CO2 Production

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PRODUCTION OF CARBON DIOXIDE FROM FUEL OIL

PREFACE

Project report espouses the humble efforts of team

which is more inspired than equipped. It covers the design

aspects of Production of Carbon Dioxide from Fuel il!.

Carbon Dioxide is one of the best "nown gases and has

found a variet# of its applications. $et at present it stands among

notorious chemicals due to its harmful effects on environment.

%ajor uses of carbon dioxide are in urea manufacture& enhanced

oil recover#& as a heat transfer media& as an inert environment&

refrigerant and beverages. 'his project report deals with design

calculations of () ton per da# of carbon dioxide production rate

along with their relevant aspects such as instrumentation and

control& economic viabilit# and environmental aspects.

In fact the art and the practice of design cannot be

learned from the boo"s. 'he intuition and judgment necessar# to

appl# theor# to practice will onl# come from practical experience.

*e are obliged to our teachers and especiall# our advisor whose

intellectual interaction helped us broaden our vision about

engineering and life as well.

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INTRODUCTION

Carbon dioxide is a colorless, odorless, incombs!ible "as, #ormed drin"

res$ira!ion, combs!ion, and or"anic decom$osi!ion and sed in #ood

re#ri"era!ion, carbona!ed be%era"es, iner! a!mos$&eres, #ire ex!in"is&ers, and

aerosols' Also called carbonic acid gas'

carbon dioxide, c&emical com$ond, CO(, a colorless, odorless,

!as!eless "as !&a! is abo! one and one)&al# !imes as dense as air nder ordinar*

condi!ions o# !em$era!re and $ressre' I! does no! brn, and nder normal

condi!ions i! is s!able, iner! and non!oxic' I! +ill &o+e%er s$$or! combs!ion o#ma"nesim !o "i%e ma"nesim oxide and carbon' Al!&o"& i! is no! a $oison, i!

can case dea!& b* s##oca!ion i# in&aled in lar"e amon!s' I! is a #airl* s!able

com$ond b! decom$oses a! %er* &i"& !em$era!res in!o carbon and ox*"en' I!

is #airl* solble in +a!er, one %olme o# i! dissol%in" in an eal %olme o# +a!er

a! room !em$era!re and $ressre- !&e resl!an! +ea.l* acidic aeos sol!ion

is called carbonic acid' T&e "as is easil* lie#ied b* com$ression and coolin"' I#

liid carbon dioxide is ic.l* decom$ressed i! ra$idl* ex$ands and some o# i!

e%a$ora!es, remo%in" eno"& &ea! so !&a! !&e res! o# i! cools in!o solid carbon

dioxide /sno+'0 A s!andard !es! #or !&e $resence o# carbon dioxide is i!s reac!ion

+i!& lime+a!er 1a sa!ra!ed +a!er sol!ion o# calcim &*droxide2 !o #orm a mil.*)

+&i!e $reci$i!a!e o# calcim &*droxide'

History

T&e exis!ence o# carbon dioxide &as been .no+n since $rimi!i%e !imes PLIN3+ro!e o# le!&al %a$ors #rom ca%erns in !&e #irs! cen!r* A'D' I! +as #irs!

reco"ni4ed as a dis!inc! "as, &o+e%er, b* 5AN 6ELMONT 17899)7:;;2, +&o

$re$ared !&e "as b* %arios ro!es and demons!ra!ed !&a! i! +as !&e same

"as as !&a! +&ic& issed #rom ca%erns and mines' 6e ob!ained i! b* #er)

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men!a!ion, b* !&e ac!ion o# acids on carbona!es, and b* !&e brnin" o#

c&arcoal, and &e s!died man* o# i!s $ro$er!ies'


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com$ressible mass' 6e obser%ed !&a! i! disa$$eared b* slo+ e%a$ora!ion

+i!&o! #irs! mel!in" !o #orm a liid 1i'e', i! sblimed2'

In 7@;8, FARADA3made lar"er an!i!ies o# liid and

solid carbon dioxide b* means o# a &*dralic $m$' 6e also sed solid carbondioxide, in a mix!re +i!& e!&er, as a re#ri"eran! #or se in #r!&er "as lie#ac!ion

s!dies'


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Properties

Name Carbon dioxideC&emical Formla CO(

A$$earance Colorless "as

PhysicalFormla +ei"&! ;;' amMel!in" $oin! Lii#ies nder &i"& $ressre

a! (7: = 189 C2Boilin" $oin! sblimes a! 78 = 19@ C2Densi!* 7': M"m?1solid2

7'@ ."m?1"as a! (@ =2


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Carbon dioxide resl!s #rom !&e combs!ion o# or"anic ma!!er i# s##icien!

amon!s o# ox*"en are $resen!' I! is also $rodced b* %arios microor"anisms

#rom #ermen!a!ion and celllar res$ira!ion' Plan!s !ili4e carbon dioxide drin"

$&o!os*n!&esis, sin" bo!& !&e carbon and !&e ox*"en !o cons!rc!

carbo&*dra!es' In addi!ion, $lan!s also release ox*"en !o !&e a!mos$&ere +&ic&

is sbseen!l* sed #or res$ira!ion b* &e!ero!ro$&ic or"anisms, #ormin" a c*cle'

I! is $resen! in !&e Ear!&Ks a!mos$&ere a! a lo+ concen!ra!ion and ac!s as a

"reen&ose "as' I! is a maor com$onen! o# !&e carbon c*cle'

CHE!IC"# "ND PH$SIC"# PROPERTIES

Carbon dioxide is a colorless "as +&ic&, +&en in&aled a! &i"&concen!ra!ions 1a dan"eros ac!i%i!* de !o !&e associa!ed as$&*xia!ion ris.2,

$rodces a sor !as!e in !&e mo!& and s!in"in" sensa!ion in !&e nose and !&roa!'

T&ese e##ec!s resl! #rom !&e "as dissol%in" in !&e mcos membranes and

sali%a, #ormin" a +ea. sol!ion o# carbonic acid'

I!s densi!* a! (8 C is 7'@ ." m?, abo! 7'8 !imes !&a! o# air' T&e carbon

dioxide molecle 1OCO2 con!ains !+o doble bonds and &as a linear s&a$e' I!

&as no elec!rical di$ole' As i! is #ll* oxidi4ed, i! is no! %er* reac!i%e and in

$ar!iclar no! #lammable'

A! !em$era!res belo+ 9@ C, carbon dioxide condenses in!o a +&i!e

solid called dr* ice' Liid carbon dioxide #orms onl* a! $ressres abo%e 8'7 a!m-

a! a!mos$&eric $ressre, i! $asses direc!l* be!+een !&e "aseos and solid

$&ases in a $rocess called sblima!ion'

a!er +ill absorb i!s o+n %olme o# carbon dioxide, and more !&an !&is

nder $ressre' Abo! 7 o# !&e dissol%ed carbon dioxide !rns in!o carbonic

acid' T&e carbonic acid in !rn dissocia!es $ar!l* !o #orm bicarbona!e and

carbona!e ions'

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Test For This Gas'hen a lighted splint is inserted into a test tube containing this gas, it

is immediately extinguished, as carbon dioxide does not support combustion. To further

confirm that the gas is carbon dioxide, the gas may be bubbled into calcium hydroxide

solution. The calcium hydroxide turns milky due to the formation of calcium carbonate.

Uses

Liid and solid carbon dioxide are im$or!an! re#ri"eran!s, es$eciall* in !&e

#ood inds!r*, +&ere !&e* are em$lo*ed drin" !&e !rans$or!a!ion and s!ora"e o#

ice cream and o!&er #ro4en #oods'

Carbon dioxide is sed !o $rodce carbona!ed so#! drin.s and soda +a!er'

Tradi!ionall*, !&e carbona!ion in beer and s$ar.lin" +ine comes abo! !&ro"&

na!ral #ermen!a!ion, b! some man#ac!rers carbona!e !&ese be%era"es

ar!i#iciall*'

T&e lea%enin" a"en!s sed in ba.in" $rodce carbon dioxide !o case

do"& !o rise' Ba.erKs *eas! $rodces carbon dioxide b* #ermen!a!ion +i!&in !&e

do"&, +&ile c&emical lea%eners sc& as ba.in" $o+der and ba.in" sodarelease carbon dioxide +&en &ea!ed or ex$osed !o acids'

Carbon dioxide is o#!en sed as an inex$ensi%e, non)#lammable

$ressri4ed "as' Li#e ac.e!s o#!en con!ain canis!ers o# $ressred carbon dioxide

#or ic. in#la!ion'

in !&e +eldin" arc, i! reac!s !o oxidi4e mos! me!als' Use in !&e a!omo!i%e

inds!r* is common des$i!e si"ni#ican! e%idence !&a! +elds made in carbon

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dioxide are bri!!ler !&an !&ose made in more iner! a!mos$&eres, and !&a! sc&

+eld oin!s de!eriora!e o%er !ime de !o !&e #orma!ion o# carbonic acid' I! is sed

as a +eldin" "as $rimaril* becase i! is mc& less ex$ensi%e !&an more iner!

"ases sc& as ar"on or &elim'

Liid carbon dioxide is a "ood sol%en! #or man* or"anic com$onds' I!

&as be"n !o a!!rac! a!!en!ion in !&e $&armace!ical and o!&er c&emical

$rocessin" inds!ries as a less !oxic al!erna!i%e !o more !radi!ional sol%en!s sc&

as or"anoc&lorides'

Plan!s reire carbon dioxide !o condc! $&o!os*n!&esis, and

"reen&oses ma* enric& !&eir a!mos$&eres +i!& addi!ional CO ( !o boos! $lan!

