, SPAIN, PORTUGAL, SOUTHERN
BELGIUM, LUXEMBOURG, SWITZERLAND,
GERMANY, AUSTRIA, TURKEY
Catherine Watkins
Ohana, 30 rue Paul Vaillant Couturier
78114 Magny-les-Hameaux, France
Tél.: +33 (0)1 30 47 92 51, Fax: +33 (0)1 30 47 92 40
E-mail: Watkins@GulfPub.com
AUSTRALIA – Perth
Brian Arnold
Phone: +61 (8) 9332-9839, Fax: +61 (8) 9313-6442
E-mail: Australia@GulfPub.com
ITALY, EASTERN EUROPE
Fabio Potestá
Mediapoint & Communications SRL
Corte Lambruschini - Corso Buenos Aires, 8
5° Piano - Interno 7
16129 Genova - Italy
Phone: +39 (010) 570-4948, Fax: +39 (010) 553-0088
E-mail: Fabio.Potesta@GulfPub.com
RUSSIA/FSU
Lilia Fedotova
Anik International & Co. Ltd.
10/2 Build. 1,B. Kharitonyevskii Lane
103062 Moscow, Russia
Phone: +7 (495) 628-10-333
E-mail: Lilia.Fedotova@GulfPub.com
UNITED KINGDOM/SCANDINAVIA, NORTHERN
BELGIUM, THE NETHERLANDS
Roger Kingswell
Gulf Publishing Co., P. O. Box 437
Maidstone, Kent
ME14 4RB United Kingdom
Phone: +44 (1622) 721222, Fax: +44 (1622) 721333
E-mail: Roger.Kingswell@GulfPub.com
BRAZIL – São Paulo
Alfred Bilyk
Brazmedia Rua General Jardim, 633 Cj 61 01223 011
São Paulo SP, Brazil
Phone: +55 (11) 3237-3269
Fax: +55 (11) 3237-3269
E-mail: Brazil@GulfPub.com
JAPAN – Tokyo
Yoshinori Ikeda
Pacific Business Inc.
Phone: +81 (3) 3661-6138, Fax: +81 (3) 3661-6139
E-mail: Japan@GulfPub.com
INDONESIA, MALAYSIA, SINGAPORE, THAILAND
Peggy Thay
Publicitas Major Media (S) Pte Ltd
Phone: +65 6836-2272, Fax: +65 6297-7302
E-mail: Singapore@GulfPub.com
KOREA – Seoul
Joong Hyon Kwon & JES MEDIA, INC>
Phone: +82 (2) 481-3411, FAX: +82 (2) 481-3414
E-mail: Korea@GulfPub.com
PAKISTAN – Karachi
S. E. Ahmed
Intermedia Communications
Karachi-74700, Pakistan
Phone: +92 (21) 663-4795, Fax: +92 (21) 663-4795
CLASSIFIED ADVERTISING AND REPRINTS
Classified e-mail: Classified@HydrocarbonProcessing.com
Reprints e-mail: EditorialReprints@GulfPub.com
FREE Product and Service Information — APRIL 2009
HOW TO USE THE INDEX: The FIRST NUMBER after the company name is the page on which an This information must be proadvertisement appears. The SECOND NUMBER, appearing in parentheses, after the company name, vided to process your request:
is the READER SERVICE NUMBER. There are several ways readers can obtain information:
PRIMARY DIVISION OF INDUSTRY
1. The quickest way to request information from an advertiser or about an editorial item is to go to www.
HydrocarbonProcessing.com/RS. If you follow the instructions on the screen your request will be forwarded for
immediate action.
2. Go online to the advertiser's Website listed below.
3. Circle the Reader Service Number below and fax this page to +1 (416) 620-9790. Include your name, company, complete
address, phone number, fax number and e-mail address, and check the box on the right for your division of industry
and job title.
Name ________________________________________________________
Company ________________________________________________________
Address ______________________________________________________
City/State/Zip ____________________________________________________
Country ______________________________________________________
Phone No. _______________________________________________________
FAX No. ______________________________________________________
e-mail ___________________________________________________________
This Advertisers’ Index and procedure for securing additional information is provided as a service to Hydrocarbon Processing
advertisers and a convenience to our readers. Gulf Publishing Co. is not responsible for omissions or errors.
