CHEMICAL PROCESS DEBOTTLENECKINGAICHE PHILADELPHIA 14 NOVEMBER 2016
CONTENT REFLECTS MY OWN VIEWS, NOT THOSE OF MY EMPLOYER, ARKEMA
05/01/20232
OUTLINE DEBOTTLENECK BACKGROUND ASSESSMENTS– where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES CURRENT PROCESS CAN BE SIMPLIFIED?
DEBOTTLENECK TRICKS AND TRAPS SOLUTIONS – INCREASE EQUIPMENT CAPACITY
INCREASE EQUIPMENT CAPACITY PROCESS SIMPLIFICATION Out of scope: intensification, new technologies,
advanced control PROJECT MANAGEMENT FOR DEBOTTLENECK (REVAMP)
PROJECTSAICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc
05/01/2023
AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc3
OUTLINE DEBOTTLENECK BACKGROUND ASSESSMENTS - where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES
TRICKS AND TRAPS SOLUTIONS
INCREASE EQUIPMENT CAPACITY PROCESS SIMPLIFICATION
PROJECT MANAGEMENT FOR DEBOTTLENECK (REVAMP) PROJECTS
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc4
ECONOMIC AND BUSINESS CLIMATE SUPPORT DEBOTTLENECKING. Plants are running maxed out
Business capacity demands can be incremental, uncertain or insufficient to justify new plant.
Increased competition and modest market growth.
Tight economic times, especially post- recession, make big spending difficult.
Smaller-capacity plants not economical.
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc5
30-YEAR OLD WISDOM “Get more from what we have,” by
upgrading existing facilities instead of building new
Still true after 30 years! L. Cabano, ChemE Progress (1987)“Retrofit Projects – the ultimate management challenge”
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc6
Background debottleneck. Debottleneck =improvements to specific
parts of a plant to increase production by relieving limitations.
Debottlenecking is playing “Moneyball” – Get more production with smart data and experience, not necessarily by spending a lot or “buying a new one.”
Limitations to overcome. Define your problem.
1. Production Losses2. Process capacity
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc7
OUTLINE DEBOTTLENECK BACKGROUND ASSESSMENTS - where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES
TRICKS AND TRAPS SOLUTIONS
INCREASE EQUIPMENT CAPACITY PROCESS SIMPLIFICATION
PROJECT MANAGEMENT FOR DEBOTTLENECK (REVAMP) PROJECTS
05/01/2023
AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc
Know your current production limitations?
Define your real problem. How can you really get more production?
Eliminate Losses (Opportunities) Planned downtime Reliability of units Availability of resources – internal and external Performance - how closely and frequently we run
relative to the Instantaneous, sustainable process capacity
Quality losses Transitions
Increase instantaneous capacity
8
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc9
OEE -operational equipment effectiveness (Williamson 2006)
A 6-Sigma and TPM (total productive maintenance) concept. Variants are TEEP (Total Effective Equipment Performance) OAU (operational asset utilization)
Can do with “pounds lost”, instead of ”time lost.”
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc10
OEE Definitions OEE is a “batting average” comprised of component
batting averages. OEE % :
Availability % x Performance efficiency % x Quality rate %
Availability:(Actual operating time ÷ Gross available time) x 100%
Performance efficiency: (Actual production rate ÷ Design production rate) x 100%
Quality rate: ((Total produced – Off-spec) ÷ Total produced)) x 100 %
Can add other “batting averages” for transitions
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc11
Pareto your losses determine where improvements are needed
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OUTLINE
DEBOTTLENECK BACKGROUND ASSESSMENTS - where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES
TRICKS AND TRAPS SOLUTIONS – INCREASE EQUIPMENT
CAPACITY PROJECT MANAGEMENT FOR
DEBOTTLENECK (REVAMP) PROJECTS
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc13
ASSESS CAPACITY BOTTLENECKS – BATCH PROCESSES Talk to the operators for clues Theory of Constraints (“The Goal,” by Goldratt.)
WIP (work in process) accumulates just ahead of the bottleneck unit.
WIP is scarce downstream of the bottleneck. Time studies on existing process phases. Collect data on
durations of phases of a batch process. Gantt charts (MS project)to depict constraints for batch
processes. (Critical path). Software such as Intelligen, SchedulePro® batch software
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc14
MAP PROCESS UNITS TIMES (Petrides 2007)
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc15
GANTT gives bottleneck critical path (Petrides 2007)
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EQUIPMENT UTILIZATION SHOWS BOTTLENECKS (Petrides 2007)
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ADD CRITICAL EQUIPMENT TO DEBOTTLENECK (Petrides 2007)
CycleTime Reduced13%
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc18
ASSESS CAPACITY BOTTLENECKS – CONTINUOUS PROCESSES Talk to the operators for clues Aspen or other simulator- to check for bottlenecks
when unit ops are well understood. Certain things can’t be predicted by simulators,
Fouling behavior.Catalyst activity.