"ro+!&' I! &as been $ro$osed !&a! carbon dioxide #rom $o+er "enera!ion be

bbbled in!o $onds !o "ro+ al"ae !&a! cold !&en be con%er!ed in!o bio)diesel

#el' 6i"& le%el o# carbon dioxide in !&e a!mos$&ere e##ec!i%el* ex!ermina!e man*

$es!s' reen&oses +ill raise !&e le%el o# CO(!o 7, $$m 172 #or se%eral

&ors !o elimina!e $es!s sc& as +&i!e#l*, s$ider mi!es, and o!&ers'

In !&e !&ea!er, dr* ice is sed !o $rodce #o" as a s$ecial e##ec! +&en dr*

ice added !o +a!er, !&e e%a$ora!in" mix!re o# CO (and cold &mid air condensesas a #o"'

Dr* ice is also sed in cleanin" s&oo!in" !in* dr* ice $elle!s a! a sr#ace

cools !&e dir! and cases i! !o $o$ o##'

In medicine, $ !o 8 o# carbon dioxide is added !o $re ox*"en sed in

medicine, #or s!imla!ion o# brea!&in" a#!er a$nea and !o s!abili4e !&e O(CO(

balance in blood'

A common !*$e o# inds!rial "as laser, !&e carbon dioxide laser, ses

carbon dioxide as a medim'

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Carbon dioxide is commonl* inec!ed in!o or adacen! !o $rodcin" oil

+ells' I! +ill ac! as bo!& a $ressri4in" a"en! and +&en dissol%ed in!o !&e

nder"rond crde oil +ill si"ni#ican!l* redce i!s %iscosi!*, enablin" !&e oil !o #lo+

more ra$idl* !&ro"& !&e ear!& !o !&e remo%al +ell' In ma!re oil #ields ex!ensi%e

$i$e ne!+or.s are sed !o carr* !&e carbon dioxide !o !&e inec!ion $oin!s'

%IO#O&$

Carbon dioxide is a +as!e $rodc! in or"anisms !&a! ob!ain ener"* #rom

brea.in" do+n s"ars or #a!s +i!& ox*"en as $ar! o# !&eir me!abolism, in a

$rocess .no+n as celllar res$ira!ion' T&is incldes all $lan!s, animals, man*

#n"i and some bac!eria' In &i"&er animals, !&e carbon dioxide !ra%els in !&eblood 1+&ere mos! o# i! is &eld in sol!ion2 #rom !&e bod*Ks !isses !o !&e ln"s

+&ere i! is ex&aled'

Carbon dioxide con!en! in #res& air is less !&an 7, in ex&aled air ca'

;'8' &en in&aled in &i"& concen!ra!ions 1abo! 8 b* %olme2, i! is !oxic !o

&mans and o!&er animals' 6emo"lobin, !&e main molecle in red blood cells,

can bind bo!& !o ox*"en and !o carbon dioxide' I# !&e CO (concen!ra!ion is !oo

&i"&, !&en all &emo"lobin is sa!ra!ed +i!& carbon dioxide and no ox*"en

!rans$or! !a.es $lace 1e%en i# $len!* o# ox*"en is in !&e air2' As a resl!, $eo$le in

a $oorl* %en!ila!ed room +ill ex$erience di##icl!* brea!&in" de !o accmla!ed

carbon dioxide, e%en be#ore lac. o# ox*"en becomes a $roblem' Carbon dioxide,

ei!&er as a "as or as dr* ice, s&old be &andled onl* in +ell %en!ila!ed areas'

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Des$i!e i!s small concen!ra!ion, CO( is a %er* im$or!an! com$onen! o#

Ear!&Ks a!mos$&ere, becase i! absorbs in#rared radia!ion and en&ances !&e

"reen&ose e##ec!'

T&e ini!ial carbon dioxide in !&e a!mos$&ere o# !&e *on" Ear!& +as$rodced b* %olcanic ac!i%i!*- !&is +as essen!ial #or a +arm and s!able clima!e

condci%e !o li#e' 5olcanic ac!i%i!* no+ releases abo! 7? !o (? !era"rams 17;8

million !o (88 million s&or! !ons2 o# carbon dioxide eac& *ear' 5olcanic releases

are abo! 7 o# !&e amon! +&ic& is released b* &man ac!i%i!ies'

lobal carbon dioxideemissions 7987Q('


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'ariation in the past

CO(concen!ra!ions o%er !&e las! ;, *ears

T&e mos! direc! me!&od #or measrin" a!mos$&eric carbon dioxide

concen!ra!ions #or $eriods be#ore direc! sam$lin" is !o measre bbbles o# air

1#lid or "as inclsions2 !ra$$ed in !&e An!arc!ic or reenland ice ca$s' T&e mos!

+idel* acce$!ed o# sc& s!dies come #rom a %arie!* o# An!arc!ic cores and

indica!e !&a! a!mos$&eric CO( le%els +ere abo! (:Q(@LL immedia!el*

be#ore inds!rial emissions be"an and did no! %ar* mc& #rom !&is le%el drin"

!&e $recedin" 7, *ears'

T&e lon"es! ice core record comes #rom 5os!o., An!arc!ica, +&ere ice &as

been sam$led !o a de$!& o# ?,: me!ers, corres$ondin" !o an a"e o# ;(,

*ears be#ore !&e $resen!' Drin" !&is !ime, !&e a!mos$&eric carbon dioxide

concen!ra!ion &as %aried be!+een 7@Q(7 LL drin" ice a"es, increasin" !o

(@Q? LL drin" +armer in!er"lacial'


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&i"&er and more %ariable CO(%ales !&an similar measremen!s in An!arc!ica'

6o+e%er, !&e "ro$s res$onsible #or sc& measremen!s 1e'"'


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O!&er $rocesses ser%e !o increase si"ni#ican!l* !&e le%el o# carbon dioxide

in !&e a!mos$&ere, in $ar!iclar !&e combs!ion o# #ossil #els' "reen&ose e##ec!> 1!&e

"lass in a "reen&ose $er#orms !&e same #nc!ion as !&e carbon dioxide2'

T&e l!ima!e e##ec!s o# !&is !em$era!re rise mi"&! be radical c&an"es in

clima!e and rain#all $a!!erns and a ra$id rise in !&e sea le%el cased b* !&e

mel!in" o# $olar ice' O!&er scien!is!s ar"e !&a! !&ere ma* be o!&er

con!rib!in" #ac!ors in !&e re"la!ion o# !&e ear!&Ks !em$era!re and !&a! !&e

carbon dioxide es!ion s&old no! be addressed in isola!ion'

PROCESS SE#ECTION

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Comparison of a(ailable processes

Carbon Dioxide from "mmonia and Hydro)en Plants *Process &as CO+

T&e $rocess #or !&e $rodc!ion o# ammonia is o!lined in

Fi"re ;' Desl#ri4a!ion o# !&e &*drocarbon #eeds!oc. 1e'"', na!ral "as,

na$&!&a2 is carried o! be#ore ca!al*!ic s!eam re#ormin" o# !&e &*drocarbon

!o "i%e a "aseos mix!re o# &*dro"en, carbon dioxide, and carbon monox)

ide' Air is added and #r!&er s!eam re#ormin" is e##ec!ed in a "aseos mix!re

!&a! !&en also con!ains ni!ro"en. Becase onl* &*dro"en and ni!ro"en arereired !o ma.e ammonia, !&e carbon oxides are remo%ed #rom !&e "as

s!ream' Mos! o# !&e carbon monoxide is ca!al*!icall* con%er!ed !o carbon

dioxide, and !&e la!!er is remo%ed b* dissol!ion nder $ressre' In !&e

man#ac!re o# &*dro"en, !&e $rocess is %er* similar, +i!& !&e ob%ios

omission o# !&e addi!ion o# !&e air' T&s, in bo!& cases, carbon dioxide ms!

be remo%ed be#ore !&e $rocess)"as s!ream can be sed'


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Potassi,m Carbonate Process

T&e $o!assim carbona!e $rocess is based on a re%ersible reac!ion'

=(CO?Y6(O CO(Y (=6CO?

T&e ra!e o# carbon dioxide absor$!ion increases +i!& decreasin"

!em$era!re, increasin" $ar!ial $ressre o# !&e "as, and increasin"

concen!ra!ion o# $o!assim carbona!e sol!ion' Fi"re 8 s&o+s !&e sal

arran"emen! o# absorber and re"enera!or' T&e absor$!ion s&old !a.e $lace

a! a lo+er !em$era!re !&an !&a! o# re"enera!ion !o maximi4e !&e amon! o#

"as remo%ed and reco%ered' T&is is ac&ie%ed b* a !+o)s!a"e absor$!ion andre"enera!ion s*s!em' T&e sol!ion con!ainin" carbon dioxide is $m$ed #rom

!&e base o# !&e absorber !o !&e !o$ o# !&e re"enera!ion colmn, s$$lied +i!&

a reboiler a! i!s base' T&e sol!ion is re!rned !o !&e absorber #rom !+o

$oin!s on !&e re"enera!or' Par! o# !&e sol!ion is +i!&dra+n #rom an

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in!ermedia!e $oin! and is onl* $ar!iall* re"enera!ed- !&is is $m$ed !o an

in!ermedia!e $oin! on !&e absorber' T&e remainder is +i!&dra+n #rom !&e

base o# !&e re"enera!or' I! is more com$le!el* re"enera!ed, and is $m$ed,

a#!er i! is cooled, !o !&e !o$ o# !&e absorber' T&e carbon dioxide and +a!er%a$or mix!re released in !&e re"enera!or is cooled' T&e +a!er condenses

o! and !&e carbon dioxide is $assed !o !&e lie#ac!ion $lan!'

Mos! commercial $o!assim carbona!e s*s!ems also em$lo* ca!al*s! !o

accelera!e !&e ra!es o# absor$!ion and desor$!ion o# carbon dioxide'

1Corrosion in&ibi!ors2are also added !o !&e sol!ion'

ETH"NO#"!INE PROCESS

T&e e!&anolamine $rocess, de%elo$ed b* !&e irdler Cor$ora!ion ses,

monoe!&anolamine ins!ead o# $o!assim carbona!e' Monoe!&anolaminereac!s

+i!& carbon dioxide and +a!er !o #orm monoe!&anolamine carbona!e'

Carbon Dioxide from -l,e &ases

Carbon dioxide is a com$onen! o# all #le "ases $rodced b* !&e Com$le!e

combs!ion o# carbonaceos #els' T*$ical concen!ra!ions o# carbon dioxide in

sc& "ases are 7) 7@ %ol' T&e #le "ases, a#!er bein" cooled and cleaned b*

$assin" !&ro"& a +a!er scrbber, are $assed !&ro"& an al.aline carbona!e

sol!ion or an amine sol!ion +&ic& absorbs carbon dioxide'

T&e "as #rom !&e #le o# !&e #rnace is !&en #ed !o an absor$!ion re"enera!ion

s*s!em' T&e CO(is remo%ed b* sin" a concen!ra!ed aeos sol!ion o# an

amine, +&ic& also con!ains corrosion in&ibi!ors, and is libera!ed, b* sin"

s!eam s$$lied #rom !&e enric&men! boiler'

A #r!&er de%elo$men! in !&e remo%al o# carbon dioxide #rom #le "ases,

annonced b* Do+, in%ol%es a !+o)s!a"e $rocess' Cas!ic soda or soda as& is

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#irs! sed !o remo%e sl#r dioxide, be#ore !&e "as s!ream is $assed !&ro"& an

amine sol!ion +&ic& remo%es !&e carbon dioxide' An ns$eci#ied sol%en! is

sed, +&ic&, i! is claimed, enables !&e a!!ainmen! o# !+o !o !&ree !imes !&e

carbon dioxide loadin" ac&ie%able +i!& con%en!ional s*s!ems'

Carbon Dioxide from -ermentation

Lar"e an!i!ies o# carbon dioxide are "enera!ed b*

#ermen!a!ion $rocesses, and $ !o @ o# !&is "as ma* be reco%erable'

Be#ore bein" si!able #or #r!&er se, &o+e%er, !&e carbon dioxide ms! be

#reed o# !&e im$ri!ies in !&is me!&od o# man#ac!re, i'e', &*dro"en sl#ide,

sl#r dioxide, and %arios or"anic com$onds >sc& as alde&*des, acids, and&i"&er alco&ols and diols' T+o "eneral me!&ods are a%ailable !o $ri#*

#ermen!a!ion carbon dioxide' Bo!& se +a!er scrbbers !o remo%e !&e bl. o#

!&e en!rained ma!erial' T&e im$ri!ies are !&en !a.en o! b* $assin" !&ro"&

ei!&er an ac!i%a!ed c&arcoal bed or sol!ions o# $o!assim $erman"ana!e and

$o!assim dic&roma!e. T&e #irs! me!&od relies on adsor$!ion, +&ereas !&e

second in%ol%es c&emical reac!ions' In !&e second case !&e "as ms! be

!rea!ed #r!&er do+ns!ream !o remo%e oxida!ion $rodc!s #ormed in !&e

earlier s!a"es as +ell as an* !races o# !&e rea"en!s sed in !&e $ri#ica!ion'

Carbon Dioxide from Carbonates

T&e $rodc!ion o# carbon dioxide b* !&e calcina!ions o# calcim

carbona!e and ma"nesim carbona!e is no lon"er economicall* im$or!an!'

