Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Task Checklist
X Introduction TOWER SIMULATION
Z Basic Concepts Z Specifications
DEVICE SELECTION
Z Contacting Devices Z Tray Hardware Definitions Z Tray Hydraulics Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
More on Fractionation
Objective Questions
How can you improve separation efficiency?
How do you decide on the optimum number of trays for a new tower?
Designers Role
Perform HMB calculations to develop tower loadings New Towers
Select optimum tower size, contacting device, and internals to meet process requirements
Existing Towers
Select optimum contacting device and internals to improve performance or expand capacity Screening - Apply Concepts to Troubleshoot Problems
Engineers Toolbox
XOM DP Section III (Intranet)
Fractionation Specialists
Task Checklist
X Introduction
DEVICE SELECTION
Z Contacting Devices Z Tray Hardware Definitions Z Tray Hydraulics Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
Conventional Tower
R D
Reflux Ratio = R / D
Rules of Thumb
More Reflux
More Trays
More Separation
Lower Pressure
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MINIMUM REFLUX
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Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts
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Operating Pressure
Factors to consider:
Temperature of available condensing fluid (air, water, etc.) Wheres the overhead product go? Is the overhead totally condensed? Possible Limitations:
+ Bottoms temperature (cracking / color) + Reboiler + Critical Point (poor separation)
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Operating Temperature
Fixed once product specifications and pressure are set
Flash Calculations
Reflux temp.
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Feed Condition
Other Considerations:
Reflux vs. Reboiler Duty / Costs Quenching
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PRODUCT
OVERRIDE
A
FEED
FUEL GAS CONTROL: FEED RATE PRODUCT VAPOR PRESSURE PRODUCT SULFUR OVERHEAD DRUM LEVEL
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Simulation Inputs
Feed Rate and Composition VLE Data Method Specifications & Control Variables Operating Pressure Initial Guess (If Required) For Rating:
Plant Test Data
Pressure, Temperature Profile Lab Data (Complete Set of Samples)
Tray Efficiencies
See DP III-I Table 2; Estimates from Past Designs
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Tower Specifications
Specifications: usually on product quality or temperatures
Can be mathematical Avoid specifying rate. Better to specify % recovery or fraction. Condenser temperature
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ProII Condensers
Stage 1, if present Different Types
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ProII Reboilers
Last Stage(s) Kettle or Thermosiphon
Kettle Thermosiphon specify if have baffle or not
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KETTLE REBOILER
Advantages: + Additional fractionation stage Disadvantages: - Low NPSH to downstream pump - Very low hold-up - Tubes can dry out - High temperature increase - Large plot space
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Reboiler (1 or 2)
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Simulation Strategy
Optimize Reflux Ratio, Stages, Feed Condition, and Feed Location
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Simulation Pitfalls
Save / Backup cases often.
Others?
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SIMULATION RESULTS
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Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
33
Device Categories
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Conventional Trays
Sieve
Most Widely Used 2:1 Turndown Low Cost (Nonproprietary)
Valve
Up to 5:1 Turndown 5-10% higher capacity over sieve Marginally higher cost Not recommended for fouling services
Bubble Cap
Standard until 1950s High Cost Maintenance / Inspection Difficult Excellent Turndown
Jet
hExxon Design for High Liquid Loads Efficiency ~20% less than sieve Mainly used in pumparounds
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Pumparound Definition
Method to provide tower reflux by cooling tower liquid
Draw-off intermediate liquid Cool liquid by pumping it through heat exchanger Return liquid to tower Use trays/packing to return
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Sulzer
MVG
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Directional effect reduces fouling and vapor jetting/entrainment 10-15% jet flood capacity advantage to 1/2 (13mm) sieve trays
Sulzer
MVG-T (not shown)
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Sulzer
Shell HiFi
~20% higher capacity, but lower efficiency than conventional sieve tray Limited access; not recommended for fouling (Very difficult to clean / inspect)
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Random Packing
3RD Generation
CMR IMTP Nutter Ring Rashig Super-Ring
2ND Generation
Pall Ring Flexirings Ballast Rings Slotted Rings
1ST Generation
Berl Saddle Intalox Saddle Rashig Ring
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Consider for:
Small tower diameter (<3 or 915mm) Low [critical] pressure drop applications (i.e. vacuum distillation, etc.) Need to minimize tower size (offshore) Revamps where acceptable tray design cannot be achieved See DP III-A, p. 34 for others applications
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Packing Warning
Fire Hazard: Some sites prevent hot work above a packed bed
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Structured Packing
Conventional
Koch-Glitsch: Flexipac, Intalox Sulzer: Mellapak Montz: Montz-Pak Type B1
High Capacity
Koch-Glitsch: Flexipac HC, Intalox Sulzer: Mellapak Plus Montz: Montz-Pak Type M
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Grid
Used for entrainment removal where fouling is too severe for a crinkle wire mesh screen (CWMS) High Open Area
Prevents plugging
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Baffles
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Revamp
Rate existing contacting device to identify potential limitations (i.e. downcomer, jet flood, etc.)
