The proposed book will be divided into three parts. The chapters in Part I provide an overview of certain aspect of process retrofitting. The focus of Part II is on computational techniques for solving process retrofit problems. Finally, Part III addresses retrofit applications from diverse process industries. Some chapters in the book are contributed by practitioners whereas others are from academia. Hence, the book includes both new developments from research and also practical considerations. Many chapters include examples with realistic data. All these feature make the book useful to industrial engineers, researchers and students.
Autorentext
Gade Pandu Rangaiah, Department of Chemical & Biomolecular Engineering, National University of Singapore, Singapore.
Inhalt
List of Contributors xiii
Preface xv
PART I OVERVIEW
1 Introduction 3
G.P. Rangaiah
1.1 Chemical Process Plants 3
1.2 Process Retrofitting and Revamping 4
1.3 Stages in Process Retrofitting/Revamping Projects 6
1.4 Conceptual Process Design for Process Retrofit/Revamp Projects 8
1.5 Research and Development in Process Retrofit/Revamp 9
1.6 Scope and Organization of this Book 12
1.7 Conclusions 16
References 17
2 Project Engineering and Management for Process Retrofitting and Revamping 19
C.C.S. Reddy
2.1 Introduction 19
2.2 Key Differences between Revamp and Grassroots Designs 20
2.3 Revamp Design Methodology 20
2.4 Project/Process Engineering and Management of Revamp Projects 24
2.4.1 Revamp Objectives and Pre-Feasibility Study 24
2.4.2 Conceptual Design (Pre-FEED) 24
2.4.3 FEED (Front End Engineering Design) 31
2.4.4 Detailed Engineering, Procurement and Construction 33
2.4.5 Project Completion 35
2.5 Key Elements of Project Management 35
2.5.1 Project Schedule 39
2.5.2 Project Execution and Progress Monitoring 39
2.5.3 Project Cost Control 40
2.5.4 Risk Management 41
2.5.5 Final Project Deliverables 41
2.6 Revamp Options for Process Equipment 41
2.7 Conclusions 53
Acronyms 53
References 54
3 Process Safety in Revamp Projects 57
Raman Balajee and C.C.S. Reddy
3.1 Introduction 57
3.2 Lessons from Past Process Safety Incidents 59
3.3 Preliminary Hazard Review during Conceptual Design 60
3.3.1 Risk Matrix for Qualitative Judgments 61
3.3.2 What-If and Process Safety Check Lists 62
3.3.3 Plot Plan and Layout Review 63
3.3.4 Area Classification Reviews 65
3.3.5 Pressure Relief System Considerations 66
3.3.6 Fire Safety for Revamp Projects 72
3.4 Process Hazard Analysis (PHA) 74
3.4.1 Process Plant Hazard Review using HAZOP 74
3.4.2 Failure Modes and Effects Analysis (FMEA) Tool 79
3.4.3 Instrumented Protective System Design 81
3.4.4 Fault Tree Analysis 82
3.4.5 Event Tree Analysis 84
3.4.6 Layer of Protection Analysis (LOPA) 85
3.4.7 Safety Instrumented System (SIS) Life Cycle 88
3.5 Revision of PSI and Operator Induction 88
3.6 Pre-Start-up Safety Review (PSSR) 90
3.7 Management of Change (MOC) 91
3.8 Conclusions 92
Acronyms 93
Exercises 94
References 95
PART II TECHNIQUES FOR RETROFITTING AND REVAMPING
4 Mathematical Modeling, Simulation and Optimization for Process Design 99
Shivom Sharma and G.P. Rangaiah
4.1 Introduction 99
4.2 Process Modeling and Model Solution 101
4.2.1 Process Modeling 101
4.2.2 Model Solution 103
4.2.3 Model for Membrane Separation of a Gas Mixture 104
4.3 Process Simulators and Aspen Custom Modeler 107
4.4 Optimization Methods and Programs 108
4.5 Interfacing a Process Simulator with Excel 112
4.6 Application to Membrane Separation Process 113
4.7 Conclusions 116
Acronyms 116
Appendix 4A: Implementation of Membrane Model in ACM 117
Appendix 4B: Interfacing of Aspen Plus v8.4 with Excel 2013 119
Appendix 4C: Interfacing of Aspen HYSYS v8.4 with Excel 2013 122
Exercises 125
References 125
5 Process Intensification in Process Retrofitting and Revamping 129
D.P. Rao
5.1 Introduction 129
5.1.1 Retrofitting and Revamping 129
5.1.2 Evolution of Chemical Industries and Process Intensification 130
5.1.3 Flow Chemistry 130
5.2 Meth...