(check one only):
A
B
C
F
G
H
J
P
䊐-Refining Company
䊐-Petrochemical Co.
䊐-Gas Processing Co.
䊐-Equipment Manufacturer
䊐-Supply Company
䊐-Service Company
䊐-Chemical Co.
䊐-Engrg./Construction Co.
JOB FUNCTION
(check one only):
B
E
F
G
I
J
䊐-Company Official, Manager
䊐-Engineer or Consultant
䊐-Supt. or Asst.
䊐-Foreman or Asst.
䊐-Chemist
䊐-Purchasing Agt.
ADVERTISERS in this issue of HYDROCARBON PROCESSING
Company
Website
Page
RS#
Company
Website
Page
RS#
Company
Website
Page
RS#
ABV Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
www.info.hotims.com/25251-161
ACS Industries Inc. . . . . . . . . . . . . . . . . . . . . . .54
www.info.hotims.com/25251-76
Aggreko . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
www.info.hotims.com/25251-177
Alstom Power, Inc. . . . . . . . . . . . . . . . . . . . . . . .96
www.info.hotims.com/25251-181
Altair Strickland. . . . . . . . . . . . . . . . . . . . . . . .106
www.info.hotims.com/25251-110
Armstrong International Inc . . . . . . . . . . . . . 76, 77
www.info.hotims.com/25251-68
Asco Filtri Srl . . . . . . . . . . . . . . . . . . . . . . . . . . .69
www.info.hotims.com/25251-171
Ashland Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
www.info.hotims.com/25251-95
Axens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
www.info.hotims.com/25251-53
Babbitt Steam Specialty Co. . . . . . . . . . . . . . . . .53
www.info.hotims.com/25251-166
BASF Catalysts Llc . . . . . . . . . . . . . . . . . . . . . .109
www.info.hotims.com/25251-67
BJ Services . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
www.info.hotims.com/25251-72
Börger GmbH . . . . . . . . . . . . . . . . . . . . . . . . .125
www.info.hotims.com/25251-191
Borsig GmbH. . . . . . . . . . . . . . . . . . . . . . . . . . .47
www.info.hotims.com/25251-164
Bryan Research & Engineering . . . . . . . . . . . . . .79
www.info.hotims.com/25251-113
Buchen-ICS GmbH. . . . . . . . . . . . . . . . . . . . . . .56
www.info.hotims.com/25251-167
Burckhardt Compression AG . . . . . . . . . . . . . . . .8
www.info.hotims.com/25251-55
Carpenteria Corsi Srl . . . . . . . . . . . . . . . . . . . . .24
www.info.hotims.com/25251-153
Carver Pump Company . . . . . . . . . . . . . . . . . . .45
www.info.hotims.com/25251-162
CB&I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
www.info.hotims.com/25251-80
Chemstations Inc. . . . . . . . . . . . . . . . . . . . . . .119
www.info.hotims.com/25251-188
Compressor Controls . . . . . . . . . . . . . . . . . . . . .20
www.info.hotims.com/25251-77
Costacurta SpA Vico . . . . . . . . . . . . . . . . . . . . .98
www.info.hotims.com/25251-71
Cudd Energy Services . . . . . . . . . . . . . . . . . . . .91
www.info.hotims.com/25251-179
Curtiss - Wright . . . . . . . . . . . . . . . . . . . . . . . . .86
www.info.hotims.com/25251-84
DMG World Media - UK . . . . . . . . . . . . . . . . . .127
www.info.hotims.com/25251-108
Dresser-Rand. . . . . . . . . . . . . . . . . . . . . . . . . . .22
www.info.hotims.com/25251-152
Eaton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
www.info.hotims.com/25251-116
Emerson Process Management
(Fisher Controls) . . . . . . . . . . . . . . . . . . . . . .28
www.info.hotims.com/25251-87
(161)
Finder Pompe SpA . . . . . . . . . . . . . . . . . . . . . . .85
www.info.hotims.com/25251-178
Flexelement Texas Inc. . . . . . . . . . . . . . . . . . . .104
www.info.hotims.com/25251-179
Flexitallic LP . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
www.info.hotims.com/25251-93
Gas Technology Products LLC. . . . . . . . . . . . . . .84
www.info.hotims.com/25251-59
Gea Wiegand GmbH . . . . . . . . . . . . . . . . . . . .125
www.info.hotims.com/25251-192
Gulf Publishing Company
Circulation . . . . . . . . . . . . . . . . . . . . . . . . . .116