Na!ral sorces o# "ases con!ainin" %er* &i"& concen!ra!ions o#

carbon dioxide are $resen! in %arios $ar!s o# !&e +orld' O#!en !&e "as is so

$re !&a! i! reires onl* dr*in" be#ore lie#ac!ion' T&e main im$ri!ies

$resen! in !&is sorce o# carbon dioxide are me!&ane and &*dro"en sl#ide'

T&ese sorces are becomin" more im$or!an! in areas +&ere en&anced oil

reco%er* is bein" $rac!iced'

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P,rification of Carbon Dioxide before #i.,efaction

Unli.e carbon dioxide deri%ed #rom #ermen!a!ion $rocesses, +&ic&

reires considerable $ri#ica!ion as described, mos! o# !&e "as #rom o!&er

sorces is %er* $re' I! con!ains onl* !race amon!s o# #orei"n ma!erials,sall* sl#r com$onds' Becase !&e l!ima!e se o# !&e "as o#!en in%ol%es

#oods!##s, !&ese !race im$ri!ies ms! be remo%ed since !&e* o#!en im$ar! dis)

!inc!i%e !as!es and odors' T&is is ac&ie%ed b* !&e se o# ac!i%a!ed carbon'

Dr*in" o# !&e "as is also %er* im$or!an!, becase ins##icien!l* dried ma!erial

!ends, on lie#ac!ion, !o c&o.e !&e lines in !&e $lan!' Ac!i%a!ed almina, silica

"el, or moleclar sie%e beds are sed #or dr*in"' Mos! $lan!s are ml!i)

s!reamed and are ei$$ed +i!& beds !&a! can be reac!i%a!ed b* means o#&o! carbon dioxide, ni!ro"en, air, or s!eam'

T&e le%el o# #orei"n "ases $resen! in !&e carbon dioxide s!ream ms! be

minimi4ed !o redce !&e ener"* reired !o lie#* and concen!ra!e !&e

circla!in" "as' T&e solbili!* o# "ases in liid carbon dioxide decreases

+i!& decreasin" !em$era!re' I# an* are $resen!, !&e* se$ara!e o! easil*

drin" !&e lie#ac!ion s!a"e

#i.,efaction of Carbon Dioxide

T&e cri!ical $arame!ers o# carbon dioxide, !cri! ?7 C,

Pcri! 9'; MPa, s&o+ !&a! !&e "as ma* be lie#ied a! an* !em$era!re

be!+een ?7 C and i!s !ri$le $oin! 1)8:': C2 b* com$ression !o !&e reired

lie#ac!ion $ressre a! !&a! $ar!iclar !em$era!re and remo%al o# !&e &ea!

o# condensa!ion' I! is, !&ere#ore, $ossible !o lie#* CO(near !&e cri!ical

!em$era!re b* sin" a $ressre o# 9'; MPa and +a!er as !&e coolan!, b!

becase i! is o#!en di##icl! !o "aran!ee a cons!an! +a!er s$$l* a!

!em$era!res belo+ ( C, !&is me!&od is less #a%ored !&an one in +&ic& a

re#ri"eran! is sed' In !&is second me!&od, !&e "as is com$ressed nder ()

;MPa be#ore bein" cooled !o sb4ero !em$era!res b* means o# a

re#ri"eran!' T&e c&oice o# re#ri"eran! ob%iosl* is a #nc!ion o# !&e cos! and

1*


20/111


a%ailabili!* o# !&e li.el* ma!erials a! !&eir $oin! o# se' T&e $roximi!* o# man*

carbon dioxide lie#ac!ion $lan!s !o ammonia $rodc!ion #acili!ies means

!&a! ammonia is o#!en !&e $re#erred re#ri"era!ion medim' Florocarbons

and brine are sed in some $lan!s'Ra+ carbon dioxide $i$ed #rom !&e ammonia $lan! is cooled b* +a!er

and !&en $assed !o !&e sc!ion side o# !&ree $arallel, !&ree)s!a"e, elec!ricall*

dri%en reci$roca!in" com$ressors' A#!er com$ression nder oil)#ree

condi!ions, !&e "as is scrbbed +i!& +a!er !o remo%e !races o# or"anic

ma!erial #ormed in ca!al*!ic s!a"es o# !&e $ri#ica!ion !rain o# !&e ammonia

$rocess' T+o #r!&er $ri#ica!ion s!a"es are !&en carried o!, and !races o# oil

and sl#r com$onds are remo%ed in an ac!i%a!ed c&arcoal bed' T&e "as!&en $asses !&ro"& one o# a $air o# $arallel driers con!ainin" ac!i%a!ed

almina' T&e +a!er con!en! is redced !o m"F." le%els' 1T&e almina

absorben! is $eriodicall* re"enera!ed b* $assin" a con!ercrren! o# +arm,

dr* carbon dioxide !&ro"& !&e bed'2 T&e dried, $ri#ied carbon dioxide is

!&en lie#ied in a doble)$ass condenser, sin" liid ammonia a! )7( EC as

re#ri"eran!' T&e "aseos ammonia resl!in" #rom !&e !rans#er o# &ea! is

$assed bac. !o !&e $lan! ammonia)"as main' T&e lie#ied carbon dioxide is

$assed do+n a s!ri$$in" colmn in +&ic& en!rained $ermanen! "ases

1&*dro"en, ni!ro"en, and me!&ane2 are remo%ed b* a con!ercrren! #lo+ o#

$rer carbon dioxide "as #rom rec*cle com$ressors' T&is s!ri$$in" "as is !&e

#las& "as #rom !&e s!ora"e %essels o# liid carbon dioxide' T&e carbon

dioxide #rom !&e !o$ o# !&e colmn, no+ ric& in $ermanen! "ases, Loins !&e

main "as s!ream #rom !&e com$ressors and "oes on !o !&e condenser'

Pr"in" o# !&e $ermanen! "ases is e##ec!ed b* means o# a $ressre)con!rolled

blo+)o## !o !&e a!mos$&ere' T&e $ressre is lo+ered and !&e liid carbon

dioxide is sen! !o s!ora"e !an.s, #rom +&ic& bo!& road and rail !an.ers ma* be

#illed' T&e liid ma* also be $rocessed #r!&er !o #orm dr* ice'

2+


21/111


!ONOETH"NO#"!INE PROCESS

Process Description A con!inos scrbbin" s*s!em is sed !o se$ara!e CO(

#rom a "aseos s!ream' T&e s*s!em consis!s o# !+o main elemen!s, an

absorber, +&ere CO( is absorbed in!o a sorben! and a re"enera!or 1or

s!ri$$er2, +&ere CO( is released 1in concen!ra!ed #orm2 and !&e ori"inal

sorben! is reco%ered' C&emical absor$!ion s*s!ems !end !o be more

e##icien! !&an !&e o!&er s*s!ems s&o+n in A$$endix A, as !&e $rocess is

accom$anied b* a c&emical reac!ion !&a! en&ances !&e o%erall mass

!rans#er #rom "as $&ase !o liid $&ase'

In a $o+er $lan! a$$lica!ion cooled #le "ases #lo+ %er!icall*

$+ards !&ro"& !&e absorber con!ercrren! !o !&e absorben! 1MEA in a

+a!er sol!ion, +i!& some addi!i%es2' T&e MEA reac!s c&emicall* +i!& !&e

CO(in !&e #le "ases !o #orm a +ea.l* bonded com$ond 1carbama!e2'

T&e scrbbed "ases are !&en +as&ed and %en!ed !o !&e a!mos$&ere' T&e

CO()ric& sol!ion lea%es !&e absorber and $asses !&ro"& a &ea!

exc&an"er, !&en #r!&er &ea!ed in a reboiler sin" lo+)$ressre s!eam' T&e

+ea.l* bonded com$ond #ormed drin" absor$!ion is bro.en

do+n b* !&e a$$lica!ion o# &ea!, re"enera!in" !&e sorben!, and $rodcin" a

concen!ra!ed CO(s!ream' T&e &o! CO(lean sorben! is !&en re!rned !o !&e

&ea! exc&an"er, +&ere i! is cooled, !&en sen! bac. !o !&e absorber'


22/111


and easil* !rans$or!ed !o lon" dis!ances !o !&e desi"na!ed s!ora"e or

dis$osal #acili!*'

Process C&emis!r* T&e $rocess c&emis!r* is com$lex, b! !&e main reac!ions !a.in" $lace are

CO "bsorption/

( R)N6( Y CO( Z R)N6? Y R)N6)COO

!E" Re)eneration

R)N6)COOY R)N6? Y 16ea!2 Z CO( Y ( R)N6(

Pre MEA 1+i!& R 6O)C6(C6(2 is an /n&indered0 amine!&a! #orms a +ea.l* bonded in!ermedia!e called /carbama!e0 !&a! is #airl*

s!able' Onl* &al# a mole o# CO( is absorbed $er mole o# amine, as s&o+n in

!&e CO( absor$!ion ea!ion abo%e' On a$$lica!ion o# &ea!, !&is carbama!e

dissocia!es !o "i%e bac. CO( and amine sorben!, as s&o+n in !&e second

ea!ion abo%e'


23/111


T&e re"enera!ion o# !&ese amines reires lesser amon! o#

&ea! ener"* as com$ared !o !&e n&indered amines' B! !&e CO ( $!a.e

ra!e o# &indered amines is %er* lo+' E##or!s are nder+a* !o #ormla!e

be!!er sorben! b* combinin" #a%orable $ro$er!ies o# !&ese !+o "ro$s o#amines'

Process E.,ipment

T&e CO( ca$!re and se$ara!ion s*s!em consis!s o# !&e

#ollo+in" ca$i!al ei$men!

[enc& !o+er

T&e #le "ases comin" o! o# a $o+er $lan! are i!e &o!' T&e!em$era!re o# #le "as ma* be ran"in" #rom as lo+ as : de"' C 1in case

o# coal)#ired $o+er $lan!s +i!& +e!


