Hydroprocessing for Clean Energy: Design, Operation, and Optimization

Provides a holistic approach that looks at changing process conditions, possible process design changes, and process technology upgrades Includes process integration techniques for improving process designs and for applying optimization techniques for improving operations focusing on hydroprocessing units. Discusses in details all important aspects of hydroprocessing – including catalytic materials, reaction mechanism, as well as process design, operation and control, troubleshooting and optimization  Methods and tools are introduced that have a successful application track record at UOP and many industrial plants in recent years Includes relevant calculations/software/technologies hosted online for purchasers of the book

Table of Contents:
Preface xiii Part 1 Fundamentals 1 1 Overview of This Book 3 1.1 Energy Sustainability 3 1.2 ULSD – Important Part of the Energy Mix 4 1.3 Technical Challenges for Making ULSD 7 1.4 What is the Book Written for 8 References 8 2 Refinery Feeds Products and Processes 9 2.1 Introduction 9 2.2 ASTM Standard for Crude Characterization 10 2.3 Important Terminologies in Crude Characterization 12 2.4 Refining Processes 13 2.5 Products and Properties 15 2.6 Biofuel 20 3 Diesel Hydrotreating Process 23 3.1 Why Diesel Hydrotreating? 23 3.2 Basic Process Flowsheeting 25 3.3 Feeds 28 3.4 Products 30 3.5 Reaction Mechanisms 36 3.6 Hydrotreating Catalysts 40 3.7 Key Process Conditions 44 3.8 Different Types of Process Designs 47 References 48 4 Description of Hydrocracking Process 51 4.1 Why Hydrocracking 51 4.2 Basic Processing Blocks 53 4.3 Feeds 58 4.4 Products 59 4.5 Reaction Mechanism and Catalysts 61 4.6 Catalysts 67 4.7 Key Process Conditions 70 4.8 Typical Process Designs 75 References 78 Part 2 Hydroprocessing Design 79 5 Process Design Considerations 81 5.1 Introduction 81 5.2 Reactor Design 81 5.3 Recycle Gas Purity 98 5.4 Wash Water 102 5.5 Separator Design 107 5.6 Makeup Gas Compression 115 References 121 6 Distillate Hydrotreating Unit Design 123 6.1 Introduction 123 6.2 Number of Separators 123 6.3 Stripper Design 127 6.4 Debutanizer Design 135 6.5 Integrated Design 136 References 147 7 Hydrocracking Unit Design 149 7.1 Introduction 149 7.2 Single-stage Hydrocracking Reactor Section 150 7.3 Two-stage Hydrocracking Reactor Section 155 7.4 Use of a Hot Separator in Hydrocracking Unit Design 158 7.5 Use of Flash Drums 160 7.6 Hydrocracking Unit Fractionation Section Design 161 7.7 Fractionator First Flow Scheme 161 7.8 Debutanizer First Flow Scheme 163 7.9 Stripper First Fractionation Flow Scheme 166 7.10 Dual Zone Stripper Fractionation Flow Scheme 168 7.11 Dual Zone Stripper – Dual Fractionator Flow Scheme 170 7.12 Hot Separator Operating Temperature 171 7.13 Hydrogen Recovery 174 7.14 LPG Recovery 175 7.15 HPNA Rejection 177 7.16 Hydrocracking Unit Integrated Design 181 References 187 Part 3 Energy and Process Integration 189 8 Heat Integration for Better Energy Efficiency 191 8.1 Introduction 191 8.2 Energy Targeting 191 8.3 Grassroots Heat Exchanger Network (Hen) Design 202 8.4 Network Pinch for Energy Retrofit 206 Nomenclature 213 References 213 9 Process Integration for Low-Cost Design 215 9.1 Introduction 215 9.2 Definition of Process Integration 216 9.3 Grand Composite Curves (GCC) 218 9.4 Appropriate Placement Principle for Process Changes 219 9.5 Dividing Wall Distillation Column 225 9.6 Systematic Approach for Process Integration 228 9.7 Applications of the Process Integration Methodology 230 9.8 Summary of Potential Energy Efficiency Improvements 246 References 247 10 Distillation Column Operating Window 249 10.1 Introduction 249 10.2 What is Distillation? 249 10.3 Why Distillation is the Most Widely Used? 251 10.4 Distillation Efficiency 253 10.5 Definition of Feasible Operating Window 255 10.6 Understanding Operating Window 256 10.7 Typical Capacity Limits 275 10.8 Effects of Design Parameters 275 10.9 Design Checklist 278 10.10 Example Calculations for Developing Operating Window 281 10.11 Concluding Remarks 296 Nomenclature 297 References 299 Part 4 Process Equipment Assessment 301 11 Fired Heater Assessment 303 11.1 Introduction 303 11.2 Fired Heater Design for High Reliability 304 11.3 Fired Heater Operation for High Reliability 310 11.4 Efficient Fired Heater Operation 315 11.5 Fired Heater Revamp 321 Nomenclature 322 References 322 12 Pump Assessment 323 12.1 Introduction 323 12.2 Understanding Pump Head 324 12.3 Define Pump Head – Bernoulli Equation 325 12.4 Calculate Pump Head 329 12.5 Total Head Calculation Examples 330 12.6 Pump System Characteristics – System Curve 332 12.7 Pump Characteristics – Pump Curve 333 12.8 Best Efficiency Point (BEP) 338 12.9 Pump Curves for Different Pump Arrangement 338 12.10 Npsh 340 12.11 Spillback 345 12.12 Reliability Operating Envelope (ROE) 346 12.13 Pump Control 347 12.14 Pump Selection and Sizing 347 Nomenclature 351 References 351 13 Compressor Assessment 353 13.1 Introduction 353 13.2 Types of Compressors 354 13.3 Impeller Configurations 357 13.4 Type of Blades 358 13.5 How a Compressor Works 358 13.6 Fundamentals of Centrifugal Compressors 360 13.7 Performance Curves 362 13.8 Partial Load Control 364 13.9 Inlet Throttle Valve 366 13.10 Process Context for a Centrifugal Compressor 367 13.11 Compressor Selection 368 Nomenclature 369 References 369 14 Heat Exchanger Assessment 371 14.1 Introduction 371 14.2 Basic Concepts and Calculations 371 14.3 Understand Performance Criterion – U Values 374 14.4 Understand Fouling 380 14.5 Understand Pressure Drop 382 14.6 Effects of Velocity on Heat Transfer Pressure Drop and Fouling 384 14.7 Heat Exchanger Rating Assessment 385 14.8 Improving Heat Exchanger Performance 396 Nomenclature 399 References 400 15 Distillation Column Assessment 401 15.1 Introduction 401 15.2 Define a Base Case 401 15.3 Calculations for Missing and Incomplete Data 403 15.4 Building Process Simulation 406 15.5 Heat and Material Balance Assessment 408 15.6 Tower Efficiency Assessment 411 15.7 Operating Profile Assessment 414 15.8 Tower Rating Assessment 417 15.9 Guidelines 419 Nomenclature 420 References 420 Part 5 Process System Evaluation 423 16 Energy Benchmarking 425 16.1 Introduction 425 16.2 Definition of Energy Intensity for a Process 426 16.3 The Concept of Fuel Equivalent for Steam and Power (FE) 427 16.4 Data Extraction 429 16.5 Convert All Energy Usage to Fuel Equivalent 432 16.6 Energy Balance 432 16.7 Fuel Equivalent for Steam and Power 435 16.8 Energy Performance Index (EPI) Method for Energy Benchmarking 441 16.9 Concluding Remarks 444 16.10 Nomenclature 445 References 446 17 Key Indicators and Targets 447 17.1 Introduction 447 17.2 Key Indicators Represent Operation Opportunities 448 17.3 Define Key Indicators 451 17.4 Set Up Targets for Key Indicators 456 17.5 Economic Evaluation for Key Indicators 460 17.6 Application 1: Implementing Key Indicators into an “Energy Dashboard” 463 17.7 Application 2: Implementing Key Indicators to Controllers 465 17.8 It is Worth the Effort 466 Nomenclature 467 References 467 18 Distillation System Optimization 469 18.1 Introduction 469 18.2 Tower Optimization Basics 470 18.3 Energy Optimization for Distillation System 475 18.4 Overall Process Optimization 481 18.5 Concluding Remarks 489 References 490 Part 6 Operational Guidelines and Troubleshooting 491 19 Common Operating Issues 493 19.1 Introduction 493 19.2 Catalyst Activation Problems 494 19.3 Feedstock Variations and Contaminants 495 19.4 Operation Upsets 496 19.5 Treating/Cracking Catalyst Deactivation Imbalance 497 19.6 Flow Maldistribution 500 19.7 Temperature Excursion 501 19.8 Reactor Pressure Drop 504 19.9 Corrosion 506 19.10 Hpna 509 19.11 Conclusion 511 20 Troubleshooting Case Analysis 513 20.1 Introduction 513 20.2 Case Study I – Product Selectivity Changes 514 20.3 Case Study II – Feedstock Changes 516 20.4 Case Study III – Catalyst Deactivation Balance 523 20.5 Case Study IV – Catalyst Migration 526 20.6 Conclusion 536 Index 537