Events - WGLC . . . . . . . . . . . . . . . . . . . . . . .128
GPC Software Video Books . . . . . . . . . . . . . .120
GPC Software Video Books . . . . . . . . . . . . . .126
GPC Software Video Books . . . . . . . . . . . . . .124
Gulf Coast Turnaround. . . . . . . . . . . . . . . . . .115
Haldor Topsøe A/S . . . . . . . . . . . . . . . . . . . . . . .31
www.info.hotims.com/25251-94
Haver & Boecker . . . . . . . . . . . . . . . . . . . . . . . .35
www.info.hotims.com/25251-157
Hermetic Pumpen GmbH . . . . . . . . . . . . . . . . .114
www.info.hotims.com/25251-186
Heurtey Petrochem . . . . . . . . . . . . . . . . . . . . . .14
www.info.hotims.com/25251-58
Hoerbiger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
www.info.hotims.com/25251-61
Honeywell International. . . . . . . . . . . . . . . . . . . .2
www.info.hotims.com/25251-51
HPI Marketplace . . . . . . . . . . . . . . . . . . . 130-132
Idrojet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
www.info.hotims.com/25251-176
INOVx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
www.info.hotims.com/25251-180
Inpro/Seal Company . . . . . . . . . . . . . . . . . . . . . .8
www.info.hotims.com/25251-88
John M Campbell & Co . . . . . . . . . . . . . . . . . . .42
www.info.hotims.com/25251-160
KBC Advanced Technologies Inc . . . . . . . . . . . . .52
www.info.hotims.com/25251-82
KBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
www.info.hotims.com/25251-89
Kobe Steel Ltd . . . . . . . . . . . . . . . . . . . . . . . . . .89
www.info.hotims.com/25251-103
KTI Corporation . . . . . . . . . . . . . . . . . . . . . . . . .62
www.info.hotims.com/25251-96
KTI Corporation . . . . . . . . . . . . . . . . . . . . . . . . .65
www.info.hotims.com/25251-97
LA Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
www.info.hotims.com/25251-182
Lectrus Corporation . . . . . . . . . . . . . . . . . . . . . .14
www.info.hotims.com/25251-74
Linde Process Plants . . . . . . . . . . . . . . . . . . . . .59
www.info.hotims.com/25251-79
Lurgi AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
www.info.hotims.com/25251-92
M3 Technology . . . . . . . . . . . . . . . . . . . . . . . .113
www.info.hotims.com/25251-185
(178)
Man Turbo AG . . . . . . . . . . . . . . . . . . . . . . . . . .93
www.info.hotims.com/25251-98
Manoir Industries . . . . . . . . . . . . . . . . . . . . . . .30
www.info.hotims.com/25251-156
MB Industries . . . . . . . . . . . . . . . . . . . . . . . . .110
www.info.hotims.com/25251-99
Merichem - Process Technology
Division . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
www.info.hotims.com/25251-86
Microtherm . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
www.info.hotims.com/25251-168
Mustang Engineering . . . . . . . . . . . . . . . . . . . .46
www.info.hotims.com/25251-163
Outokumpu. . . . . . . . . . . . . . . . . . . . . . . . . . . .36
www.info.hotims.com/25251-91
Paharpur Cooling Towers, Ltd. . . . . . . . . . . . . . .58
www.info.hotims.com/25251-169
Paratherm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
www.info.hotims.com/25251-155
Prosim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
www.info.hotims.com/25251-173
Rizzi Engineering Srl . . . . . . . . . . . . . . . . . . . . .37
www.info.hotims.com/25251-158
Sabin Metals Corporation . . . . . . . . . . . . . . . . .49
www.info.hotims.com/25251-78
Samson GmbH . . . . . . . . . . . . . . . . . . . . . . . . . .4
www.info.hotims.com/25251-151
Scanjet Marine AB . . . . . . . . . . . . . . . . . . . . . . .73
www.info.hotims.com/25251-172
Selas Fluid Processing Corp . . . . . . . . . . . . . . . .94
www.info.hotims.com/25251-100
Siirtec Nigi SpA . . . . . . . . . . . . . . . . . . . . . . . .118
www.info.hotims.com/25251-187
Soteica LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