24/111


T&e #le "as &as !o o%ercome a sbs!an!ial $ressre dro$ as

i! $asses !&ro"& a %er* !all absorber colmn, con!ercrren! !o !&e

sorben! #lo+' 6ence !&e cooled #le "as &as !o be $ressri4ed sin" a

blo+er be#ore i! en!ers !&e absorber'

"bsorber

T&is is !&e %essel +&ere !&e #le "as is made !o con!ac! +i!&

!&e MEA)based sorben!, and some o# !&e CO( #rom !&e #le "as "e!s

dissol%ed in !&e sorben!' T&e colmn ma* be $la!e !*$e or a $ac.ed one'

Mos! o# !&e CO( absorbers are $ac.ed colmns sin" some .ind o#

$ol*mer)based $ac.in" !o $ro%ide lar"e in!er#acial area'

Rich1lean cross heat exchan)er

T&e CO()loaded sorben! needs !o be &ea!ed in

order !o s!ri$ o## CO( and re"enera!e !&e sorben!' On !&e o!&er &and, !&e

re"enera!ed 1lean2 sorben! comin" o! o# !&e re"enera!or &as !o be cooled

do+n be#ore i! cold be circla!ed bac. !o !&e absorber colmn' 6ence

!&ese !+o sorben! s!reams are $assed !&ro"& a cross &ea! exc&an"er,

+&ere !&e ric& 1CO() loaded2 sorben! "e!s &ea!ed and !&e lean

1re"enera!ed2 sorben! "e!s cooled'

Re)enerator

T&is is !&e colmn +&ere !&e +ea. in!ermedia!e com$ond

1carbama!e2 #ormed be!+een !&e MEA)based sorben! and dissol%ed CO( is

bro.en do+n +i!& !&e a$$lica!ion o# &ea! and CO( "e!s se$ara!ed #rom !&e

sorben! !o lea%e resable sorben! be&ind' In case o# n&indered amines

li.e MEA, !&e carbama!e #ormed is s!able and i! !a.es lar"e amon! o#

2$


25/111


ener"* !o dissocia!e' I! also consis!s o# a #las& se$ara!or +&ere CO ( is

se$ara!ed #rom mos! o# !&e mois!re and e%a$ora!ed sorben!, !o "i%e a

#airl* ric& CO( s!ream'

Reboiler

T&e re"enera!or is connec!ed +i!& a reboiler +&ic& is basicall* a

&ea! exc&an"er +&ere lo+)$ressre s!eam ex!rac!ed #rom !&e $o+er $lan!

is sed !o &ea! !&e loaded sorben!'

!E" reclaimer

Presence o# acid "as im$ri!ies 1


26/111


CO dryin) and compression ,nit

T&e CO( $rodc! ma* &a%e !o be

carried !o %er* lon" dis!ances %ia $i$elines' 6ence i! is desirable !&a! i!does no! con!ain an* mois!re in order !o a%oid corrosion in !&e $i$elines'

Also, i! &as !o be com$ressed !o %er* &i"& $ressres so !&a! i! "e!s

lie#ied and can o%ercome !&e $ressre losses drin" !&e $i$eline

!rans$or!' T&e ml!is!a"e com$ression ni! +i!& in!er)s!a"e coolin" and

dr*in" *ields a #inal CO( $rodc! a! !&e s$eci#ied $ressre 1abo! (

$si"2 !&a! con!ains mois!re and o!&er im$ri!ies 1e'"' N(2 a! acce$!able

le%els'Limi!a!ions o# !&e MEA Process

Al!&o"& MEA)based absor$!ion $rocess is !&e mos! si!able

!ec&nolo"* a%ailable #or ca$!re o# CO( #rom $o+er $lan! #le "ases, i! &as

i!s o+n dra+bac.s' e'" corrosion and loss o# sol%en!'

2&


27/111


!aterial andEner)y %alance

2(


28/111


%asis/

7&r o$era!ion

COprod,ced/ 234 5)1hr

O%erall BalanceProdc! ;79 ."&r CO(

Ra+ ma!erial Fle "as #rom combs!ion o# #el oil

Fel oil Brn! 7?; ."&r

C in #el oil 7?;'@9? 779 ."&r

7( ." C $rodces CO( ;; ."

779 ." $rodces CO( 11(12$$

;( ."&r

Reco%er* e##icienc* ,1++$2*

$1(

9'(

-,rnace

Reactions

22 COOC +

OHOH22

2$ +

22 SOOS +

22222 NOON +

-,el oil composition

C @9'?

6 7(':

O ';

N '7

2)


29/111


< '((

As& '7

!o!al 7

[an!i!* Brn!7?; ."&r

"ir

Ox*"en Reired O( reired #or reac!ions 7, (, ?

O(reired #or reac!ion 7 12

)(3.+13$." mol

'98 .")mol

O(reired #or reac!ion ( 22

12&.+13$

.")mol

;'(( .")mol

O(reired #or reac!ion ? 32

++22.+13$

'7 .")mol

Ox*"en $resen! in #el oil 2

+++$.+13$.")mol

'(9 .")mol

To!al O(reired '98Y;'((Y'7)'(9

7;'; .")mol

( excess air is s$$lied

T&ere#ore O(s$$lied 17Y'(27;';

7:'@8 .")molAir s$$lied

21.+

)%.1&

@'( .")mol

N(s$$lied @'()7:'@8

:?'?8 .")mol

2*


30/111


6midi!* '@.")mol.")mol air

To!al +a!er +i!& air '@ 2.)+

':; .")mol

-l,e &as Composition

Fle "as

COMPONEN

T

MOL =)

MOL

=

CO( 77';@ '@ ;?6(O 7'@ '? 7::'9N( 9;'?? :?'( 79:@

O( ?'( ('@


31/111


Fle "as (;8: ."&r +i!& com$osi!ion as "i%en abo%e'

From !o$-

Coolin" +a!er78 ."&r


32/111


N( 9;':9 :?'( 79:O( ?'?7 ('@


33/111


CO(absorbed '9)'7;

';@ .")mol


34/111


Unabsorbed #le "as 1s+ee! "as2

@8)'8

98'8 ." mol &r

Enterin) the "bsorber =")mol&r ."

CO( 77';( '9 ;(86(O 7': ' 7:7N( 9;':9 :?'( 79:O( ?'?7 ('@


35/111


Balance

Ma!erial en!erin" 7;@88Y(;;:

79? ."&r

Ma!erial lea%in" 78(9?Y((

79? ."&r

T&ere#ore

SO#'ENT Rich .")mol mol 5) +! MEA ;9'; :'9 (@@ 7@'(6(O :;7'8 ': 778;@ 98':7CO( 7' (':@ @?: 8';9!o!al 99' 7' 3748 7'#ean MEA ;9'; :' (@@ 7'@(6(O :;7'8 7'9 778;@ 99'?CO( '8 7'; ;7@ ('@@!o!al :@'; 7' 32977 7'

3%


36/111


Ma!erial in Ma!erial o!

STRIPPER

Enterin)

Ric& Amine 1 CO(Yamine sol!ion299 .")mol

To$ $rodc! con!ains ?; CO(

To!al !o$ $rodc! #lo+ ra!e 3$.+

%.*

(9'; .")mol

Stripped Prod,ct Composition

Eilibrim $ressre o# CO(a! !o$ condi!ions is

8 .Pa

No+ #rom !ernar* 5LE o# CO(, 6(O and MEA

*iP

xiPisat

CO( in s!ri$$ed $rodc!

*7879?

?;'7

Also #rom 5LE

*i xiPisa! P!o!al

For +a!er a! 78oC,

Psa! 7(.Pa

*( :8'?

And #or Mono)e!&anolamine

Psa!77 .Pa

*? ':

T&ere#ore !o$$rodc! is

3$.+

%.*

(9'; "lom

3&


37/111


CO( '8 .")mol

6(O ':8S(9';

7@'( .")mol

MEA ':S(9';'( .")mol

Bo!!om Lean Amine

CO( 7:':)'8

9'7

6(O :;?)7@'(

:(;'@ .")mol

MEA ;9';)'(;9'( .")mol

To!al 9'7Y:(;'@Y;9'(

:9'7 ." mol

Ma!erial en!erin" 99' .")mol&r

78(?? ."&r

Ma!erial lea%in" Lea%in" as lean sol%en! YLea%in" as !o$ $rodc!

:9'7Y(9';

99';.")mol&r

78(?."&r

Balance

Ma!erial en!erin" Ma!erial Lea%in"

))

3(


38/111


DESI&NIN& O- -URN"CE

STEPS

C"#CU#"TE TOT"# HE"T RE6UIRED

C"#CU#"TE "!OUNT O- -UE# RE6UIRED

R"DI"TION SECTION C"#CU#"TION

HE"T DUT$

NU!%ER O- TU%E RE6UIRED

R"DI"TION SECTION "RE"

CON'ECTION SECTION C"#CU#"TION

HE"T DUT$

NU!%ER O- TU%ES RE6UIRED

CON'ECTION SECTION "RE"

3)


39/111


D"T" RE6UIREDLo+er &ea!in" %ale o# #el7@( B!lb

;'((S7

H."Pro$er!ies o# $rocess #lid i'e'1Oil25iscosi!* $1+$ = Pa'sDensi!* %.(11= ."m?

T&ermal ca$aci!* +(*&.+=k m'=6ea! Ca$aci!* *3.2=pc .H."'=

C"#CU#"TION O- "!OUNT O- -UE# %URNT

Fel reired is #ond o! b* !&e #ormla

Fel consm$!ion mF fuelofvalueheateinglowerreleasdHeatNet --

B! &ere +e calcla!e i! #rom ma!erial balance o# #le "ases $rodced

Com$osi!ion o# #el oil No' ( is

C @9'?

6 7(':

O ';

N '7


40/111


CO(com$osi!ion 7'9?

C Balance "i%es amon! o# #el consmed

FluegasmF =

1+(3.+

12

)(3.+

Fel ra!e )(3.+

12*11+(3.+

7?; ."

C"#CU#"TE TOT"# HE"T RE6UIRED

Ne! 6ea! releasedLo+er &ea!in" %ale S Amon! o# Fel brn!

;'((S79H."S7?; ."&r

[F 8':S7 H&r

Ta.in" e##icienc* o# #rnace 98

6ea! U!ili4ed '98S8':S7 H

;'(;S7 H

R"DI"TION SECTION C"#CU#"TION

72 6EAT DUT3

(2 NUMBER OF TUBE RE[UIRED

?2 RADIATION


41/111


Assmed 9 o# !o!al &ea! is absorbed in !&e radia!ion sec!ion'


42/111


En!erin" air !em$era!re ?C

En!&al$* o# en!erin" air 6Air (8'7.H."