(See Table 1 Design Principles in appropriate DP III Section)
Identify new layout and device where all design parameters are satisfied
(Use Pegasys / EMoTIP)
Consider:
Multi-pass Conventional Trays High Performance Fixed Valves Enhanced Downcomer Trays Multiple Downcomer Trays Packing
Dont consider High Capacity Trays for new towers - Instead Increase Diameter, etc.
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Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION
X Contacting Devices
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Downcomer Types
Stepped / Sloped: Provide sufficient DC inlet area for adequate vapor / froth disengagement while maximizing bubble area
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Downcomer Expansion
Can expand downcomer without welding
Commonly called Z-bar or downcomer adapter
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Weir Types
Picketing: Can reduce spray regime operation by increasing effective liquid height; Also used to balance multipass designs by making their effective weir lengths the same.
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Process Seal
Mechanical Seals
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Area Definitions
Also see DP III-A, Figures 12-13
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Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions
X Tray Hydraulics
Z Packing Hydraulics Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
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Hydraulic Limitations
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FRI VIDEO
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Jet Flooding
At high vapor rates, liquid is jetted to tray above Vapor handling limitation; sets design in most cases Expressed as Percent; Rigorously Calculated
(See DP III-B / Use Pegasys)
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85
Late Breaking News: XOM Jet Flood Limit now 80% for new designs
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Ultimate Capacity
Highest vapor rate tower can handle -- Stokes Law Cannot be increased by hardware changes; only way to increase it is by increasing the tower diameter
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Flow Regimes
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Entrainment
Function of:
Vapor Rate Liquid Rate Tray Spacing Other Hardware Parameters
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Downcomer Backup
DC froth height expressed as percent of tray spacing plus the weir height
DC Filling Components:
hi = inlet head; f(inlet & outlet weir) ht = total tray dP hud = head loss under DC; f(DC Clearance) hdc = head loss due to two-phase flow in DC
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Flooding Symptoms
Jet Flooding
Tower unstable Liquid entrainment into overhead system; sharp increase in reflux rate with no separation improvement Pressure drop increases sharply with a small incremental increase in vapor rate Separation efficiency gradually decreases
Downcomer Flooding
Tower unstable, surging High pressure drop with a small increase in either vapor or liquid rate Separation efficiency suddenly decreases Loss of tower bottoms liquid level
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Downcomer Choking results when the DC inlet area is too small. Velocity Under the Downcomer
If too high, can produce channeling effect leading to vapor / liquid maldistribution on the tray.
Downcomer Seal
If not sealed, vapor can bypass the tray and flow upward through the downcomer resulting in reduced efficiency. Two types:
Mechanical [Static] Process [Dynamic]
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Tray Hydraulics
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Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics
X Packing Hydraulics
Z Other Process Considerations Z Other Tower Internals Z Tower Revamps
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Packing Hydraulics
Packing Hydraulics
Flooding -- (Use Pegasys)
Harder to define than tray hydraulics (i.e. no tray spacing or downcomer
to fill with liquid)
As vapor rate increases, liquid accumulates and the pressure drop begins to rise more sharply. With further increases in vapor rate, the pressure drop rises almost vertically and liquid stacks up on top of the packing.
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Packing Hydraulics
Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics X Packing Hydraulics
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Packing Hydraulics
Tray Efficiency
Overall Efficiency, EO, is a measure of the effectiveness of an entire tower or tower section. Allows designer to determine the number of actual trays to provide and sets the tower height.
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Packing Height
To specify correct packing height, designer must calculate height equivalent to a theoretical plate (HETP)
Other methods for packing efficiency exist, but HETP applies to most systems Factors affecting HETP:
Distributor Design Packing Size / Geometry VLE Properties and Tower Loading
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Turndown
Defines range of loadings for acceptable device performance Excessive Weeping Decreases Efficiency
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Foaming
Foaming Mechanisms:
Presence of surface active materials or solids HC entrainment or condensation in aqueous systems
Known Foamers
Amine and Glycol Absorbers Caustic Towers Ethylene Demethanizers Sour Water Strippers
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20" Manway
254
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357
180
Redistributor
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20" Manway
800
480
Top of Packing
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Bed Limiter
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Bed Support
This FLEXSORB absorber tower foams. What changes would you make to improve it? Units are in mm (25mm=1) unless stated.