FRI rating program for distillation towers Well-designed test runs, under representative
conditions. (Texas summer versus winter, for cooling).
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc19
Beware of tricks/traps in assessing bottlenecks I. Hydraulics - Line sizes, Pumps and pump suction
conditions (NPSH) Powder handling systems, including pneumatic
conveying systems Bottlenecks can be right behind each other.
Story moment: Spray dry dryer was bottlenecked by performance of rotary atomizer. Replaced it and found that pneumatic conveying system downstream was limiting, right away.
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc20
Beware of tricks/traps in assessing bottlenecks II.
Assess your Quality – check the quality required by your customer . Sometimes relaxing quality can get more capacity. Story moment: water level in a product. Organic product was dried in process by molecular
sieves which were a bottleneck. It had a very low water level specification, to avoid freezing problems in cold weather applications.
All customers had shifted to use in warm locations on US Gulf Coast.
Water level spec was then relaxed with customer approval, eliminating process bottleneck.
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc21
Beware of tricks/traps in assessing bottlenecks III. (Jaafar 2005) Use Gamma ray scans to assess distillation tower
performance
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc22
Gamma-ray scans of towers
Liquid level on trays
Distillation tower loading: Gamma-ray scans of towers are very helpful.
(Jaafar 2005)
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc23
Gamma-ray scans of towersLiquid level on trays(Jaafar 2005)
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc24
Summarize unit capacities – where are the bottlenecks? (Litzen, Bravo 1999)
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc25
OUTLINE DEBOTTLENECK BACKGROUND ASSESSMENTS - where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES
TRICKS AND TRAPS SOLUTIONS
INCREASE EQUIPMENT CAPACITY PROCESS SIMPLIFICATION
PROJECT MANAGEMENT FOR DEBOTTLENECK (REVAMP) PROJECTS
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc26
INCREASING CAPACITY I. - EQUIPMENT Pumps – sometimes one can replace an impeller in
centrifugal pumps. Trap: Check motor hP and NPSH first!!!
Heat exchangers - Larger, more plates, corrugated tubes, twisted tubes
Trap: If upsizing diameter to get more A, we can reduce shell side velocity and U.
Powder processing – vibrating bottom bins. Steeper bin walls, larger vessels, mass Flow screws.
Story moment: powder feed system for extrusion was under producing. Cohesive powder being fed through 2” bin outlet, 60º angle walls.
Increased to 6” with 70º angle, solved problems
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc27
INCREASING CAPACITY II. - REACTIONS Catalyst modification in catalytic reactors for improved
yield, or selectivity (check tosca) Increasing active concentration in batch reactions. Story
moment: emulsion polymerizations, story time, increase capacity 60% by increasing emulsion activity from 25% to 40%.
Use a separate post treatment vessel, for example to scavenge residual reactant or to wash out impurities.
INCREASING VACUUM DISTILLATION TOWER CAPACITY (from Fair 1996)
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Stepwise debottlenecking of trays operating at low pressureAction Advantages DisadvantagesIncrease pressure More capacity
No column changesLower relative volatilityHigher temperatures
Decrease hole size More capacity New tray panelsChange style of tray (e.g., to Nye, MD=multiple downcomer)
More capacity New tray panelsPossible downcomer modificationsPossible increase in # of trays and support rings
Switch to structured packing
More capacity, if larger crimp heightLower pressure drop
Cost of packing and attendant hardwareCost of removing trays and tray rings
Install new high-capacity device(e.g., cocurrent tray)
More capacity Higher pressure dropCost of new deviceCost of removing old trays and possibly tray rings
INCREASING PRESSURE DISTILLATION TOWER CAPACITY (Fair 1996)
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Stepwise debottlenecking of trays operating at high pressureAction Advantages DisadvantagesEnlarge downcomers and increase open area
More capacity Loss of active areaCost of modifications
Change style of tray (e.g., to MD)and decrease tray spacing
More capacity Lower efficiency; need more traysCost of new traysCost of removing old trays and some tray rings
Switch to larger-size structured packing
More capacity Lower efficiencyCosts of removing and replacing packing
Install new high-capacity device
More capacity Higher pressure dropCost of new deviceCost of removing old device
IMPROVED PROCESS CONTROL
Shorten transitions Stabilize process & operate closer to our
capacity limits Operate closer to our quality limits
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Further equipment debottleneck modes (Rangaiah 2016)
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Equipment/System Debottleneck modePneumatic system -increase capacity
Change air velocity, air-to-solid ratio, blower speed, screw or rotary valve speed
Centrifugal compressors
Modify internals, including rotor; increase speed
Conveying fans Install bigger impeller and/or additional fans in parallel.Reduce pipe/duct pressure losses
Fin-Fan coolers Increase fan pitch angle and/or fan speed,reduce tip clearances, install inlet bells,fan seal disk and/or high
Mixers Use static mixers or high-shear rotary disperser to retrofit/replaceexisting tank mixers.
