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PREFACE ..............................................................................................
X
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1
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What is a Process Design?
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1
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The Elements of a Process Design Package.
Process Description. Overall Material Balance. Process
Flowsheet. Composition Summary. Line List. Heat Exchanger
Specifications. Pump Data. Fired Heater Data Sheets. Vessel
Sketches. Tray Data Sheets. Compressor Data Sheet.
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2
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Packed Column Pitfalls
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6
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Structured Packing. Rings Versus Structured
Packing. Migrating Rings. Designing Tower Internals. Support
Grid. Other Ideas to Increase the Capacity of Packed Towers.
Hold-Down Grids. Vapor Distributor. Liquid Distribution
and Collection. Propylene-Isobutane Splitter. References.
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3
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Vacuum Tower Design .........................................................................
27
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Wash-Oil Section Design. Flash-Zone Temperature.
Pumparound Design. Tower Top Temperature. Wet Versus Dry
Towers.
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4
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Trayed Tower Internals
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38
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Avoid Internal Level Connections. The Dangers
of Internal Draw-Off. Overflowing Draw-Off Sumps. Coordinating
Nozzle Location with Tray Design. Feed and Reflux Distributors.
Never Seal a Downcomer. Side-Stream Steam-Stripper Hydraulics.
Combination Pumparound Draw-Off and Product Trap-Out Pan.
Leak-Proofing Draw-Off Pans. Strengthening Trays to Withstand
Pressure Surges. Vacuum Tower Trap-Out. Tray Leakage.
Chimney Tray Design. Reviewing Vendor Tray Drawings. References.
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5
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Washing Flash-Zone Vapors
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57
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Choice of Wash-Oil Internals. Bubble-Cap
Trays. Valve Trays. Shed Decks or Side-to-Side Baffles.
Demisters. Ring Packing. Washing-Oil Grid.
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6
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Revamping Distillation
Columns .........................................................
61
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Tower Capacity. Trayed Towers. Packed Towers.
Overhead Condensers. Fin-Tube Exchangers. Reboilers. Optimum
Reboiler Retrofit. Energy Savings. High-Flux Tubing. Errors
Made in Revamping Distillation Columns. Reference.
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7
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Distillation Tower Reboiler
Details .....................................................
83
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Kettle Reboilers. Thermosiphon Reboilers.
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8
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Sizing Vessels .......................................................................................
91
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Sizing the Boot. Hydrocarbon-Water Separation.
Inlet Piping Design. Flooded Condenser Reflux Drum. Liquid
Hold time. Vapor-Liquid Separators. Horizontal Vapor-Liquid
Separators. Hydrocarbon Skimming Vessel.
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9
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Steam Turbines and Surface
Condensers ......................................... 101
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Topping Steam Turbine Drives. How Steam
Turbines Function. An Energy Conservation Incident. The
Vacuum-Jet System. Condensate Pumpout System. Surface
Condenser. An Unusual Incident. Reference.
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10
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How to Pull a Deep Vacuum
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121
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Steam Pressure Affects Vacuum. Jet Capacity.
Seal Leg Design. Design of Seal Drums. Tail-Gas Quantity.
Disposal of Ejector Tail Gas. Liquid Seal Ring Compressors.
References.
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11
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Centrifugal Compressors:
Designing to Avoid Surge ....................... 135
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Reciprocating Compressors. Centrifugal
Compressor Characteristics. What Is Surge? What Causes
Surge? Variable Molecular Weight. Compression Work. Practical
Problems of Variable Molecular Weight. Adjusting for Low
Molecular Weights. Maximum Number of Wheels. Allowing
for High Molecular Weight. Suction Throttling. References.
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12
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Sizing Centrifugal Pumps
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143
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How Much Head Is Required? How Much Flow
Is Required? Selecting a Pump's Impeller. Selecting a
Pump's Motor. Shut-In Pressure. Expanding Pumping Capacity.
Reducing Hydraulic Bottlenecks. Larger Impeller. Correct
Process Design Minimizes Pump Maintenance. Protecting
Against Low NPSH.
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13
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Shell-and-Tube Heat Exchangers
- The Pitfalls of Oversizing ......... 153
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Three Feet Per Second. Calculating. Tube-Side
Velocity. How to Design for High Tube-Side Velocity. Calculating
Shell-Side Velocity. Fouling Factors. Tube Configuration.
Revamp Errors Made in Expanding Condensers. Reboiler Design
Errors. References.
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14
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Fired Heater Design for
Maximum Run Lengths ............................ 175
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Mass Velocity. Velocity Steam. Heat Flux.
Uneven Heat Distribution. Air Preheater - Effect on Radiant
Heat Flux. Burning Waste Gas. Convective Section. Soot
Blowers. Finned Versus Studded Tubes. Afterburn in Convective
Sections. Metallurgy of Tubes. Auxiliary Drums. References.
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15
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Corrosion Control Techniques
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188
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Controlling Condensate pH in Crude Oil
Distillation. Equipment Sizing. Dead Ends. Water Accumulation
Can Cause Hydrogen Blistering of Steel. Draining Small
Amounts of Water Continuously. Carbon Dioxide in Steam
Is Corrosive. Use Corrosion to Prevent Corrosion. Sacrificial
Anode. Excessive Velocity Erosion. References.
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16
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Safety ..................................................................................................
200
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Startups and Shutdowns. Hazards of Water.
Dehydrating by Circulation. Fluctuating Feed. Water in
Feed. Electric Power Failure. Loss of Cooling. Instrument
Air Failure. Level Control. Anticipating Heat Exchanger
Leaks. Vessel Collapse. A Word of Caution. References.
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17
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Liquid Level Control ...........................................................................
212
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Level Indication. Redundancy in Liquid
Level Indication. Other Methods of Liquid Level Measurement.
Minimizing Level Tap Plugging. References.
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18
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Saving Energy Through
Flexibility ....................................................
220
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Turndown in Distillation. Dual Reflux Distributors.
Turndown in Trayed Columns. Dual-Cap Valve Trays. Adjustable
Weirs. Avoid Leaking Trays. Fired Heaters. Air Preheaters.
Heat Exchangers. Laminar Flow. Centrifugal Pumps. Flexibility
Items Which Waste Energy. Reference.
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19
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Cost Estimate - How to
Allow For Installation Factors .................... 229
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Installation Costs. Installation Costs
for Individual Process Items. Utilizing Used Equipment.
Major Plant Costs. References.
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GLOSSARY ........................................................................................
234
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INDEX ................................................................................................
242
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