Preface Acknowledgement Part 1: Basics 1. Overview of This Book 1.1 Why Petrochemical Products are Important for the Economy? 1.1.1 Polyethylene 1.1.2 Polypropylene 1.1.
3 Styrene and Polystyrene 1.1.4 Polyester 1.1.5 Polycarbonate and Phenolic Resins 1.1.6 Economic Significance of Polymers 1.1.
7 Petrochemicals and Petroleum Utilization 1.2 Overall Petrochemical Complex Configurations 1.3 Context of Process Design and Operation for Petrochemical Production 1.4 Who is this Book Written for? 2 Market and Technology Overview 2.1 Overview of Aromatic Petrochemicals 2.2 Introduction and Market Information 2.2.1 Benzene 2.
2.2 Benzene Production Technologies 2.2.3 Toluene 2.2.4 Toluene Production Technologies 2.2.5 Ethylbenzene/Styrene 2.
2.6 Ethylbenzene/Styrene Production Technologies 2.2.7 Para-Xylene 2.2.8 Para-Xylene Production Technologies 2.2.9 Meta-Xylene 2.
2.10 Meta-Xylene Production Technologies 2.2.11 Ortho-Xylene 2.2.12 Ortho-Xylene Production Technologies 2.2.13 Cumene/Phenol 2.
2.14 Cumene/Phenol Production Technologies 2.3 Technologies in Aromatics Synthesis 2.4 Alternative Feeds for Aromatics 2.5 Technologies in Aromatic Transformation 2.5.1 Transalkylation 2.5.
2 Selective Toluene Disproportionation 2.5.3 Thermal Hydro-Dealkylation 2.5.4 Xylene Isomerization 2.6 Technologies in Aromatics Separations 2.6.1 Liquid-Liquid Extraction and Extractive Distillation 2.
6.2 Liquid-Liquid Extraction 2.6.3 Extractive Distillation (ED) 2.7 Separations by Molecular Weight 2.8 Separations by Isomer Type - Para-Xylene 2.8.1 Crystallization of Para-Xylene 2.
8.2 Adsorptive Separation of Para-Xylene 2.9 Separations by Isomer Type - Meta-Xylene 2.10 Separations by Isomer Type - Ortho-Xylene and Ethylbenzene 2.11 Other Related Aromatics Technologies 2.11.1 Cyclohexane 2.11.
2 Ethylbenzene/Styrene 2.11.3 Cumene/Phenol/Bisphenol A 2.11.4 Linear Alkyl Benzene Sulfonate for Detergents 2.11.5 Oxidation of Para- and Meta-Xylene 2.11.
6 Melt Phase Polymerization of PTA to PET 2.11.7 Melt Phase Polymerization and Solid State Polymerization of PET Resin 2.11.8 Oxidation of Ortho-Xylene 2.12 Integrated Refining and Petrochemicals 3 Aromatics Process Description 3.1 Overall Aromatics Flowscheme 3.2 Adsorptive Separations for Para-Xylene 3.
3 Technologies for Treating Feeds for Aromatics Production 3.4 Para-Xylene Purification and Recovery by Crystallization 3.5 Transalkylation Processes 3.6 Xylene Isomerization 3.7 Adsorptive Separation of Pure Meta-Xylene 3.8 Para-Selective Catalytic Technologies for Para-Xylene 3.8.1 Para-selective Toluene Disproportionaiton 3.
8.2 Para-selective Toluene Methylation Part 2: Process Design 4 Aromatic Process Unit Design (Dave; done) 4.1 Introduction 4.2 Aromatics Fractionation 4.2.1 Reformate Splitter 4.2.2 Xylene Fractionation 4.
2.3 Heavy Aromatics Fractionation 4.3 Aromatic Extraction 4.3.1 Liquid-Liquid Extraction 4.3.1.1 Operating Variables 4.
3.2 Extractive Distillation 4.3.2.1 Operating Variables 4.4 Transalkylation 4.4.1 Process Flow Description 4.
5 Xylene Isomerization 4.6 Para-Xylene Separation 4.7 Process Design Considerations - Design Margin Philosophy 4.7.1 Equipment Design Margins 4.8 Process Design Considerations - Operational Flexibility 4.9 Process Design Considerations - Fractionation Optimization 4.10 Safety Considerations 4.
10.1 Reducing Exposure to Hazardous Materials 4.10.2 Process Hazard Analysis (PHA) 4.10.3 Hazard and Operability Study (HAZOP) 4.11 References 5 Aromatics Process Revamp Design 5.1 Introduction 5.
2 Stages of Revamp Assessment and Types of Revamp Studies 5.3 Revamp Project Approach 5.3.1 Specified Target Capacity 5.3.2 Target Production with Constraints 5.3.3 Maximize Throughput at Minimum Cost 5.
3.4 Identify Successive bottlenecks 5.4 Revamp Study Methodology and Strategies 5.5 Setting the Design Basis for Revamp Projects 5.5.1 Agreement 5.5.2 Processing Objectives 5.
5.3 Define the Approach of the Study 5.5.4 Feedstock and Make-up Gas 5.5.5 Product Specifications 5.5.6 Getting the Right Equipment Information 5.
5.7 Operating Data or Test Run Data 5.5.8 Constraints 5.5.9 Utilities 5.5.10 Replacement Equipment Options 5.
5.11 Guarantees 5.5.12 Economic Evaluation Criteria 5.6 Process Design for Revamp Projects 5.6.1 Adjusting Operating Conditions 5.6.