Vacuum systems Install pre-condensers cooled withcooling/chilled water. Use multi-stage steam ejectors arranged in series/series- parallel arrangement.
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc32
OUTLINE DEBOTTLENECK BACKGROUND ASSESSMENTS - where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES
TRICKS AND TRAPS SOLUTIONS
INCREASE EQUIPMENT CAPACITY PROCESS SIMPLIFICATION
PROJECT MANAGEMENT FOR DEBOTTLENECK (REVAMP) PROJECTS
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc33
Process Simplification
Ways to simplify process, using ingenuity with minimal technology risk?
Can challenge the accepted norms? Parallel reactor usage, instead of series. Story
moment: Two reactors in series for polymer line converted to parallel, doubled plant capacity for very low investment.
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Reactor 1Conversion
Monomer 2
Monomer 1
InitiatorContinuous
flow reactors in series
Reactor 2Residual scavenging
Radical Scavenger
Devolatilizer
Reactor 1
Monomer 1
Initiator + Scavenger
Reactor 2
Devolatilizer
Monomer 2
Continuous flow reactors
in parallel
Doubled Production byPutting 2PolymerReactors in Parallel Instead of Series
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INCREASING CAPACITY IIIa.- Feeds
BATCH POWDER BLENDER
Powder 1
Powder 2
Liquid ingredient
Batch feedSingle Screw Extruder
Manual loading to
powder blender
Pharmaceutical dispersion made from single screw extrusion, melting down and making micro droplets out of a powder blend. Team replaced the 2 step operation by a single-step compounding and meltdown in a twin screw extruder.
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INCREASING CAPACITY IIIb.- Feeds
Twin Screw Extruder
Continuous feed to
extruder
Mass flow powder feed
Powder 1
Mass flow powder feed
Powder 2
Liquid pump
Liquid Ingredient
Eliminate powder blender. Use Twin-screw, doubled capacity and improved quality & ergonomics
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc37
OUTLINE DEBOTTLENECK BACKGROUND ASSESSMENTS - where’s your problem?
CURRENT PRODUCTION LOSSES CURRENT VS FUTURE UNIT CAPACITIES
TRICKS AND TRAPS SOLUTIONS
INCREASE EQUIPMENT CAPACITY PROCESS SIMPLIFICATION
PROJECT MANAGEMENT FOR DEBOTTLENECK (REVAMP) PROJECTS
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AICHE Phila, 14 November 2016. Content reflects author’s views, not those of Arkema Inc38
What’s different about debottleneck projects? I. Debottleneck projects build onto/into all the sins of the past. Heavy dependence on accurate facility data for existing
plant. Requires extensive field verifications of what’s in the
plant (drawings, manuals, specifications and performance histories). But! Sometimes our surveys can’t access easily what’s already there, OR it’s under insulation.
Need to have good drawings, PIDs, ISO drawings. Most plants don’t have them up to date. Need a budget for this prework!
Laser scans of piping can be useful. (Image from PTQ)
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Laser scanning of piping (Smith 2015)
SCAN THE PLANT
CONVERT POINT CLOUD INTO 3D MODEL
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What’s different about debottleneck projects? II. The existing plant is a stakeholder. Heavy dependency on
cooperation with existing plant leadership, and their production plan.
Usually the work is constrained to a short period. If performing work during an overall plant shutdown, integrate the work into an overall project plan for the plant’s work.
Budget for plant staff time in the project – it’s extensive. Budget for staff, time, budget and responsibilities for pre-
cleaning the equipment. Account for any waste disposal. Budget & plan for inclusion of the modifications into existing
plant’s IT systems and databases, such as maintenance and mechanical integrity.
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Debottleneck Project Traps I. Be sure to define a good owner scope agreement,
detailing what plant problems WILL be fixed and what WON’T. If adding a new unit, will you fix the problems
with the old one? Will you demolish or mothball in place?
Constructibility studies are key. Piping, utilities conflicts, safety (working near other work), available space, laydown areas, use of existing foundations.
3D CAD models are indispensable for revamp projects
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Debottleneck Project Traps II. Be wary of condition od existing, mothballed equipment.
