Petroleum Refining Design and Applications Handbook, Volume 5

Pressure Relieving Devices and Emergency Relief System Design, Process Safety and Energy Management, Product Blending, Cost Estimation and Economic Evaluation, Sustainability in Petroleum Refining
1. Auflage 2023
ISBN: 978-1-394-20698-8
Verlag: Wiley

Buch, Englisch, 976 Seiten, Format (B × H): 218 mm x 279 mm, Gewicht: 2472 g

PETROLEUM REFINING

With no new refineries having been built in decades, companies continue to build onto or reverse engineer and re-tool existing refineries. With so many changes in the last few years alone, books like this are very much in need. There is truly a renaissance for chemical and process engineering going on right now across multiple industries.

This fifth and final volume in the “Petroleum Refining Design and Applications Handbook” set, this book continues the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student.

Besides the list below, this groundbreaking new volume describes blending of products from the refinery, applying the ternary diagrams and classifications of crude oils, flash point blending, pour point blending, aniline point blending, smoke point and viscosity blending, cetane and diesel indices. The volume further reviews refinery operational cost, cost allocation of actual usage, project and economic evaluation involving cost estimation, cash flow involving return on investment, net present values, discounted cash flow rate of return, net present values, payback period, inflation and sensitivity analysis, and so on. It reviews global effects on the refining economy, carbon tax, carbon foot print, global warming potential, carbon dioxide equivalent, carbon credit, carbon offset, carbon price, and so on. It reviews sustainability in petroleum refining and alternative fuels (biofuels and so on), impact of the overall greenhouse effects, carbon capture and storage in refineries, process intensification in biodiesel, biofuel from green diesel, acid-gas removal and emerging technologies, carbon capture and storage, gas heated reformer unit, pressure swing adsorption process, steam methane reforming for fuel cells, grey, blue and green hydrogen production, new technologies for carbon capture and storage, carbon clean process design, refinery of the future, refining and petrochemical industry characteristics. The text is packed with Excel spreadsheet calculations and Honeywell UniSim Design software in some examples, and it includes an invaluable glossary of petroleum and petrochemical technical terminologies.

Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world’s foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area.

Autoren/Hrsg.

Coker, A. Kayode

Fachgebiete

• Technische Wissenschaften Verfahrenstechnik | Chemieingenieurwesen | Biotechnologie Verfahrenstechnik, Chemieingenieurwesen
• Technische Wissenschaften Energietechnik | Elektrotechnik Technologien für Fossile Energieträger
• Technische Wissenschaften Verfahrenstechnik | Chemieingenieurwesen | Biotechnologie Chemische Verfahrenstechnik

Inhaltsverzeichnis

Preface xxiv

Acknowledgments xxvii

23 Pressure Relieving Devices and Emergency Relief System Design 1

23.0 Introduction 1

23.1 Types of Positive Pressure Relieving Devices (See Manufacturers’ Catalogs for Design Details) 2

23.2 Types of Valves/Relief Devices 6

23.3 Materials of Construction 18

23.4 General Code Requirements [1] 20

23.5 Relief Mechanisms 20

23.6 Pressure Settings and Design Basis 21

23.7 Unfired Pressure Vessels Only, But Not Fired or Unfired Steam Boilers 24

23.8 Relieving Capacity of Combinations of Safety Relief Valves and Rupture Disks or Non-Reclosure Devices (Reference ASME Code, Par. UG-127, U-132) 24

23.9 Establishing Relieving or Set Pressures 27

23.10 Selection and Application 28

23.11 Capacity Requirements Evaluation for Process Operation (Non-Fire) 29

23.12 Piping Design 37

23.13 Selection Features: Safety, Safety-Relief Valves, and Rupture Disks 44

23.14 Calculations of Relieving Areas: Safety and Relief Valves 46

23.15 Standard Pressure Relief Valves Relief Area Discharge Openings 46

23.16 Sizing Safety Relief Type Devices for Required Flow Area at Time of Relief 47

23.17 Effects of Two-Phase Vapor-Liquid Mixture on Relief Valve Capacity 47

23.18 Sizing for Gases or Vapors or Liquids for Conventional Valves with Constant Backpressure Only 47

23.19 Orifice Area Calculations [42] 54

23.20 Sizing Valves for Liquid Relief: Pressure-Relief Valves Requiring Capacity Certification [5D] 60

23.21 Sizing Valves For Liquid Relief: Pressure Relief Valves Not Requiring Capacity Certification [5D] 61

23.22 Reaction Forces 66

23.23 Calculations of Orifice Flow Area using Pressure Relieving Balanced Bellows Valves, with Variable or Constant Backpressure 72

