Petroleum Refining Design and Applications Handbook, Volume 3

Kayode Coker PhD, is Engineering Consultant for AKC Technology, an Honorary Research Fellow at the University of Wolverhampton, U.K., a former Engineering Coordinator at Saudi Aramco Shell Refinery Company and Chairman of the department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a Fellow of the Institution of Chemical Engineers, U.K. and a senior member of the American Institute of Chemical Engineers. He holds a B.Sc. honors degree in Chemical Engineering, a Master of Science degree in Process Analysis and Development and Ph.D. in Chemical Engineering, all from Aston University, Birmingham, U.K. and a Teacher’s Certificate in Education at the University of London, U.K. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of five books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design. Vol 61. He was named as one of the International Biographical Centre’s Leading Engineers of the World for 2008. Also, he is a member of International Who’s Who of ProfessionalsTM and Madison Who’s Who in the U.S.

• Preface xxiiAcknowledgments xxiv18 Mechanical Separations 118.1 Particle Size 118.2 Preliminary Separator Selection 618.3 Gravity Settlers 1618.4 Terminal Velocity 1918.5 Alternate Terminal Velocity Calculation 2418.6 American Petroleum Institute’s Oil Field Separators 2818.7 Liquid/Liquid, Liquid/Solid Gravity Separations, Decanters, and Sedimentation Equipment 2818.8 Horizontal Gravity Settlers or Decanters, Liquid/Liquid 2918.9 Modified Method of Happel and Jordan 3318.10 Decanter 3618.11 Impingement Separators 4218.12 Centrifugal Separators 68References 24619 Distillation 24919.1 Distillation Process Performance 24919.2 Equilibrium Basic Considerations 25219.3 Vapor–Liquid Equilibria 25319.4 Activity Coefficients 26219.5 Excess Gibbs Energy—GE 26319.6 K-Value 26419.7 Ideal Systems 26619.8 Henry’s Law 26819.9 K-Factor Hydrocarbon Equilibrium Charts 26919.10 Non-Ideal Systems 27719.11 Thermodynamic Simulation Software Programs 28019.12 Vapor Pressure 28319.13 Azeotropic Mixtures 29619.14 Bubble Point of Liquid Mixture 31119.15 Equilibrium Flash Computations 31619.16 Degrees of Freedom 32519.17 UniSim (Honeywell) Software 32619.18 Binary System Material Balance: Constant Molal Overflow Tray to Tray 33319.19 Determination of Distillation Operating Pressures 34319.20 Condenser Types From a Distillation Column 34419.21 Effect of Thermal Condition of Feed 34819.22 Effect of Total Reflux, Minimum Number of Plates in a Distillation Column 35219.23 Relative Volatility α Separating Factor in a Vapor–Liquid System 35519.24 Rapid Estimation of Relative Volatility 36619.25 Estimation of Relative Volatilities Under 1.25 (α < 125) by Ryan 36719.26 Estimation of Minimum Reflux Ratio: Infinite Plates 36819.27 Calculation of Number of Theoretical Trays at Actual Reflux 37019.28 Identification of “Pinch Conditions” on an x-y Diagram at High Pressure 37319.29 Distillation Column Design 37619.30 Simulation of a Fractionating Column 37819.31 Determination of Number of Theoretical Plates in Fractionating Columns by the Smoker Equations at Constant Relative Volatility (α = constant) 39619.32 The Jafarey, Douglas, and McAvoy Equation: Design and Control 40119.33 Number of Theoretical Trays at Actual Reflux 41119.34 Estimating Tray Efficiency in a Distillation Column 41319.35 Steam Distillation 42219.36 Distillation with Heat Balance of Component Mixture 43219.37 Multicomponent Distillation 45319.38 Scheibel–Montross Empirical: Adjacent Key Systems: Constant or Variable Volatility 49419.39 Minimum Number of Trays: Total Reflux−Constant Volatility 49719.40 Smith–Brinkley (SB) Method 51219.41 Retrofit Design of Distillation Columns 51419.42 Tray-by-Tray for Multicomponent Mixtures 51719.43 Tray-by-Tray Calculation of a Multicomponent Mixture Using a Digital Computer 53119.44 Thermal Condition of Feed 53219.45 Minimum Reflux-Underwood Method, Determination of αAvg for Multicomponent Mixture 53319.46 Heat Balance-Adjacent Key Systems with Sharp Separations, Constant Molal Overflow 53919.47 Stripping Volatile Organic Chemicals (VOC) from Water with Air 54219.48 Rigorous Plate-to-Plate Calculation (Sorel Method) 54719.49 Multiple Feeds and Side Streams for a Binary Mixture 55119.50 Chou and Yaws Method 55819.51 Optimum Reflux Ratio and Optimum Number of Trays Calculations 56119.52 Tower Sizing for Valve Trays 57419.53 Troubleshooting, Predictive Maintenance, and Controls for Distillation Columns 58919.54 Distillation Sequencing with Columns Having More than Two Products 62219.55 Heat Integration of Distillation Columns 63019.56 Capital Cost Considerations for Distillation Columns 63419.57 The Pinch Design Approach to Inventing a Network 64419.58 Appropriate Placement and Integration of Distillation Columns 64419.59 Heat Integration of Distillation Columns: Summary 64519.60 Common Installation Errors in Distillation Columns 645References 693Bibliography 69920 Packed Towers and Liquid–Liquid Extraction 70320.1 Shell 70720.2 Random Packing 70820.3 Packing Supports 70920.4 Liquid Distribution 73420.5 Packing Installation 73920.6 Contacting Efficiency, Expressed as Kga, HTU, HETP 75520.7 Packing Size 75620.8 Pressure Drop 75720.9 Materials of Construction 75920.10 Particle versus Compact Preformed Structured Packings 75920.11 Minimum Liquid Wetting Rates 76020.12 Loading Point Loading Region 76120.13 Flooding Point 77220.14 Foaming Liquid Systems 77320.15 Surface Tension Effects 77320.16 Packing Factors 77320.17 Recommended Design Capacity and Pressure Drop 77620.18 Pressure Drop Design Criteria and Guide: Random Packings Only 77820.19 Effects of Physical Properties 78120.20 Performance Comparisons 78420.21 Capacity Basis for Design 78420.22 Proprietary Random Packing Design Guides 79620.23 Liquid Hold-Up 82220.24 Packing Wetted Area 82420.25 Effective Interfacial Area 82620.26 Entrainment from Packing Surface 82720.27 Structured Packing 83020.28 Structured Packing: Technical Performance Features 84920.29 New Generalized Pressure Drop Correlation Charts 85520.30 Mass and Heat Transfer in Packed Tower 85520.31 Number of Transfer Units, NOG, NOL 85620.32 Gas and Liquid-Phase Coefficients, kG and kL 86820.33 Height of a Transfer Unit, HOG, HOL, HTU 86920.34 Distillation in Packed Towers 87420.35 Liquid–Liquid Extraction 89320.36 Process Parameters 90820.37 Solvents Selection for the Extraction Unit 91120.38 Phenol Extraction Process of Lubes 91320.39 Furfural Extraction Process 91420.40 Dispersed-Phase Droplet Size 91620.41 Theory 92020.42 Nernst’s Distribution Law 92120.43 Tie Lines 92120.44 Phase Diagrams 92920.45 Countercurrent Extractors 93120.46 Extraction Equipment 935References 956Glossary 961Appendix D 1087Appendix F 1163About the Author 1179Index 1181