[Air 6Air mair

[Airis !&e sensible &ea! in combs!ion air abo%e (8oC[Air 89@ .H&r

[ ( o# [F

[is !&e &ea! loss !&ro"& #rnace +alls, 17 !o 7 o# [ F, ( is a

"ood desi"n #i"re2

&ere [Fis !&e &ea! libera!ed b* #el

i'e' [F [n

[ '( 8':S7

[ 7'7(S7@ H&r

CO!%USTION &"SES

Considerin" !&e re$resen!a!i%e reac!ions occrrin"

C Y O( CO(

;6Y O( (6(O

< Y O(


43/111


:7'(; .")mol&r

CO(in #le "ases '@ .")mol&r

6(O in #le "ases '?.")mol&r

A! T 7@@ = !&e en!&al$* o# di##eren! "ases is s&o+nin !&e !able

Name o# "as En!&al$*

1.H.")mol2N (8;9(CO ?@(6O ?777O (:;

[N( (8;9( :7'(;

7'8:S7

H&r[O( (:; ('@

9'8;S7@ H&r

[6(O ?777 '?

('@@S7@ H&r

[CO( ?@( '@

?'S7@ H&r

[ N( Y O( Y 6(O Y CO(

7'8:S7 Y9'8;S7@ Y('@@S7@ Y ?'S7@

('S7H&r

[ ('S7: .H&r

No+ Ne! &ea! load

$3


44/111


[R [FY [AQ [Q [

[R 8':S7 Y 89@ Q7'7(S7@Q('S7

[R (';@S7H&r

1I! is close !o ac!al &ea! load i'e' ('9 7

H&r2C"#CU#"TION O- NU!%ER O- TU%ES

OD o# !bes ;'8 in

ID o# !bes ;'(: in

Cen!re !o cen!re dis!ance @ in

Assme !be len"!& 7'8#!


45/111


ACP$er !be 9 #!(

1E##ec!i%eness #ac!or2

Ra!io tubesof!O

cedisCC

.

tan

Ra!io 7'@

From Fi" 7'77 =ern

'79

ACP!be '799 #!(

:';( #!(

Ta.in" ( s&ield !bes, also #or s&ield !bes 7

ACP#or s&ield !bes 97(

7; #!(

ACP#or o!&er !bes (::';( #!(

7::' #!(

To!al ACP 7::' Y7;

7@' #!(

RE-R"CTOR$ SUR-"CE

Len"!& o# !be 7'8#!

Tbe in one ro+ 7(

6ei"&! 16R2 17(Y72 1C Q C dis!ance2

17(Y72 @7(

@':9#!\#!

id!& 1R2 1s&ield !besY72 1arc !besY72 1C Q C dis!ance2 1(Y72 1(Y72 @7(

;#!

End +alls (6RR

(;

$%


46/111


9( #!(


47/111


L 33

2umeFurancevol 1!able 7'7 .ern2

L 3 3()3

2

L;'@(#!Emissi(ity of &as/E&

Par!ial $ressre o# CO(and 6(O is

P '(?a!m

PL'(?;'@(

7'77a!m)#!

From "ra$& emissi%i!* o# !&e "as 1]"2 a! PL7'(( and T

78F is

]"'?? 1Fi"' 7'@2


48/111


=Qn

Qg

Qn

Qw

Qn

Q

1

[R[n 17)'()';?2

[R?'7x7H&r (?@B!&r

F"#$A

Q

t

=

@;7 B!&r#!(

1T&is is close !o assmed %ale o# @ B!&r#!(2

CON'ECTION SECTION C"#CU#"TION

72 6EAT DUT3

(2 NUMBER OF TUBE RE[UIRED

?2 CON5ECTION


49/111


T&e crosso%er !em$era!re o# !&e #lid7;oC

TE!PER"TURE DI--ERENCE

6o! #lid1#le"as2

Cold#lid1C6;Y


50/111


AF

'F

.

12%.&

%1.1

'(;: lbsec #!(

O%erall &ea! !rans#er coe##icien! UCin con%ec!ion sec!ion is

UC 1aYbYc(2 1;'8d2'(8

&ered is !&e !be o!side diame!er 1in2 is !&e #le "as mass %eloci!*a(';:7)'98^Y7':(8^(

b'9:98Y(7'?9?^)'::(8^(

c'9?@)?'@^Y7;'???^(

^TF7 a%era"e o! side #ilm !em$era!reB* $!!in" !&e %ales TF 1;9Y(8Y88(2( ;(oC

7@oF ^ 7@7 '7@ a?'7?;

b7('(;8 c):';76ence UC 8'9: B!&r#!()oF

?('9:@ m_'=


51/111


77@7(

9'?#!

id!& 1C2 1s&ield !besY72 1C Q C dis!ance2

1;Y72 @7( ?'?#!

5olme o# con%ec!ion sec!ion 15C2

5C LC6C

7'8?'?9'? #!?

(8? #!?

To!al %olme o# !&e #rnace 152

5T 5RY5C

?9@Y(8?

:?7 #!?

79' m`

%1


52/111


DESI&N O- 6UENCHIN& TO:ER/

Heat D,ty/

Fle as Flo+ Ra!e

mo (;; ."&r

A%" c$ 7'7(? .H."'.T& ;9 oC

Tc 8 oC

[o mo c$T

mo c$1T&)Tc2

7'( x 7:.H&r


53/111


54/111


Specification Sheet

Fle as Flo+ Ra!e (;;."&r

Fle "as

!em$era!re

;9 oC

6ea! D!* 7'(7:.H&r

Coolin" a!er

Reired

78."&r

[enc& To+er

rond Dimensions

7'(8m x 7'(8m


55/111


"%SOR%ER DESI&N

&as absorption/ as Absor$!ion is de#ined as /!&e remo%al o# one or morecom$onen!s #rom a mix!re o# "ases in!o a si!able sol%en!0'P,rpose/ T&e abo%e exam$les s&o+ !&a! absor$!ion o# !&e "as in !&eliid can be !rea!ed as a $&*sical $rocess, +&en c&emical reac!ion &a%in"no a$$reciable e##ec!' 6o+e%er, a c&emical reac!ion ma* occr +&ic& ma*a##ec! !&e ac!al ra!e o# absor$!ion'

Types of absorptionT&ere are !+o !*$es o# absor$!ion-

C&emical absor$!ion P&*sical Absor$!ion

Physical absorption Remo%al o# one com$onen! #rom a mix!re o# "asesb* sin" a si!able sol%en! is called $&*sical absor$!ion'Chemical "bsorption/

Absor$!ion #ollo+ed b* a c&emical reac!ion in liid$&ase is o#!en sed !o "e! more com$le!e remo%al o# a sol!e #rom a "asmix!re' For exam$le, a dil!e acid sol!ion can be remo%ed !o scrbammonia #rom "as s!reams, and basic sol!ions are sed !o remo%ecarbon dioxide and o!&er acid "ases'

6ere reac!ion in !&e liid $&ase redces !&e eilibrim $ar!ial$ressre o# sol!e o%er !&e sol!ions, +&ic& "rea!l* increase !&e dri%in"#orce #or !&e mass !rans#er'

"bsorption col,mns/T&ere are !+o !*$es o# absor$!ion colmns i'e-

Pac.ed colmns Pla!e colmns

Characteristics of pac5ed and plate col,mns

Pac5ed col,mns/ Necessar* !o assre "ood liid dis!rib!ion

%%


56/111


No! si!able #or %er* lo+ liid ra!es 6andlin" corrosi%e, !oxic and #lammable liids de !o small &old $ Lo+ $ressre dro$ In!ernal cons!rc!ion is sim$le More con!ac! !ime is a%ailable #or !&e mass !rans#er' Liid &old$ is a$$reciabl* lo+er, si!able #or !oxic or #lammable

liids

Plate col,mns

6andle lar"e an!i!* o# liid and "as #lo+ ra!es E##icienc* can be $redic!ed more e##icien!l* Necessi!a!es !&e se o# coolin" coils and side s!reams +i!&dra+al Easier !o ma.e $ro%ision #or cleanin" +&en !&e liid case #olin"

:hy pac5ed col,mn is selected/

On !&e basis o# !&e, abo%e discssion $ac.ed colmn is selec!ed #oror $rocess since $ac.ed !o+er sall* $ro%ide more con!ac! !ime as com$ared !o

$la!e colmn Lo+ $ressre dro$ Pac.ed colmn is si!able #or #oamin" s*s!em

Follo+in" s!e$s are considered in !&e desi"nin" o# $ac.ed colmns

Per#ormance o# ma!erial Balance Per#ormance o# Ener"* Balance T&e O$era!in" condi!ions


57/111


Lean amine en!erin" a! ; C Fle "as lea%in" absorber a! ;8 C Ric& amine lea%in" a! 87C Absor$!ion !a.es $lace a! 8 C

Ma!erial balance O%er !&e Absorber

%(

Unabsorbed

gas

2+2*kghr

/02+.2&H2011.*$

2)$.+)

023.(3

Rich solvent

1%2(3kghr

452)*+kg

H2011%&3kg/02)33kg

Flue gas In2$$&kghr

/0211.$2

H201+.&+2($.&(

023.31

Lean solvent

1$%3+kghr

452(%%kg

H2011%%$kg/02$1&kg


58/111


Monoe!&anolamine Ma!erial Balance

Fle as Ma!erial Balance

Component #ea(in) rich "mine*5)1hr+

Enterin) lean "mine*5)1hr+

MEA (@@ (@99

CO( @?: ;7@

6(O 778;@ 77(7

To!al 78(9? 7;8?

%)


59/111


60/111


61/111


Molar #lo+ ra!e o# "as in ':9."secMolar #lo+ ra!e o# sol%en! o! L ;'(;."sec

7'(."m?'L ."m?

5iscosi!* o# liid '@8: $a)sec5iscosi!* o# "as '79@ $a)sec


62/111


&ere

=; 17?'715+2(SF$S 1LL2 '7 f5 1L)5 2gNo+

FL L+S5+S 1%L2 h

;'(;':917'(27( '((Recommended %ale #or $ressre dro$ is (8 mm6(OFrom "ra$& !&e ordina!e #or Isobar 1(8 mm6(O2 is=; '@

=;a! #loodin"

=; ('(

No+ c&ec. #or a"e #loodin" %eloci!*

1'@('(27( S7 :'7( 6ence o$era!in" %eloci!* is : o# !&e #loodin" %eloci!* and sa!is#ac!or* #ordesi"n

=; 17?'715+2(F$1LL2 '7 f5 1L)5 2g

P!!in" !&e %ale in E' and calcla!in" #or !&e as mass %eloci!*

F$ 7:5+ j =;5 1L)5 2 7?'7(F$1LL2 '75+ 7'7@ ."m()secB! ':9."sec

6ence Area o# cross sec!ion 5+

':97'7@Area A ':9? m(

Diame!er j 1;SA?'7;7:2 '(8 m ?'? #!Rond o## i! !o ?' #!'T&en

Ads!ed area A '78 m

&2


63/111


And !&e ads!ed %ales o#

5+ 7'7 ."m()sec

=; '@

6ence !&e GP (9 mm6(O m $ac.in" 1#rom "ra$&2

-loodin) (elocity

As =; ('(And

5+ j ('(S7'(17'(27?'717:21'@8:2'7

5+ 7'9."m()sec

Calc,lation of Hei)ht of col,mn

Number of Transfer Unit/ As !&e c&emical absor$!ion &ere and !&e reac!ion

in !&e liid $&ase reses !&e eilibrim $ar!ial $ressre o# sol!e o%er!&e sol!ion +&ic& "rea!l* increase !&e dri%in" #orce #or mass !rans#er soeilibrim $ar!ial $ressre is 4ero and No*can be calcla!ed #or *

NO ln *(*7

As*( 77';( and *7 '(:

NO ;

Height of the transfer unit

A$$l*in" Onda me!&odFirs! o# all !&e e##ec!i%e area is calcla!ed as

a+a 7) ex$W1kckL2'98 1L+aL2'71L+(a L("2)'81L+( LkLa2'(

&3


64/111


Calcla!ed e##ec!i%e area #or !&e mass !rans#era+ @:'( m(m?

