Hydroprocessing for Clean Energy

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.

• Preface xiiiPart 1 Fundamentals 11 Overview of This Book 31.1 Energy Sustainability 31.2 ULSD – Important Part of the Energy Mix 41.3 Technical Challenges for Making ULSD 71.4 What is the Book Written for 8References 82 Refinery Feeds Products and Processes 92.1 Introduction 92.2 ASTM Standard for Crude Characterization 102.3 Important Terminologies in Crude Characterization 122.4 Refining Processes 132.5 Products and Properties 152.6 Biofuel 203 Diesel Hydrotreating Process 233.1 Why Diesel Hydrotreating? 233.2 Basic Process Flowsheeting 253.3 Feeds 283.4 Products 303.5 Reaction Mechanisms 363.6 Hydrotreating Catalysts 403.7 Key Process Conditions 443.8 Different Types of Process Designs 47References 484 Description of Hydrocracking Process 514.1 Why Hydrocracking 514.2 Basic Processing Blocks 534.3 Feeds 584.4 Products 594.5 Reaction Mechanism and Catalysts 614.6 Catalysts 674.7 Key Process Conditions 704.8 Typical Process Designs 75References 78Part 2 Hydroprocessing Design 795 Process Design Considerations 815.1 Introduction 815.2 Reactor Design 815.3 Recycle Gas Purity 985.4 Wash Water 1025.5 Separator Design 1075.6 Makeup Gas Compression 115References 1216 Distillate Hydrotreating Unit Design 1236.1 Introduction 1236.2 Number of Separators 1236.3 Stripper Design 1276.4 Debutanizer Design 1356.5 Integrated Design 136References 1477 Hydrocracking Unit Design 1497.1 Introduction 1497.2 Single-stage Hydrocracking Reactor Section 1507.3 Two-stage Hydrocracking Reactor Section 1557.4 Use of a Hot Separator in Hydrocracking Unit Design 1587.5 Use of Flash Drums 1607.6 Hydrocracking Unit Fractionation Section Design 1617.7 Fractionator First Flow Scheme 1617.8 Debutanizer First Flow Scheme 1637.9 Stripper First Fractionation Flow Scheme 1667.10 Dual Zone Stripper Fractionation Flow Scheme 1687.11 Dual Zone Stripper – Dual Fractionator Flow Scheme 1707.12 Hot Separator Operating Temperature 1717.13 Hydrogen Recovery 1747.14 LPG Recovery 1757.15 HPNA Rejection 1777.16 Hydrocracking Unit Integrated Design 181References 187Part 3 Energy and Process Integration 1898 Heat Integration for Better Energy Efficiency 1918.1 Introduction 1918.2 Energy Targeting 1918.3 Grassroots Heat Exchanger Network (Hen) Design 2028.4 Network Pinch for Energy Retrofit 206Nomenclature 213References 2139 Process Integration for Low-Cost Design 2159.1 Introduction 2159.2 Definition of Process Integration 2169.3 Grand Composite Curves (GCC) 2189.4 Appropriate Placement Principle for Process Changes 2199.5 Dividing Wall Distillation Column 2259.6 Systematic Approach for Process Integration 2289.7 Applications of the Process Integration Methodology 2309.8 Summary of Potential Energy Efficiency Improvements 246References 24710 Distillation Column Operating Window 24910.1 Introduction 24910.2 What is Distillation? 24910.3 Why Distillation is the Most Widely Used? 25110.4 Distillation Efficiency 25310.5 Definition of Feasible Operating Window 25510.6 Understanding Operating Window 25610.7 Typical Capacity Limits 27510.8 Effects of Design Parameters 27510.9 Design Checklist 27810.10 Example Calculations for Developing Operating Window 28110.11 Concluding Remarks 296Nomenclature 297References 299Part 4 Process Equipment Assessment 30111 Fired Heater Assessment 30311.1 Introduction 30311.2 Fired Heater Design for High Reliability 30411.3 Fired Heater Operation for High Reliability 31011.4 Efficient Fired Heater Operation 31511.5 Fired Heater Revamp 