مراجعة امتحان الهندسة الكيميائية

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I am a Chemical Engineer

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I am a chemical engineer
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2014
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PONA
.1
.2
.3
.4
P

O
.
N
.
A
.
API gravity
The American Petroleum Institute gravity, or API
gravity, is a measure of how heavy or light
a petroleum liquid is compared to water. If its API
gravity is greater than 10, it is lighter and floats on
water; if less than 10, it is heavier and sinks.
..

ASTM TBP true boiling point
%5
%10
ASTM TBP


:
.1 " " Separation
.2 " " Conversion
.3 Treatment

.
.

( 48 )
() -

32
65
150
()
130
270
200
400
250
480
300
570
330
620
370
700
()
400 759
- Desalter -
.

" "
. "
" .

.

.

: .
. 20 > -

.
Atmospheric -
- Distillation unit .
feedstock
650 700

(

)
- - .
. -
10
Vacuum -
- Distillation unit
.

residuum

demister .

11
Hydrotreater -
-Naphtha (
)
.
90
.

.
.

12
-Catalytic reformer -
-
( ) .

.

.

.
13
Distillate -
-Hydrotreater
.

.
()(FCC) -
Fluid Catalytic Cracker
( ) (
) .
() - - (
) ( )
.
14
-Hydrocracker -
( )
( ).
15
- Visbreaking -

( )

16
- delayed coking unit

.
17
Base Oil Production

. -
18

-
( (MEK
.
-Merox -

( )
( ).
19
Alkylation - -

-Dimerization -

.
20
-Isomerization -

.
( )Hydrogen -
Production
.
- - 80
.

()CO2

21
- Vapor Recovery

.
( )Amine gas -
- treater, Claus unit
( )H2S

22
-:
:
.1
.2
.3
Pumps
Compressors
turbine
:
.1
.2
.3
.4
.5
.6
Heaters
Boilers
Towers
Vessels
Storage tanks
Heat exchangers
23
:

.
24
Method of heat transfer

.1 Radiation

.
.2 Convection
.3 Conduction

.
.
25
:
.1
.2
.3
.4
.5
.6

( )

.1
Temperature difference
.2 Thermal
Conductivity

.
K
.
26
:
.3 surface area
Thickness
.4
.5
Residence time
.6 Flow direction

Counter current
parallel current
27
:
Counter current

.
Parallel current

.
28

shell and type exchanger
: : Fixed Head Exchanger

65 .
: Floating head
: exchanger

floating head

... : : U
U

SHELL

REBOILERS
.
29

30

31
condenser

partial & total condenser

condenser
.1
.2

condenser
:
32

cooler VS condenser

phase
phase

Reboilers

Debutanizer tower
Absorber
.
:
.1 Thermosyphon reboiler
.2 Kettle
Steam
33
Reboilers
.1
.2
: Thermosyphon
reboiler

.
: Kettle

( , ,)

- -
( )

()
.

.
34
Reboilers
35
fire heater
5
.1 ..
.2 ..
.3 ..
.4 ..

.5 .. ( )

:
: :
.1
.2 steam
reformer
.3
:
.1
.2
:
36
fire heater
:

:
.1 radiation
..
.2 convection
flue gas ..

.3

shield
zone
37
fire heater
38
fire heater
39
PUMPS
) (PUMP
) (COMPRESSOR

40
compressors

Positive Pumps

Dynamic pumps
41
Storage Tanks types

:
.1 Small tk < 2000 m3 < large tk :
.2 Hot & cold tanks :
.3 :

.4 :
( ).
( )
.5 :
* >> - .
Fixed roofs - Cone roofs - Standard
* >> Floating
roofs
*
* Spheroids
* Spheres
.
:
( : )
( : )
( : )
42
Fixed Roof Tanks

:
.1 Cone fixed roof tank .
.2 Flat fixed roof tank .
.3 Aluminum dome roof
.4 Umbrella fixed roof tank
.
:
.1 : -
.2 :
.3 : Flash family
(-130
0 )140
.
: Advantages
.1 .
.2 / /.
.3 Safety.
: Disadvantages
.1 .
.2 .
.3
(+ +)
.4 .
43
44
45
Floating Roof Tanks
:
(dn < 20m) Pan
(dn 50m) Single deck
(dn > 50m) Double deck
*** :

( flash
) less family :
.
: Advantages
1. ()Close System
2. Safety.
.3 .
: Disadvantages
.
/ /.
46
47
48

Fixed Roof with internal floating roof

MTBE
. :
.1 ......
.2 .

MTBE
.
49
Pressure Storage

.
.