www.info.hotims.com/25251-165
SpectraSensors, Inc. . . . . . . . . . . . . . . . . . . . . . .60
www.info.hotims.com/25251-56
Spectro Analytical Instruments . . . . . . . . . . . . . .95
www.info.hotims.com/25251-184
Spraying Systems Co . . . . . . . . . . . . . . . . . . . . .70
www.info.hotims.com/25251-62
Sulzer Chemtech Ltd . . . . . . . . . . . . . . . . . . . . .41
www.info.hotims.com/25251-159
Superbolt Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .75
www.info.hotims.com/25251-174
Swagelok Co. . . . . . . . . . . . . . . . . . . . . . . . . . .10
www.info.hotims.com/25251-63
Swagelok Co. . . . . . . . . . . . . . . . . . . . . . . . . . .10
www.info.hotims.com/25251-75
T.D. Williamson . . . . . . . . . . . . . . . . . . . . . . . .135
www.info.hotims.com/25251-66
Taper-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
www.info.hotims.com/25251-170
Thermo Fisher Scientific . . . . . . . . . . . . . . . . . .105
www.info.hotims.com/25251-104
Uhde GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
www.info.hotims.com/25251-81
Visionary Insulation Products Ltd. . . . . . . . . . . .26
www.info.hotims.com/25251-154
(98)
(76)
(177)
(181)
(110)
(68)
(171)
(95)
(53)
(166)
(67)
(72)
(191)
(164)
(113)
(167)
(55)
(153)
(162)
(80)
(188)
(77)
(71)
(179)
(84)
(108)
(152)
(116)
(87)
(179)
(93)
(59)
(192)
(189)
(193)
(190)
(94)
(157)
(186)
(58)
(61)
(51)
(176)
(180)
(88)
(160)
(82)
(89)
(103)
(96)
(97)
(182)
(74)
(79)
(92)
(185)
For information about subscribing to HYDROCARBON PROCESSING, please visit www.HydrocarbonProcessing.com
(156)
(99)
(86)
(168)
(163)
(91)
(169)
(155)
(173)
(158)
(78)
(151)
(172)
(100)
(187)
(165)
(56)
(184)
(62)
(159)
(174)
(63)
(75)
(66)
(170)
(104)
(81)
(154)
133
HPIN AUTOMATION SAFETY
WILLIAM GOBLE, CONTRIBUTING EDITOR
wgoble@exida.com
Are you the designated jailee?
In a popular European industry newsletter, I spotted an unsetPersonally, I can imagine being in a court of law and being
tling story—“Criminal proceedings have been commenced against
asked, “How did you decide which particular level transmitter
Total UK Ltd., Hertfordshire Oil Storage Ltd., British Pipeline
to use?” I would be very comfortable answering with my wellAgency Ltd., TAV Engineering Ltd. and Motherwell Control
documented, prior-use study backed up by failure recording
Systems 2003 Ltd., following a thorough and complex criminal
procedures and several years of data. I would also be very cominvestigation conducted by the Health and Safety Executive and
fortable answering that the level transmitter has been indepenthe Environment Agency.”1
dently third-party certified as fit for use per IEC 61508—our
I am certainly not a lawyer. And the case history stories of which
global functional safety consensus standard. What I would not be
I am aware relate primarily to the US, not the United Kingdom.
comfortable with is an answer such as: “I have seen these (transBut this does not sound good. Many quesmitters) in use around the plant, and no one
tions come to mind. Does anyone go to jail? ■ Does anyone go to jail? ever reported a problem.” Any good lawyer
Who is responsible? Is the company’s CEO
could tear this argument to shreds.
responsible for such incidents? Are all of the Are company officers
Likewise, I would be very comfortable
company officers responsible or are design
stating that I used a 61508 certified engineerengineers likewise legally liable? I began responsible or are
ing tool to do my design verification calculathinking about what this means for the engitions. I am unsure how well an answer such
neers who designed these systems. What does design engineers
as, “I made my own spreadsheet,” would be
this mean for those of us who regularly design
received in court.
likewise legally liable?
automatic protection systems?