23.24 Sizing Valves for Liquid Expansion (Hydraulic Expansion of Liquid Filled Systems/ Equipment/Piping) 80

23.25 Sizing Valves for Subcritical Flow: Gas or Vapor But Not Steam [5d] 81

23.26 Emergency Pressure Relief: Fires and Explosions Rupture Disks 84

23.27 External Fires 84

23.28 Set Pressures for External Fires 85

23.29 Heat Absorbed 85

23.30 Surface Area Exposed to Fire 86

23.31 Relief Capacity for Fire Exposure 87

23.32 Code Requirements for External Fire Conditions 87

23.33 Design Procedure 88

23.34 Pressure Relief Valve Orifice Areas on Vessels Containing Only Gas, Unwetted Surface 92

23.35 Rupture Disk Sizing Design and Specification 93

23.36 Specifications to Manufacturer 93

23.37 Size Selection 94

23.38 Calculation of Relieving Areas: Rupture Disks for Non-Explosive Service 94

23.39 The Manufacturing Range (MR) 95

23.40 Selection of Burst Pressure for Disk, P b (Table 23.3) 95

23.41 Effects of Temperature on Disk 98

23.42 Rupture Disk Assembly Pressure Drop 101

23.43 Gases and Vapors: Rupture Disks [5a, Par, 4.8] 101

23.44 API for Subsonic Flow: Gas or Vapor (Not Steam) 103

23.45 Liquids: Rupture Disk 104

23.46 Sizing for Combination of Rupture Disk and Pressure Relief Valve in Series Combination 105

23.47 Pressure-Vacuum Relief for Low-Pressure Storage Tanks 110

23.48 Basic Venting For Low-Pressure Storage Vessels 111

23.49 Non-Refrigerated Above Ground Tanks; API-Std. 2000 112

23.50 Boiling Liquid Expanding Vapor Explosions (BLEVEs) 113

23.51 Managing Runaway Reactions 116

23.52 Hazard Evaluation in the Chemical Process Industries 120

23.53 Hazard Assessment Procedures 121

23.54 Thermal Runaway Chemical Reaction Hazards 122

23.55 Two-Phase Flow Relief Sizing for Runaway Reaction 128

23.56 Discharge System 145

23.57 Sizing for Two-Phase Fluids 155

23.58 Flares/Flare Stacks 182

23.59 Compressible Flow for Discharge Piping 197

23.60 Vent Piping 204

24 Process Safety and Energy Management in Petroleum Refinery 249

24.1 Introduction 249

24.2 Process Safety 250

24.3 General Process Safety Hazards in a Refinery 265

24.4 Example of Process Safety Incidents and Hazards 267

24.5 Process Safety Hazards 270

24.6 Hazards Relating to Equipment Failure 278

24.7 Columns and Other Process Pressure Vessels and Piping 279

24.8 Inadequate Design and Construction 290

24.9 Inadequate Material of Construction Specification 290

24.10 Material Failures and Process Safety Prevention Programs 291

24.11 Hazard and Operability Studies (HAZOP) 297

24.12 Hazan 315

24.13 Fault Tree Analysis 317

24.14 Failure Mode and Effect Analysis (FMEA) 318

24.15 The Swiss Cheese Model 319

24.16 Bowtie Analysis 320

24.17 Inherently Safer Plant Design 325

24.18 Energy Management in Petroleum Refinery 330

24.19 Benchmarking in Refinery 345

25 Product Blending 357

25.0 Introduction 357

25.1 Blending Processes 360

25.2 Ternary Diagram of Crude Oils 361

26 Cost Estimation and Economic Evaluation 467

26.1 Introduction 467

26.2 Refinery Operating Cost 468

27 Sustainability in Engineering, Petroleum Refining and Alternative Fuels 571

27.0 Introduction 571

27.1 Impacts on the Overall Greenhouse Effect 576

27.2 Carbon Capture and Storage in Refineries 578

27.3 Sustainability in the Refinery Industries 580

27.4 Sustainability in Engineering Design Principles 582

27.5 Alternative Fuels (Biofuels) 587

27.6 Process Intensification (PI) in Biodiesel 589

27.7 Biofuel from Green Diesel 592

27.8 Fast Pyrolysis 609

27.9 Acid Gas Removal 617

27.10 Alkaline Salt Process (Hot Carbonate) 629

27.11 Ionic Liquids 632

27.12 Advanced Modeling 650

27.13 Carbon Capture and Storage (CCS) 652

27.14 Risk Management 655

27.15 The Institution of Chemical Engineers (IChemE, U.K.) Position on Climate Change 655

27.16 Oil & Gas and Petrochemical Companies with Zero Carbon Emissions Targets by 2050 658

27.17 Offshore Petroleum Regulator for Environment and Decommissioning (OPRED), UK 661

27.18 Gas Heated Reformer (GHR) 668

27.19 Pressure Swing Adsorption (PSA) 672

27.20 Distribution and Storage 675

27.21 Steam Methane Reforming (SMR) for Fuel Cells 678

27.22 New Technologies of Carbon Capture Storage 680

27.23 Carbon Clean Process Design (CC) 681

27.24 Electrochemically Mediated Amine Regeneration (EMAR) 700

27.25 Refinery of the Future 704

27.26 The Crude Oil to Chemical Strategy (COC) 710

27.27 Available Crude to Chemicals Processing Routes 720

27.28 Chemical Looping 721

27.29 Conclusions 722

Glossary 723

References 729

Bibliography 732

Appendix D 733

Glossary of Petroleum and Petrochemical Technical Terminologies 809

About the Author 937

Index 939

Über Autor(innen)

A. 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 (SASREF) 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. (C. Eng., FIChemE), and a senior member of the American Institute of Chemical Engineers (AIChE). 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 10 books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train - the mentor trainer. A Technical Report Assessor and Interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, U.K. (IBC) as 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.