50

.
500 . Dip
. Uallage
.1 gauge Dip.
"- ".
zero plate .
.2 . gauge Uallage

.
51
separators
vertical VS horizontal
horizontal
.1
.2
.3
.4
.5

three phase

vertical
5

head
separator

52
53
Tower Sections

rectifying stages : The upper two stages .1
stripping stages : These below the feed .2

sripping
54
crude distillation of products across

temp. range and specific gravities
Butane and lighter gas
90 oF
32 oC
specific
gravities
Straight run Gasoline
80 220 oF
32 104 oC
Naphtha
220 315 oF
104 157 oC
0.68 - 0.74
0.7 - 0.76
0.78 - 0.82
Kerosene
315 450 oF
157 232 oC
Light Gas oil
450 650
232 343 oC
0.835 0.87
oF
Heavy Gas oil
0.86 - 0.89
650 800 oF
343 427 oC
Straight run redidue
0.94 0.98
+800 oF oR +427 oC
55
56
57

demister

strainer
58
59

weir

weir
downcomer

()
foaming
60

cavitaion

61

There are other methods of separation used in a
refinery for example, extraction with a solvent,

crystallization, and absorption.
gab & overlap

Gap :

.
Overlap :
.

.
62

jet ejector vacuum pump

continuity equation and bernoulli equation
63
64
Equilibrium Stage :
is defined as any portion of the distillation column
such that the liquid and vapor leaving it have

composition similar in equilibrium with each other.
Kinds of Reflux
Cold Reflux .1

latent and sensible
heat

Hot Reflux .2

latent heat

Internal Reflux .3

hot reflux

latent heat
65
Kinds of Reflux
Circulating Reflux .4
pumparound

2
4
sensible heat

Side Reflux .5
circulating reflux

PUMPAROUND
66

1. REFLUX RATIO
2. TEMPERATURE GRADIENT
REFLUX RATIO
The amount of reflux compared to the product is

known as the 'Reflux Ratio'.
_____________________________________
..

67
REFLUX RATIO
When reflux ratio is increased, the amount of reflux
increases. The top product will therefore be purer.
In general, the higher the reflux ratio, the fewer the
number of trays required for a given separation.
However, too high a ratio may cause flooding in the
tower resulting in poor separation and causing 'offspec' products throughout the system.
The reflux rate is normally controlled by a
temperature controller in the vapour outlet which
operates a control valve in the reflux pump
discharge. An increase in tower top temperature will
cause the valve to open, increasing the reflux rate,
and vice versa.
_____________________________________
Two points to consider
1. A minimum number of plates (stages) required at
total reflux.
2. There is a minimum reflux ratio below which it is
impossible to obtain the desired enrichment
however many plates are used.
_____________________________________
68
REFLUX RATIO
Total Reflux
Total reflux is the conclusion when all the condensate
is returned to the tower as reflux, no product is taken
off and there is no feed.

_____________________________________
Minimum Reflux
At minimum reflux, the separation can only be
achieved with an infinite umber of stages. This sets
the minimum possible reflux ratio for the specified
separation.
_____________________________________
Optimum Reflux Ration
Practical reflux ratio will lie between the minimum for
the specified separation and total reflux. The
optimum value will be the one at which the specified
separation is achieved at the lowest annual cost
(steam or vapor). For many systems, the optimum
value of reflux ratio will lie between 1:2 to 1:5 times
the minimum reflux ratio.
69
TEMPERATURE GRADIENT

reboiler feed

if feed and bottom temperatures are too high, too
much heavy vapour will rise up the tower and put
side-stream products off-spec. This condition,
combined with high reflux rate will again lead to
flooding and poor separation. Opposite conditions
can lead to liquid starvation across the trays and
again, a very upset process will result.
Remember, changes in pressure will affect the
boiling points of the components in the crude oil.
The vapour pressures therefore, will also be
affected and again, if the control parameters are
incorrect, the system will be inefficient.
_________________________
Examples:
High top temperature will result in heavy
components in the overhead product.
Low top temperature will result in a lighter top
product.
70
High feed temperature will give heavier side
streams and vice-versa.

High reboiler temperature will produce heavier
bottoms product and pass heavier vapours up the
tower to affect the side-streams.
Increased pressure in the system will give lighter
components in the overhead LIQUID product and
decrease its Initial Boiling Point, whereas the FBP
is governed by the tower top temperature.
Also, with regard to the purity of the side-streams,
control of the stripping towers' steam supply is very
important.
A further point is, that high water content in the
crude feed will cause pressure surges as the water
vaporises in the tower. The crude oil should be as
water free as possible.
71
72
73
Adverse vapour flow conditions can

cause
Foaming
Foaming refers to the expansion of liquid due to
passage of vapour or gas.