No+ ." and .Lare calcla!ed b* sin" Ondas correla!ions6ence,

."RTaD% =815+a%2'91% 5 D%27?1adP2 )('

=8 8'(? #or $ac.in" si4e abo%e 78 mm

D% 7'( S7):

." ;'?9 S7);.")molm()bar)secAnd.L1L L"27? '871L+a+L2(? 1L LDL2)7( 1ad$2';

DL 7':8: S7):

.L 7';?:S7); msec

To!al concen!ra!ion o# lea%in" amine

CT densi!* o# aminemol'+!' (7'89 ;:'?7 .molm?

AsPT 7'7?(8 barNo+

6 m ."a+Pm '?89 .")molm()sec6 '?9 m

And

6L Lm.La+CTLm '(@ .")molm()sec6L '87 mNo+ o%erall &ei"&! o# !rans#er ni!6O 6" Y m'mLmS 6Lm'mLm ': ) '@8is O$!imm ran"e "i%en b* Colbrn6O '?9 Y'@81'872 7'?9@ m

&$


65/111


Total height of packing:

^! NOS 6O^! ; S7'?9@^! 8'8( m

Pro%idin" !&e 78 o# !&e $ac.in" #ree s$ace #or liid "as se$ara!ionabo%e and belo+ !&e $ac.in" +&ic& is ( me!er


66/111


67/111


Col,mn Internals

T*$e o# $ac.in" Pall Rin"s


68/111


Condenser

Reboiler

Cooler

All o# !&ese are s&ell and !be &ea! exc&an"ers'

Selection &,ide To Heat Exchan)er Types

TypeSi)nificant

feat,re"pplications best

s,ited#imitations

"pproximate

relati(ecost incarbon

steelconstr,ction

Fixed !bes&ee!

Bo!& !be s&ee!s#ixed !o s&ell'

Condensers-liid)liid- "as)"as- "as)liid-

coolin" and&ea!in", &ori4on!al

or %er!ical,reboilin"'

Tem$era!redi##erence a!

ex!remes o# abo!( oF De !o

di##eren!ialex$ansion'

7'

Floa!in"&ead or!bes&ee!1remo%abl

e andnonremo%

ablebndles2

One !bes&ee!/#loa!s0 in s&ell or+i!& s&ell, !be

bndle ma* or ma*no! be remo%able

#rom s&ell, b!bac. co%er can beremo%ed !o ex$ose

6i"& !em$era!redi##eren!ials, abo%eabo! ( oF

ex!remes- dir!*#lids reirin"

cleanin" o# insideas +ell as o!sideo# s&ell, &ori4on!al

In!ernal "as.e!so##er dan"er o#lea.in"'

Corrosi%eness o##lids on s&ell)side

#loa!in" $ar!s'Usall* con#ined !o

&ori4on!al ni!s'

7'(@

&)


69/111


!be ends' or %er!ical'

U)!be-U)Bndle

Onl* one !bes&ee! reired'Tbes ben! in U)s&a$e' Bndle is

remo%able'

6i"& !em$era!redi##eren!ials, +&ic&

mi"&! reire$ro%ision #orex$ansion in #ixed!be ni!s' Easil*

cleaned condi!ionson bo!& !be and

s&ell side'

Bends ms! becare#ll* made, or

mec&anicaldama"e and

dan"er o# r$!recan resl!' Tbe

side %eloci!ies cancase erosion o#inside o# bends'Flid s&old be

#ree o# ss$ended$ar!icles'

')7'7

Doble$i$e

Eac& !be &as o+n

s&ell #ormin"annlar s$ace #or

s&ell side #lid'Usall* se

ex!ernall* #inned!be'

Rela!i%el* small!rans#er area

ser%ice, or inban.s #or lar"er

a$$lica!ions'Es$eciall* si!ed

#or &i"& $ressresin !be 1"rea!er!&an ; $si"2'

CH"N&ER

&*


70/111


In $rocess inds!ries, s&ell and !be exc&an"ers are sed in "rea!

nmbers, #ar more !&an an* o!&er !*$e o# exc&an"er' More !&an o#

&ea! exc&an"ers sed in inds!r* are o# !&e s&ell and !be !*$e' T&e s&ell

and !be &ea! exc&an"ers are !&e /+or. &orses0 o# inds!rial $rocess &ea!!rans#er' T&e* are !&e #irs! c&oice becase o# +ell)es!ablis&ed $rocedres

#or desi"n and man#ac!re #rom a +ide %arie!* o# ma!erials, man* *ears o#

sa!is#ac!or* ser%ice, and a%ailabili!* o# codes and s!andards #or desi"n and

#abrica!ion' T&e* are $rodced in !&e +ides! %arie!* o# si4es and s!*les'

T&ere is %ir!all* no limi! on !&e o$era!in" !em$era!re and $ressre'

Classification of Shell and T,be Heat Exchan)ersT&ere are #or basic considera!ions in c&oosin" a mec&anical

arran"emen! !&a! $ro%ides #or e##icien! &ea! !rans#er be!+een !&e !+o

#lids +&ile !a.in" care o# sc& $rac!ical ma!!ers as $re%en!in" lea.a"e

#rom one in!o !&e o!&er'

Considera!ion #or di##eren!ial !&ermal ex$ansion o# !bes and

s&ell'

Means o# direc!in" #lid !&ro"& !&e !bes'

Means o# con!rollin" #lid #lo+ !&ro"& !&e s&ell'

Considera!ion #or ease o# main!enance and ser%icin"'

6ea! exc&an"ers &a%e been de%elo$ed +i!& di##eren! a$$roac&es !o

!&ese #or #ndamen!al desi"n #ac!ors' T&ree $rinci$al !*$es o# &ea!

exc&an"ers

72 Fixed !be)s&ee! exc&an"ers

(2 U)!be exc&an"ers and

?2 Floa!in" &ead exc&an"erssa!is#* !&ese desi"n reiremen!s'

(+


71/111


!7 !(

T( T7

?2 shell and t,be heat exchan)er

3@PH$SC"# PROPERTIES/

RICH CO#D "!INE #E"N HOT "!INE

!7 88 C T7 7( C!( 7(C T( m ;'(8 ."s M ;'7? ."s7 ':8 $a's ( '; $a'sC$ ;7:': H."'oC c$ ;?9 H."'oC7 9 ."m? ( : ."m?

.7 '8 .( '8

!"#EAT LOAD

[ mc$!

1;'(821;7:':217()882

@(?78'@8 Hs

[ Mc$T

@(?78'@81;'7?21;?9217()T(2

T(9 oC 1as abo%e +ri!!en2

8@ #!TD/

T& T7)!( 7()7( ( oCTc T()!7 9)88 78 oC

(1


72/111


LMTD 1T& ) Tc 2ln1T&Tc2

79'8C o

2@ "SSU!ED '"#UE O- Uo/

Uo 78 m('.

7@ HE"T TR"NS-ER "RE"/

A [ 1Uo'LMTD2

?'8 m(

A@ CORRECTED "RE"/

R 1T7) T(21!()!72 7'(8

< 1!()!721 T7)!72 ':;8F! '@@ 1For (); &ea! exc&an"er2

6T7 becomes 1%.$o/

A [1Uo'LMTD2A ?;'8 m(

4@ SE#ECTED P"R"!ETERS/

(2


73/111


Len"!& o# Tbe ;'@9: m

7; B ID '7;@? mOD '78 mPi!c& P! '(?@7 m

Ba##le


74/111


'7? m(

Ei%alen! Diame!er 1De2 17'7OD21P!(Q 1'79OD(22

De'7?8( m(

5ol' Flo+ Ra!e on


75/111


Area o# One Tbe 1DL2 '(7::9 m

No o# Tbes 1N!2 AArea o# One Tbe 77:

No o# Passes 1N$2 ;'Tbes $er Pass N!; (

B@3 TU%E CROSS SECTION"# "RE"/

1;21ID2( '79(: m(

Area Per Pass 1Tbes Per ; Pass21Tbe Cross


76/111


LID ?(@'@

6ea! Trans#er Fac!or 6 '9

Nssel! Nmber 1Re621Pr27? ?7?'(

&i 1N.2ID 788 m('.

3@ O'ER "## HE"T TR"NS-ER COE--ICINT/

e &a%e a Rela!ion

7Uo 1dodi217&idY 7&i2Y17&o2Y17&od2Y1do'ln1dodi2('=+22

':Uo 7;;8 m('.

&id '7 m('. 1Pa"e ::7 P D2 1inside Dir! Coe##icien!2&od '( m('. 1Pa"e ::? P D2 1o!side Dir! Coe##icien!2

=+ T&ermal condc!i%i!* o# +all ;8 Carbon

Ps 1@#1DsDe21LLb211 (s(2(22

Ps 8@(8 Nm(

As,

7 Nm( '7;8 $si

Ps '@;8 $si

(&


77/111


78/111


!low rate $.2% kgs

Temp %&o/ to 1+2o/

.7 8 +.+1$)3 m

+.+23)1 in. triangular pitch

o of tubes 8 11&

@ressure drop 33&(+ m2$.)) psi


79/111


!aterial %alance

Rich "mine

.molF&r

CO( 7'6(O :;7'8MEA ;9';

To!al 99'

Prod,ct

.molF&rCO( '8

6(O 7@'(MEA '(

To!al (9'

#ean "mine

.molF&r

CO( '86(O :(?'?MEA ;9'(To!al :@'

79('? .Pa

(*


80/111


!aterial %alance/

Lean Amine

="&r

Prodc! as

="&r

CO( @?? ;7:'8 ;7:'8

6(O 778:? 77(?: ?(9

MEA (@7 (@@'@ 7'(

To!al 78(@9 7;8??'? 98?'9

Operatin) Conditions/Bo!!om Tem$era!re 7(oC

Colmn O$era!in" Pressre 79? .Pa

Ric& Loadin" '; mol CO(mol MEA

Lean Loadin" '( mol CO(mol MEA

To$ Tem$era!re 78oC

Preliminary diameter calc,lation/

5a$or #lo+ ra!e 98?'9 ."&r

$.13&++

(.(%3

m?s

'7; m?s

Assme a s$er#icial %eloci!* ':7 ms 1( #!s2

)+


81/111


Preliminar* diame!er &1.+

1$*.+

'(8m V('8#!