650
396
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1830
Design Contingency
To insure 90% chance of successful operation, safety margins should be adhered to and are built into EMoTIP.
Examples
Jet Flooding (Trays) Downcomer Filling Packing Flooding Tray efficiency Packing HETP 80-90% of predicted 35-50% 80-85% of predicted Point efficiency debited 10% Predicted divided by 0.85
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Try high capacity designs instead of packing for revamps Prevent water from entering tower
#1 cause of refinery tray damage
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Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics X Packing Hydraulics X Other Process Considerations
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Tray Internals
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Hole/Slot Area should give 0.25-0.5 psi (0.018-0.035 kg/cm2) pressure drop
(See Fluid Flow Equations, DP III-H)
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Insulate baffle to prevent vaporization in downcomer 0.25-0.5 psi (0.02-0.04 kg/cm2) for distributor hole/slots Chimneys
Long rectangular lowest cost, then round, last square
Size CWMS for 100% Vc, unless foaming service Useful fluid flow equations hidden in DP III-H Some drawoffs require self venting flow (eq 13)
Chance that vapor can enter drawoff line
Low residence time Lack of seal in drawoff pan (coking or fouling services)
Packing Internals
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Packing Distributor
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Sprays in action: Water Test of BTRF PS 8 VPS Wash Oil Distributor at Turndown Rate - 2003
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Distribution Quality
Area samples and individual random sample are compiled to verify performance
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Packing Supports
Located at bottom of packed bed Open Area sized for at least 100% of tower cross section to prevent flooding Design details by vendor
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Bed Limiters
Restrain packing during upsets - keep out of draw nozzles, etc. Fastened to clips welded to shell or suspended from distributor
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Either type may be a partial or total draw Reboiler Draws are unique (see DP III-H)
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1 1/2"
11" 4"
1' - 0" 71
4" 15
2' - 10"
4' - 10"
1' - 6"
2"
2' - 0"
3' - 3"
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8"
1' - 12"
4"
3' - 10"
Task Checklist
X Introduction
TOWER SIMULATION
X Basic Concepts X Specifications
DEVICE SELECTION
X Contacting Devices X Tray Hardware Definitions X Tray Hydraulics X Packing Hydraulics X Other Process Considerations X Other Tower Internals
X Tower Revamps
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Tower Revamps
Tower Revamps
Always consider process alternatives first!!!
(e.g. increase tower pressure, etc.)
Explore high capacity tray options discussed previously before considering packing Fundamental design concepts remain the same. However, sometimes design criteria are too conservative - consult with a Fractionation Specialist.
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Tower Revamps
Options Guide
Revamp Objective: Increased capacity at constant separation efficiency
(XOM DP III-A Table 4A)
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Tower Revamps
Debottleneck Examples
Cheap Operational changes Reduce weir height, increase DC clearance or add a shaped lip to lower DC filling Change tray decks Packed Towers:
Increase Packing Size Install Structured Packing Replace liquid distributor(s)
Expensive Install sloped or mod. arc downcomers Increase number of liquid passes Install high capacity trays Changing tray spacing Install packing Change amine type or concentration
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Tower Revamps
Packing Selection
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Tower Revamps
Expansion Example
What consider for expansion?
Top Trays Jet Flood Limit Base Expansion <85% 42% 45% DC Flood <85% 90% 95% DC Choke <100% 150% 160%
Bottom Trays Jet Flood Limit Base Expansion <85% 29% 31% DC Flood <85% 62% 66% DC Choke <100% 97% 103%
Preheat: 6.1 MBtu/hr (6.4 M.kJ/h) Base, 6.5 MBtu/hr (6.9 M.kJ/h) Expansion Reboiler: 60% of capacity
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Tower Inspection
All vessels need technical inspection Inspect every tray, every pass, recording dimensions
DC clearance, DC rise, weir heights, number of holes (within reason) Verify bolts are tight Make sure internals are put together correctly Levelness of weirs Helmet mounted and hand held flashlights (explosion proof recommended) Rechargeable spotlight for large vessels/furnaces Knee pads, and maybe seating pad Wrench (to check bolts) Ruler, tape measure, and wooden blocks cut to measurement tolerances Water bottle Level (consider laser type) Hardhat, gloves, clear safety glasses, pool FRCs Marker or paint pen Shoulder bag
Tools
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20" Manway
Bed Support
Replace packing with one with higher capacity. Newer packings can give similar performance with higher capacity (at lower % jet flood).
396
20" Manway
Velocity through chimneys was 21.5 ft/sec (6.6 m/s), with only 3 (76 mm) gap between top of chimney and bed support. Chimneys were missing hats. Lower distributor and install hats on chimneys.
633
825
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