Although it provides high interfacial liquid-vapour
contact, excessive foaming often leads to liquid
buildup on trays.
Foaming will occur depends primarily on physical
properties of the liquid mixtures, but is sometimes
due to tray designs and condition. Whatever the
cause, separation efficiency is always reduced.
74

cause
Entrainment
Entrainment refers to the liquid carried by vapour
up to the tray above and is again caused by high

vapour flow rates.
It is detrimental because tray efficiency is reduced:
lower volatile material is carried to a plate holding
liquid of higher volatility. It could also contaminate
high purity distillate.
Excessive entrainment can lead to flooding.
75

cause
Flooding
Flooding is brought about by excessive vapour
flow, causing liquid to be entrained in the vapour up

the column.
The increased pressure from excessive vapour
also backs up the liquid in the downcomer, causing
an increase in liquid holdup on the plate above.
76

cause
Weeping/Dumping
This phenomenon is caused by low vapour flow.
The pressure exerted by the vapour is insufficient
to hold up the liquid on the tray. Therefore, liquid

starts to leak through perforations.
Excessive weeping will lead to dumping. That is the
liquid on all trays will crash (dump) through to the
base of the column (via a domino effect) and the
column will have to be re-started.
77

cause

500

78
Sour gas sweetening

()

absorber column

stripper column or
desorber column

absorber
stripper

( )
79

stripper column or desorber
column
80
81
82
adsorption

Molecular Sieves

adsorption

regeneration
dehydration
silica gels

83
84
membranes

membranes

85
reynold number
fluid

Viscosity decrease with temperature increase
(liquid(
Viscosity increase with temperature increase (gas(
86
:
indicator sensor
pressure indicator or flow indicator :
:
transmitter
: controller

feedforward control
feedback control

cascade control

cascade feedback
feedforward
87
88
refrigeration cycle

1 2
shell
tube

2 3

3 4

4 1

joule thomson valve

89
refrigeration cycle
90

1.
2.
3.
4.
5.
6.
7.
8.
Quality control over distillation products is

maintained by setting specifications for these
products.
An initial boiling point test identifies the presence
of light hydrocarbons.
An end point test identifies heavy hydrocarbons.
The temperature at which a petroleum product
generates ignitable vapors is called the flash
point.
Light hydrocarbon products have relatively high
API gravity readings. Reduced crude has a
relatively low API gravity reading.
Whatever material enters a tower as feed leaves
the tower as products.
You can increase the temperature in a crude
column by increasing the feed temperature or
decreasing the reflux rate.
A temperature increase means that products get
heavier.
91

Cut point changes are made on distillation
products by adjusting the heat balance inside a
tower.
cut
160 270

290

140

10. You can decrease the temperature in a crude
column by decreasing the feed temperature or
increasing the reflux rate.
11. A temperature decrease means that products get
lighter.
9.
92

12. When the tower temperature increases, the
amount of overhead product produced increases

and the amount of bottom product formed
decreases.
13. When the tower temperature decreases, the
amount of overhead product produced
decreases and the amount of bottom product
formed increases.
14. When we close a stripper draw on the side of a
crude unit more reflux flows to the trays below
the draw-off tray.

93

API
94
..

https://www.youtube.com/watch?v=Z6CJ909lEcA&i
ndex=3&list=PLRKcHnkA6shd8SN18Z0rO8baDQjo
1butg

https://www.youtube.com/watch?v=WDxJhONYuR
E&index=7&list=PLRKcHnkA6shd8SN18Z0rO8baD
Qjo1butg

https://www.youtube.com/watch?v=rhUTp8JXDYk&
index=8&list=PLRKcHnkA6shd8SN18Z0rO8baDQj
o1butg

https://www.youtube.com/watch?v=pFUtVMXCuLQ
&feature=youtu.be
jet ejector
https://www.youtube.com/watch?v=N7pGkkVAMKo
Refining Primer - Table of Content
http://www.setlaboratories.com/Resources/Refining
/tabid/57/Default.aspx
95
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مراجعة امتحان الهندسة الكيميائية

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- delayed coking unit

Base Oil Production

Method of heat transfer

Storage Tanks types

Fixed Roof Tanks

Floating Roof Tanks

crude distillation of products across

Straight run Gasoline

Heavy Gas oil

Straight run redidue

refinery for example, extraction with a solvent,

gab & overlap

such that the liquid and vapor leaving it have

The amount of reflux compared to the product is

streams and vice-versa.

Adverse vapour flow conditions can

passage of vapour or gas.

Adverse vapour flow conditions can

up to the tray above and is again caused by high

Adverse vapour flow conditions can

flow, causing liquid to be entrained in the vapour up

Adverse vapour flow conditions can

to hold up the liquid on the tray. Therefore, liquid

Adverse vapour flow conditions can

Sour gas sweetening

Quality control over distillation products is

amount of overhead product produced increases

Thank You For Your Time

Connecting chemical engineers

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