82/111


Com$osi!ion

CO( (':9 b* mol

6(O ':8

MEA :':@

Stripped Prod,ct Composition

Eilibrim $ressre o# CO(a! !o$ condi!ions is

8 .Pa

CO( in s!ri$$ed $rodc!

*7 879

?;'7


83/111


#ean amine/ :@'.")mol&rCom$osi!ion o# !&e lean sol%en!

CO( 7'? b* mol

6(O 7':@

MEA :'?

Pac5in) Selection

Plas!ic ma* no! +or. sa#el*

Amine is corrosi%e

Me!al $ac.in" is no! %iable


84/111


L+5+ L+ 5+ 7'?

No+ #lo+ #ac!or

FL5 L+5+ 1 % L2

T&ere#oreFL5 '9


85/111


';9 m

Rondin" o##

'8m


86/111


Plo!!in" x %sexx

1and #indin" area nder !&e cr%e

NOL:

Eilibrim Cr%e #or Desor$!ion

Re#erence Bas Trea!in" +i!& c&emical sol%en!s, As!ari!a e!' al

Hei)ht of Transfer Unit

Usin" ceramic in!alox saddle o# ?@mm

6OL is "i%en in li!era!re i'e'

6OL;'7 #! a! "i%en #lo+ ra!e

6OL7'(8 m

Hei)ht of Pac5in)

^6OLNOL

^7'(8 x :

9'8 m

A dis!rib!ion allo+ance o# 7m +ill be made a! !o$ and bo!!om

)&


87/111



88/111


T ;: C T ? C

CO( ;79 =" CO( ;79 ="

Enterin) !oles

"t inlet

5'P o#

8@'?=Pa"t O,tlet

Par!ial $ +a!er 7( =PaIner! Pressre 78@ =Pa


89/111


[7 &ea! o# condensa!ion Y&ea! #rom UN condensed s!eam Y &ea! #romCO(

8((?77=H&


90/111


SPECI-IC"TIONS

Shell Side T,be Side

(7 , C '(80 7OD, 7sr' Pi!c&

B 8 in 7:' B

T,be side heat transfer coefficient

a! N! a! p n

a! '7( m(

9 =" sec m(

A! +&ic&&i :'?: . m( =&iO &i ID OD 8'(8 . m( =

Shell side heat transfer coefficient

!ean Properties/

C$m 7'8@ .H =" =

. '(8 . m= '78 mNs m(

as t1$$@

>/.7 a< ';77m(

&s F m1as


91/111


Clean o(erall heat transfer coefficient

1CP .2'A4 7'71 D2 ':(. &o1CP .2'A4cPs#Mm1 .d2 '7(Ps#Point/ 3

T" (9@ =$" 7( .Pa$< ?@ .PaT+ ?7=G T 8 =Es!ima!e Tc ?8(=

$


92/111


UD [ A U GT '(. m(=

Desi)n CoefficientA%ailable sr#ace area ono! side o# !bes ': m( m

??' m(

Uc '78 . m(=Rd 1'( Q '782 1'( '782 7'( m(= .

Press,re Drop

Shell side press,re drop

Separate flo0 model

1GPL2TP qL(1GPL2LqL( E Y ?'(; F 6 1F r ';8 "'?82E ';@@ F r ';8@F ('9 " '98(@6 '::

GP ; # LWL di m!(1 7 ) x(2 W 7 (LGP 7';? $siGPTPF @ psi

T,be Side Press,re Drop

GP # !( L n 18'(( 772# ' (: #rom "ra$&GP! : $siGPr 1; n


93/111


Specification Sheet

Iden!i#ica!ion Par!ial condenser

No' Reired 7

Fnc!ion Condense %a$ors b* remo%in" !&e la!en! &ea! o# %a$ori4a!ion

O$era!ion Con!inosT*$e 7)( 6ori4on!al Condenser

Ba##les s$acin" '7(9 m'

U!ili!ies Cold +a!erUd assmed 78 m(= Ud calcla!ed ( m(=Uc calcla!ed 78 m(= Allo+ed dir! #ac!or Rd 7'(

PU!P SE#ECTION

-"CTORS "--ECTIN& CHOICE O- " PU!P

*3


94/111


Man* di##eren! #ac!ors can in#lence !&e #inal c&oice o# a $m$ #or a

$ar!iclar o$era!ion' T&e #ollo+in" lis! indica!es !&e maor #ac!ors !&a!

"o%ern $m$ selec!ion'

'72 T&e amon! o# #lid !&a! ms! be $m$ed' T&is #ac!or de!ermines !&e

si4e o# $m$ 1or $m$s2 necessar*'

(2 T&e $ro$er!ies o# !&e #lid' T&e densi!* and !&e %iscosi!*- o# !&e #lid

in#lence !&e $o+er reiremen! #or a "i%en se! o# o$era!in"

condi!ions, corrosi%e $ro$er!ies o# !&e #lid de!ermine !&e acce$!able

ma!erials o# cons!rc!ion' I# solid $ar!icles are ss$ended in !&e #lid,

!&is #ac!or dic!a!es !&e amon! o# clearance necessar* and ma*elimina!e !&e $ossibili!* o# sin" cer!ain !*$es o# $m$s'

?2 T&e increase in $ressre o# !&e #lid de !o !&e +or. in$! o# !&e

$m$s' T&e &ead c&an"e across !&e $m$ is in#lenced b* !&e inle!

and do+ns!ream reser%oir $ressres, !&e c&an"e in %er!ical &ei"&! o#

!&e deli%er* line, and #ric!ional e##ec!s' T&is #ac!or is a maor i!em in

de!erminin" !&e $o+er reiremen!s'

;2 T*$e o# #lo+ dis!rib!ion' I# non$lsa!in" #lo+ is reired, cer!ain

!*$es o# $m$s, sc& as sim$lex reci$roca!in" $m$s, ma* be

nsa!is#ac!or*'


95/111


Measremen! is a #ndamen!al reisi!e !o $rocess

con!rol' Ei!&er !&e con!rol can be a##ec!ed a!oma!icall*, semi)a!oma!icall*

or manall*' T&e ali!* o# con!rol ob!ainable also bears a rela!ions&i$ !o!&e accrac*, re)$rodcibili!* and reliabili!* o# !&e measremen! me!&ods,

+&ic& are em$lo*ed' T&ere#ore, selec!ion o# !&e mos! e##ec!i%e means o#

measremen!s is an im$or!an! #irs! s!e$ in !&e desi"n and #ormla!ion o#

an* $rocess con!rol s*s!em'

Obecti(e of process control/

T&e basic obec!i%e o# $rocess con!rol is-


96/111


PRESSURE !E"SURE!ENT "ND CONTRO#

Li.e !em$era!re $ressre is a %alable indica!ion o# ma!erial

s!a!e and com$osi!ion' In #ac!, !&ese !+o measremen!s considered

!o"e!&er are !&e $rimar* e%ala!in" de%ices o# inds!rial ma!erials'

Pm$s, com$ressor and o!&er $rocess ei$men! associa!ed +i!&

$ressre c&an"es in !&e $rocess ma!erial are #rnis&ed +i!& $ressre

measrin" de%ices' T&s $ressre measremen! becomes an indica!ion

o# ener"* increase or decrease'

Mos! $ressre measremen! in inds!r* are elas!ic elemen! de%ices, ei!&erdirec!l* connec!ed #or local se or !ransmission !*$e !o cen!rali4ed loca!ion'

Mos! ex!ensi%el* sed inds!rial $ressre elemen! is !&e Borderi Tbe or

a Dia$&ra"m or Bello+s "a"es'

-#O: !E"SURE!ENT "ND CONTRO#

Flo+)indica!or)con!rollers are sed !o con!rol !&e amon! o# liid'

Also all manall* se! s!reams reire some #lo+ indica!ion or some eas*

means #or occasional sam$le measremen!' For accon!in" $r$oses,

#eed and $rodc! s!ream are me!ered' In addi!ion !ili!ies !o indi%idal and

"ro$ed ei$men! are also me!ered'

Mos! #lo+ measres in !&e inds!r* are b* 5ariable 6ead de%ices' To a

lesser ex!en! 5ariable Area is sed, as are !&e man* a%ailable !*$es as

s$ecial me!erin" si!a!ions arise'

Control schemes of re)eneration to0er

Obecti(es

*&


97/111


In re"enera!ion !o+er con!rol an* o# #ollo+in" ma* be !&e "oals

!o ac&ie%e

7' $ressre in !&e condenser

(' com$osi!ion o# %a$ors #rom Reboiler?' Pressre in !&e Reboiler '

!anip,lated (ariables

An* one or an* combina!ion o# #ollo+in" ma* be !&e mani$la!ed %ariables

7'

(' Com$osi!ion o# #eed'

?' Tem$era!re o# #eed'

;'

8' Inle! !em$era!re o# +a!er #or condenser'

Control scheme/

O%er&ead $rodc! ra!e is #ixed and an* c&an"e in #eed ra!e ms! be

absorbed b* c&an"in" bo!!om $rodc! ra!e' T&e c&an"e in %a$or $ressre

o# Reboiler is con!rolled b* mani$la!in" !&e s!eam ra!e !o Reboiler,&ence

con!rollin" !&e in!ernal re#lx !o !&e bo!!om o# Re"enera!or'

H"OP STUD$

Haop

*(


98/111


A 6AÔP sr%e* is one o# !&e mos! common and +idel* acce$!ed

me!&ods o# s*s!ema!ic ali!a!i%e &a4ard anal*sis' I! is sed #or bo!& ne+

or exis!in" #acili!ies and can be a$$lied !o a +&ole $lan!, a $rodc!ion ni!,

or a $iece o# ei$men! I! ses as i!s da!abase !&e sal sor! o# $lan! and$rocess in#orma!ion and relies on !&e d"men! o# en"ineerin" and sa#e!*

ex$er!s in !&e areas +i!& +&ic& !&e* are mos! #amiliar' T&e end resl! is,

!&ere#ore reliable in !erms o# en"ineerin" and o$era!ional

ex$ec!a!ions, b! i! is no! an!i!a!i%e and ma* no! consider !&e

conseences o# com$lex seences o# &man errors'

T&e obec!i%es o# a 6AÔP s!d* can be smmari4ed as #ollo+s

72 To iden!i#* 1areas o# !&e desi"n !&a! ma* $ossess a si"ni#ican!

&a4ard $o!en!ial'

(2 To iden!i#* and s!d* #ea!res o# !&e desi"n !&a! in#lence !&e

$robabili!* o# a &a4ardos inciden! occrrin"'

?2 To #amiliari4e !&e s!d* !eam +i!& !&e desi"n in#orma!ion

a%ailable'

;2 To ensre !&a! a s*s!ema!ic s!d* is made o# !&e areas o#

si"ni#ican! &a4ard $o!en!ial'

82 To iden!i#* $er!inen! desi"n in#orma!ion no! crren!l* a%ailable !o

!&e !eam'

:2 To $ro%ide a mec&anism #or #eedbac. !o !&e clien! o# !&e s!d*

!eamKs de!ailed commen!s'

A 6AÔP s!d* is condc!ed in !&e #ollo+in" s!e$s

72


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o# !&e ris. o# n exis!in" ni!' i%en !&e $r$ose and !&e

circms!ances o# !&e s!d*, !&e obec!i%es lis!ed abo%e can &e

made more s$eci#ic' T&e sco$e o# !&e s!d* is !&e bondaries o#

!&e $&*sical ni!, and also !&e ran"e o# e%en!s and %ariablesconsidered' For exam$le, a! one !ime 6A^OPKs +ere mainl*

#ocsed on #ire and ex$losion end$oin!s, +&ile no+ !&e sco$e

sall* incldes !oxic release, o##ensi%e odor, and en%ironmen!al

end)$oin!s' T&e ini!ial es!ablis&men! o# $r$ose, obec!i%es, and

sco$e is %er* im$or!an! and s&old be $recisel* se! do+n so !&a!

i! +ill be clear, no+ and in !&e #!re, +&a! +as and +as no!

inclded in !&e s!d*' T&ese decisions need !o be made b* ana$$ro$ria!e le%el o# res$onsible mana"emen!'