About the Author :
Frank Zhu, PhD, is Senior Fellow at Honeywell UOP, Des Plaines. He is a leading expert in industrial process design, modeling and energy optimization with more than 80 publications and 30 patents. He is the co-founder of the ECI International Conference: CO2 Summit, the recipient of AIChE Energy and Sustainability Award, and the author of Energy and Process Optimization for the Process Industries by Wiley/AICHE. Richard Hoehn is a Senior Fellow at Honeywell UOP, Des Plaines where he has been employed for 42 years, 31 of which have been in the field of hydroprocessing.  He received a BS in chemical engineering from Purdue University. He currently holds 36 US patents and has received the Ernest W. Thiele Award from the Chicago Section of the AIChE. Dr. Vasant Thakkar, PhD, was a Senior Fellow at Honeywell UOP, Des Plaines, before retiring in 2015. Vasant worked in Refining R&D Group for over 36 years. Vasant received Honeywell Distinguished Technologist award in 2014. Vasant holds 38 US patents. He received Ph. D. in chemical Engineering from Colorado school of Mine. He held membership in AIChE and ASTM D2 committee. Edwin Yuh is a Fellow at Honeywell UOP, Des Plaines where he has been employed for 37 years, 35 of which have been in the field of hydroprocessing. He received a BS in chemical engineering from Columbia University and a MS in chemical engineering from Northwestern University. Most of his UOP career is in technical service.