Plant may say “we have another one available.” Cleaning, MI inspection Check last performance. Budget for the above
Lots of carbon steel out there; modification can be difficult. Story moment: Carbon steel, versus stainless steel
in new lines. Carbon steel was cheaper, but with the pre and post-weld heat treatment needed, it cost more in these services and delays waiting.
Pipe replacements go flange to flange when possible. Modification of vessels can take time:
Rerating vessels for new conditions takes time. Code approvals for modifications also require time.
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Debottleneck Project Traps III.
Harder to estimate cost. No simple costing “rules of thumb,” such as 4x to
8x major equipment cost More contingency. More engineering, per $ of capital cost. Add productivity allowances for labor, in such
projects. Add allowances (in cost and schedule) for field
adjustments and fit-up. Check everything and communicate the scope well
to your EPC.
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Scope must include OSBL and HES Utilities - water, air, steam, and probably most important
electrical power. Include logistics and packaging, storage, filling systems. Check your environmental permitting implications for the
new capacity! Incorporate into the project plan. Enviro abatement systems need to be checked. Safety systems need to be checked. Reliefs need to be
checked. Watch you’re not operating too closely to relief points and rupture discs burst points. (Rupture pin, instead of disc, can be useful)
Facility siting (safety) studies, if adding new storage. Story moment: OSHA auditee was required to show all past
capacity increases and show verifications that the relief valves were checked each time.
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DISCUSSION AND QUESTIONS
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REFERENCES and Further ReadingJoseph C. Gentry, Succeed at Plant Debottlenecking, Chemical Processing, Mar 10, 2004. A basic introduction with specific examples.S. Ottewell, Debottlenecking Takes A Broader View, Chemical Processing, April 18, 2011. Treats use of simulation.Hans-Jürgen Bittermann, Dr. Jörg Kempf, Debottlenecking: Exploiting Opportunities to Boost Performance, Process Worldwide.com, 10/17/2014, downloaded 24 Sept 2016.D .F. Schneider, Debottlenecking Options and Optimization, white paper of 1997, downloaded 24 Sept 2016. Manganaro, J. L. Estimate the Capacity of Simple Batch Processes. Chemical Engineering Progress, 98(8): 70-75, August 2002.GP. Rangaiah, Chemical Process Retrofitting and Revamping, Wiley, 2016.N. P. Lieberman, Process Engineering for a Small Planet, Wiley 2010.Litzen and Bravo, “Uncover low-cost debottlenecking opportunities,” CHEMICAL ENGINEERING PROGRESS • MARCH 1999L. J. Cabano, Retrofit projects: the ultimate management challenge, Chemical engineering progress, 1987, vol. 83, no 4, pp. 27-31Fair, J. R., and A. F. Seibert, “Understand Distillation-Column Debottlenecking Options,” Chemical Engineering Progress, 92, (6), p. 42 (June 1996).Seiichi Nakajima, “Introduction to TPM and TPM Development Program,” Japan Institute for Plant Maintenance 1988. Translated into English, Productivity Press, ShopFloor Series, called “OEE for Operators.”Pablo F. Navarrete, William C. Cole, Planning, Estimating, and Control of Chemical Construction Projects, Second Edition, CRC press, 2001Distillation-How to Push a Tower to Its Maximum Capacity: Proper analysis and operating adjustments help boost separation capacity without increasing flooding, Simon X. Xu, Charles Winfield, John D. Bowman Tru-Tec Services, Inc.; Shelley, Suzanne. Chemical Engineering105.8 (August, 1998): 100.G. Towler, R. Sinnott, Chemical engineering design : principles, practice, and economics of plant and process design, 2nd ed., Elsevier (2013)D. H. Stamatis, “The OEE Primer: Understanding Overall Equipment Effectiveness, Reliability, and maintainability” CRC Press, 2010.R. Ogle and A. Carpenter, Chemical Engineering Progress August 2014, Calculating the capacity of chemical plants.Al-Zahrani; Bright, S; Roy, E; S.. Debottleneck crude-unit preheat exchanger network inefficiencies.Hydrocarbon Processing (Feb 2012).M. Smith, Laser scanning for revamps, PTQ, 39-43, 2015Petrides et al, “OPTIMIZE MANUFACTURING OF PHARMACEUTICAL PRODUCTS WITH PROCESS SIMULATION AND PRODUCTION SCHEDULING TOOLS,” Chemical Engineering Research and Design Trans IChemE, Part A, July 2007Jaafar, HYDROCARBON ASIA, JAN/FEB 2005, “Gamma-ray scanning for troubleshooting,….”M. Smith, “Laser Scanning for Revamps” PTQ 2015