(2


100/111


Da!a on !&e c&emical, $&*sical and !oxicolo"ical $ro$er!ies o#

all ra+ ma!erials,, in!ermedia!es, and $rodc!s'

Pi$in" and ins!rmen! dia"rams 1PIDs2

Ei$men!, $i$in", and ins!rmen! s$eci#ica!ions Process con!rol lo"ic dia"rams

La*o! dra+in"s

O$era!in" $rocedres

Main!enance $rocedres

Emer"enc* res$onse $rocedres


101/111


1+1


102/111


H"OP &,ide :ords and !eanin)s

&,ide :ords !eanin)No

Less

More

Par! o#

As +ell as

Re%erse

O!&er !&an

Ne"a!ion o# desi"n in!en!

[an!i!a!i%e decrease

[an!i!a!i%e increase

[ali!a!i%e decrease

[ali!a!i%e Increase

Lo"ical o$$osi!e o# !&e in!en!

Com$le!e sbs!i!!ion

;2 Condc! !&e s!d*' Usin" !&e in#orma!ion collec!ed, !&e ni! is

di%ided in!o s!d* >nodes> and !&e seence dia"rammed in

Fi"re , is #ollo+ed #or eac& node' Nodes are $oin!s in !&e

$rocess +&ere $rocess $arame!ers 1$ressre, !em$era!re,

com$osi!ion, e!c'2 &a%e .no+n and in!ended %ales' T&ese

%ales c&an"e be!+een nodes as a resl! o# !&e o$era!ion o#

%arios $ieces o# ei$men!K sc& as dis!illa!ion colmns, &ea!

exc&an"es, or $m$s' 5arios #orms and +or. s&ee!s &a%e been

de%elo$ed !o &el$ or"ani4e !&e node $rocess $arame!ers and

con!rol lo"ic in#orma!ion'

&en !&e nodes are iden!i#ied and !&e $arame!ers are iden!i#ied, eac&

node is s!died b* a$$l*in" !&e s$eciali4ed "ide +ords !o eac&$arame!er' T&ese "ide +ords and !&eir meanin"s are .e* elemen!s o# !&e

6A^OP $rocedre' T&e* are lis!ed in Table17'72'

1+2


103/111


Re$ea!ed c*clin" !&ro"& !&is $rocess, +&ic& considers &o+ and +&* eac&

$arame!er mi"&! %ar* #rom !&e in!ended and !&e conseence, is !&e

sbs!ance o# !&e 6AÔP s!d*'

82 ri!e !&e re$or!' As mc& de!ail abo! e%en!s and !&eir

conseence as is nco%ered b* !&e s!d* s&old be recorded'

Ob%iosl*, i# !&e 6AÔP iden!i#ies a no! im$robable seence o#

e%en!s !&a! +old resl! in a disas!er, a$$ro$ria!e #ollo+)$ ac!ion

is needed' T&s, al!&o"& ris. redc!ion ac!ion is no! a $ar! o# !&e

6AÔP, !&e 6AÔP ma* !ri""er !&e need #or sc& ac!ion'

T&e 6AÔP s!dies are !ime consmin" and ex$ensi%e' Hs! "e!!in" !&e P

IDKs $ !o da!e on an older $lan! ma* be a maor en"ineerin" e##or!'

#or $rocesses +i!& si"ni#ican! ris., !&e* are cos! e##ec!i%e +&en balanced

a"ains! !&e $o!en!ial loss o# li#e, $ro$er!*, bsiness, and e%en !&e #!re o#

!&e en!er$rise !&a! ma* resl! #rom a maor release'

3@H"OP STUD$ O- CO/

PRODUCT N"!E/ CARBON DIOXIDE

CHE!IC"# N"!E/ Carbon Dioxide

3@3 H""RD IDENTI-IC"TION/

EMERENC3 O5ER5IE

Ox*"en le%els belo+ 7'8 ma* case as$&*xia' Carbon dioxide

ex$osre can case nasea and

res$ira!or* $roblems' 6i"& concen!ra!ions ma* case %asodila!ion leadin"

!o circla!or* colla$se'

Con!ac! +i!& liid $rodc! ma* case #ros!bi!e in ex$osed !isses'

1+3


104/111


ROUTE O- ENTR$/


105/111


Lo+ concen!ra!ions o# carbon dioxide case increased res$ira!ion and

&eadac&e'

E##ec!s o# ox*"en de#icienc* ma* inclde ra$id brea!&in", diminis&ed

men!al aler!ness, im$aired msclar coordina!ion, #al!* d"emen!,de$ression o# all sensa!ions, emo!ional ins!abili!*, and #a!i"e' As

as$&*xia!ion $ro"resses, nasea, %omi!in", $ros!ra!ion, and loss o#

consciosness ma* resl!, e%en!all* leadin" !o con%lsions, coma, and

dea!&'

Ox*"en de#icienc* drin" $re"nanc* &as $rodced de%elo$men!al

abnormali!ies in &mans and ex$erimen!al animals'

3@ -IRST "ID !E"SURES/

E$ES/

Ne%er in!rodce oil or oin!men! in!o !&e e*es +i!&o! medical ad%ice In

case o# #ree4in" or cr*o"enic >brns>

b* ra$idl* e%a$ora!in" liid' DO NOT A


106/111


$rom$! medical a!!en!ion is manda!or* in all cases o# o%erex$osre !o

carbon dioxide' Resce $ersonnel s&old be ei$$ed +i!& sel#)con!ained

brea!&in" a$$ara!s' Conscios $ersons s&old be assis!ed !o an

ncon!amina!ed area and in&ale #res& air' [ic. remo%al #rom !&econ!amina!ed area is mos! im$or!an!' Unconscios $ersons s&old be

mo%ed !o an ncon!amina!ed area, "i%en mo!&)!o)mo!& ressci!a!ion

and s$$lemen!al ox*"en' Fr!&er !rea!men! s&old be s*m$!oma!ic and

s$$or!i%e'

H"ND#IN& "ND STOR"&E/

Non)6a4ardos'

Dr* carbon dioxide can be &andled in mos! common s!rc!ral ma!erials'Mois! carbon dioxide is "enerall* corrosi%e b* i!s #orma!ion o# carbonic

acid' For a$$lica!ions +i!& mois! Carbon Dioxide, ?7:, ? and ?7

s!ainless s!eels ma* be sed as +ell as 6as!ello* A, B, C, and Monel

' Ferros Nic.el allo*s are sli"&!l* ssce$!ible !o corrosion' A! normal

!em$era!res carbon dioxide is com$a!ible +i!& mos! $las!ics and

elas!omers' Use onl* in +ell)%en!ila!ed areas' Carbon dioxide %a$or is

&ea%ier !&an air and +ill accmla!e in lo+ areas' 5al%e $ro!ec!ion ca$s

ms! remain in $lace nless con!ainer is secred +i!& %al%e o!le! $i$ed !o

se $oin!' Do no! dra", slide or roll con!ainers' Use a si!able &and !rc.

#or con!ainer mo%emen!' Do no! &ea! con!ainers b* an* means !o increase

!&e disc&ar"e ra!e o# $rodc! #rom !&e c*linder' Use a c&ec. %al%e or !ra$

in !&e disc&ar"e line !o $re%en! &a4ardos bac. #lo+ in!o !&e s*s!em'

Pro%ide $ro$er $ressre relie# %al%e'

Pro!ec! con!ainers #rom $&*sical dama"e'

area a+a* #rom &ea%il* !ra##ic.ed areas and emer"enc* exi!s' Do no! allo+

!&e !em$era!re +&ere con!ainers are s!ored !o exceed 7(8oF 18( C2'

Con!ainers s&old be s!ored $ri"&! and #irml* secred !o $re%en! #allin" or

bein" .noc.ed o%er' Fll and em$!* c*linders s&old be se"re"a!ed' Use a

1+&


107/111


>#irs! in)#irs! o!> in%en!or* s*s!em !o $re%en! #ll con!ainers bein" s!ored #or

excessi%e $eriods o# !ime'

Ne%er carr* a com$ressed "as c*linder or a con!ainer o# a "as in cr*o"enic

liid #orm in an enclosed s$ace sc& as a car !rn., %an or s!a!ion +a"on'A lea. can resl! in a #ire, ex$losion, as$&*xia!ion or a !oxic ex$osre'

EN&INEERIN& CONTRO#S/

Use local ex&as! !o $re%en! accmla!ion o# &i"& concen!ra!ions so as !o

redce !&e ox*"en le%el in !&e air !o less !&an 7'8 and !&e carbon

dioxide concen!ra!ion belo+ !&e ex$osre limi!'

E$E1-"CE PROTECTION/


108/111


Condi!ions !o A%oid Lon" ex$osre !o ma!erials con!ainin" co$$er,

alminm and s!ron" oxidi4in" a"en!s ma* case discolora!ion'

Incom$a!ible Ma!erials

@ S$!PTO!S O- O'ERE>POSURE/


109/111



110/111


COST ESTI!"TION

An acce$!able $lan! desi"n ms! $resen! a $rocess !&a! is ca$able o#

o$era!in" nder condi!ions +&ic& +ill *ield a $ro#i!'


111/111


Prc&ased ei$men! ins!alla!ion ';9 7@:@98 @9@?7

Ins!rmen!a!ion Process Con!rol '7( 7@:@98 ((;(8

Pi$in" 1ins!alled2 ':: 7@:@98 7(???9

Bildin" 1Incldin"

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CO2 Production

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