Many companies following IEC 61511
or IEC 61508 have discovered favorable ecoIs personal liability in your future? I have consistently
nomic justifications for taking this path. One justification is that
been taught about engineering responsibility and morals. I
the quantitative methods allow the designer to optimize safety and
remember the IEEE Code of Ethics that we learned as electrito match the risk, while avoiding overly expensive, overdesigned
cal engineering students. But along with the morals and ethics
systems. Others have eliminated weak hypp-link designs in which
was the protection of a corporation—the “corporate veil” that
tremendous capital was spent with little safety in return. Still,
prevented personal involvement. The corporation could be sued
others have even recognized cost-effective ways to implement a
but individual engineers rarely, if ever, made the news. Has this
significant reduction in the spurious trip rate with corresponding
changed? Will it change?
improvement in production. But now we have another reason for
Since the passing of the Sarbanes-Oxley (SOX) Act in the US,
following our functional safety standards—a layer of protection
the public’s attitude toward corporate behavior has changed. A
against possible legal consequences.
number of bad actors in various countries globally apparently
In our company, we did a legal liability review a few years ago.
created an environment of corporate distaste. While it is true
It was recommended that we implement a stronger documentathat SOX has only been used to prosecute financial misbehavior,
tion review and archive process. I can now clearly see why that is
some have speculated that the act could be used for any corporate
so important. As I think about all the things we should be doing
behavior deemed unacceptable.
to avoid trouble in this new anti-corporate environment, I see
Consider the overall public attitude toward corporate leaders. Is
more that should be done. I am also thinking that these things
the news program from your television reporting glowing positive
should be done anyway. They are just part of good engineering
stories about responsible corporate executive activities? Mine is not.
practice. What else should you be doing? HP
Combine this attitude with the stories about strong prosecutors
LITERATURE CITED
working to gain political influence. So, you are not sure on what
1 Health and Safety Executive, United Kingdom, press release, Jan. 12, 2008,
I’m talking about, then do an Internet search on the term “overzealB002:08, http://www.buncefieldinvestigation.gov.uk/press/b08002.htm.
ous prosecution.” The legal logic being applied in these stories does
not correlate with any engineering logic that I can use.
What does this mean for safety system designers?
Maybe, this is a big deal and maybe not. But, we are all advised to
carefully watch this development. In the meantime, it is clear that
design engineers should follow the industry consensus standards
for functional safety and do a good job documenting their work.
No more excuses!
134
I APRIL 2009 HYDROCARBON PROCESSING
The author is a principal partner of exida.com, a company that does consulting,
training and support for safety-critical and high-availability process automation. He
has over 25 years of experience in automation systems, doing analog and digital
circuit design, software development, engineering management and marketing.
Dr. Goble is the author of the ISA book Control Systems Safety Evaluation and
Reliability. He is a fellow member of ISA and a member of ISA’s SP84 committee on
safety systems. Dr. Goble can be reached by e-mail at: wgoble@exida.com.
As the world’s leading provider of pressurized piping system maintenance and repair capabilities, TDW delivers innovative, customized
products, services and solutions that optimize system performance
with a minimum of downtime.
Give us a call. And put our solutions to work for you.
NORTH & SOUTH AMERICA: 918-447-5000
ASIA/PACIFIC: 65-6364-8520 |
| EUROPE/AFRICA/MIDEAST: 32-67-28-36-11
OFFSHORE SERVICES: 832-448-7200
® Registered trademarks of T.D. Williamson, Inc. in the United States and in foreign countries. ™ Trademarks of T.D. Williamson, Inc. in the United States and in foreign countries.
Select 66 at www.HydrocarbonProcessing.com/RS
Simplify
sulfur recovery
and cut your costs
Low-temperature tail-gas hydrogenation catalysts
that deliver superior and cleaner performance from simplified operations, and significantly
lower CO2 emissions. Axens’ TG catalysts can work with steam reheating technologies to reduce
energy consumption. Operating costs and investments are also reduced. It’s a winner every time.
Single source ISO 9001 technology and service provider
www.axens.net
Moscow
Beijing +86 10 85 27 57 53 Houston
+7 495 933 65 73 Paris +33 1 47 14 25 14 Tokyo
+1 713 840 11 33
+81 335 854 985
Select 53 at www.HydrocarbonProcessing.com/RS