2 Design margin 5.7 Revamp Impact on Utilities 5.8 Equipment Evaluation for Revamps 5.8.1 Fired Heaters 5.8.1.1 Data Required 5.
8.1.2 Fired Heater Evaluation 5.8.1.3 Heater Design Limitations 5.8.1.
4 Radiant Flux Limits 5.8.1.5 Tube Wall Temperature (TWT) Limits 5.8.1.6 Metallurgy 5.8.
1.7 Tube Thickness 5.8.1.8 Coil Pressure Drop 5.8.1.9 Burners 5.
8.2 Vessels - Separators, Receivers, and Drums 5.8.2.1 Data required 5.8.2.2 Separator, Receiver, and Drum Evaluation 5.
8.2.3 Process and Other Modifications 5.8.2.4 Test Run Data 5.8.2.
5 Possible Recommendations 5.8.3 Reactors 5.8.3.1 Data Required 5.8.3.
2 Reactor Process Evaluation 5.8.3.3 Process and Other Modifications 5.8.3.4 Test Run Data 5.8.
3.5 Possible Recommendations 5.8.4 Fractionators 5.8.4.1 Data Required 5.8.
4.2 Fractionator Evaluation 5.8.4.3 Retraying and Other Modifications 5.8.4.4 High Capacity Trays 5.
8.4.5 Test Run data 5.8.4.6 Possible Recommendations 5.8.5 Heat Exchangers 5.
8.5.1 Data Required 5.8.5.2 Overall Exchanger Evaluation 5.8.5.
3 Thermal Rating Methods 5.8.5.4 Rating Procedures 5.8.5.5 Pressure Drop Estimation 5.8.
5.6 Use of Operating Data 5.8.5.7 Possible Recommendations 5.8.5.8 Special Exchanger Services 5.
8.5.9 Overpressure Protection 5.8.6 Pumps 5.8.6.1 Data Required 5.
8.6.2 Centrifugal Pump Evaluation 5.8.6.3 Proportioning Pumps 5.8.6.
4 Use of Operating Data 5.8.6.5 Possible Recommendations 5.8.6.6 Tools 5.8.
6.7 Special Pump Services 5.8.7 Compressors 5.8.7.1 Data Required 5.8.
7.2 Centrifugal Compressor Evaluation 5.8.7.3 Reciprocating Compressor Evaluation 5.8.7.4 Driver Power 5.
8.7.5 Materials of Construction 5.8.7.6 Use of Operating data 5.8.7.
7 Potential Remedies 5.8.8 Hydraulics/Piping 5.8.8.1 New Unit Line Sizing Criteria are Generally Not Applicable 5.8.8.
2 Pressure Drop Requires Replacement of Other Equipment 5.8.8.3 Approaching Sonic Velocity 5.8.8.4 Erosion Concerns 5.8.
8.5 Pressure Drop Affects Yield 5.8.8.6 Pressure Drop Affects Fractionator Operation or Utilities 5.9 Economic Evaluation 5.9.1 Costs 5.
9.2 Benefits 5.9.3 Data Requirements 5.9.4 Types of Economic Analyses 5.10 Example Revamp Cases 5.10.
1 Aromatics Complex Revamp with Adsorbent Reload 5.10.2 Aromatics Complex Revamp with Xylene Isomerization Catalyst Change 5.10.3 Transalkylation Unit Revamp 5.11 References Part 3: Process Equipment Assessment 6 Distillation Column Assessment 6.1 Introduction 6.2 Define a Base Case 6.
3 Calculations for Missing and Incomplete Data 6.4 Building a Process Simulation 6.5 Heat and Material Balance Assessment 6.6 Tower Efficiency Assessment 6.7 Operating Profile Assessment 6.8 Tower Rating Assessment 6.9 Guidelines 6.10 Nomenclature 6.
11 References 7 Heat Exchanger Assessment 7.1 Introduction 7.2 Basic Concepts and Calculations 7.3 Understand Performance Criterion - U Value 7.3.1 Required U Value (UR) 7.3.2 Clean U Value (UC) 7.
3.3 Actual U Value (UA) 7.3.4 Overdesign (ODA) 7.3.5 Controlling Resistance 7.4 Understand Fouling 7.4.
1 Root Causes of Fouling 7.4.2 Estimate Fouling Factor (Rf) 7.4.3 Determine Additional Pressure Drop Due to Fouling 7.5 Understand Pressure Drop 7.5.1 Tube Side Pressure Drop 7.
5.2 Shell Side Pressure Drop 7.6 Effects of Velocity on Heat Transfer, Pressure Drop, and Fouling 7.6.1 Heat Exchanger Rating Assessment 7.6.2 Assess the Suitability of an Existing Exchanger for Changing Conditions 7.6.
3 Determine Arrangement of Heat Exchangers in Series or Parallel 7.6.4 Assess Heat Exchanger Fouling 7.7 Improving Heat Exchanger Performance 7.7.1 How to Identify Deteriorating Performance 7.8 Nomenclature 7.9 References 8 Fired Heater Assessment 8.
1 Introduction 8.2 Fired Heater Design for High Reliability 8.2.1 Flux Rate 8.2.2 Burner to Tube Clearance 8.2.3 Burner Selection 8.
2.4 Fuel conditioning System 8.3 Fired Heater Operation for High Reliability 8.4 Efficient Fired Heater Operation 8.5 Fired Heater Revamp 8.6 Nomenclature 8.7 References 9 Compressor Assess.