321Nomenclature 322References 32212 Pump Assessment 32312.1 Introduction 32312.2 Understanding Pump Head 32412.3 Define Pump Head – Bernoulli Equation 32512.4 Calculate Pump Head 32912.5 Total Head Calculation Examples 33012.6 Pump System Characteristics – System Curve 33212.7 Pump Characteristics – Pump Curve 33312.8 Best Efficiency Point (BEP) 33812.9 Pump Curves for Different Pump Arrangement 33812.10 Npsh 34012.11 Spillback 34512.12 Reliability Operating Envelope (ROE) 34612.13 Pump Control 34712.14 Pump Selection and Sizing 347Nomenclature 351References 35113 Compressor Assessment 35313.1 Introduction 35313.2 Types of Compressors 35413.3 Impeller Configurations 35713.4 Type of Blades 35813.5 How a Compressor Works 35813.6 Fundamentals of Centrifugal Compressors 36013.7 Performance Curves 36213.8 Partial Load Control 36413.9 Inlet Throttle Valve 36613.10 Process Context for a Centrifugal Compressor 36713.11 Compressor Selection 368Nomenclature 369References 36914 Heat Exchanger Assessment 37114.1 Introduction 37114.2 Basic Concepts and Calculations 37114.3 Understand Performance Criterion – U Values 37414.4 Understand Fouling 38014.5 Understand Pressure Drop 38214.6 Effects of Velocity on Heat Transfer Pressure Drop and Fouling 38414.7 Heat Exchanger Rating Assessment 38514.8 Improving Heat Exchanger Performance 396Nomenclature 399References 40015 Distillation Column Assessment 40115.1 Introduction 40115.2 Define a Base Case 40115.3 Calculations for Missing and Incomplete Data 40315.4 Building Process Simulation 40615.5 Heat and Material Balance Assessment 40815.6 Tower Efficiency Assessment 41115.7 Operating Profile Assessment 41415.8 Tower Rating Assessment 41715.9 Guidelines 419Nomenclature 420References 420Part 5 Process System Evaluation 42316 Energy Benchmarking 42516.1 Introduction 42516.2 Definition of Energy Intensity for a Process 42616.3 The Concept of Fuel Equivalent for Steam and Power (FE) 42716.4 Data Extraction 42916.5 Convert All Energy Usage to Fuel Equivalent 43216.6 Energy Balance 43216.7 Fuel Equivalent for Steam and Power 43516.8 Energy Performance Index (EPI) Method for Energy Benchmarking 44116.9 Concluding Remarks 44416.10 Nomenclature 445References 44617 Key Indicators and Targets 44717.1 Introduction 44717.2 Key Indicators Represent Operation Opportunities 44817.3 Define Key Indicators 45117.4 Set Up Targets for Key Indicators 45617.5 Economic Evaluation for Key Indicators 46017.6 Application 1: Implementing Key Indicators into an “Energy Dashboard” 46317.7 Application 2: Implementing Key Indicators to Controllers 46517.8 It is Worth the Effort 466Nomenclature 467References 46718 Distillation System Optimization 46918.1 Introduction 46918.2 Tower Optimization Basics 47018.3 Energy Optimization for Distillation System 47518.4 Overall Process Optimization 48118.5 Concluding Remarks 489References 490Part 6 Operational Guidelines and Troubleshooting 49119 Common Operating Issues 49319.1 Introduction 49319.2 Catalyst Activation Problems 49419.3 Feedstock Variations and Contaminants 49519.4 Operation Upsets 49619.5 Treating/Cracking Catalyst Deactivation Imbalance 49719.6 Flow Maldistribution 50019.7 Temperature Excursion 50119.8 Reactor Pressure Drop 50419.9 Corrosion 50619.10 Hpna 50919.11 Conclusion 51120 Troubleshooting Case Analysis 51320.1 Introduction 51320.2 Case Study I – Product Selectivity Changes 51420.3 Case Study II – Feedstock Changes 51620.4 Case Study III – Catalyst Deactivation Balance 52320.5 Case Study IV – Catalyst Migration 52620.6 Conclusion 536Index 537