Steam optimization

The thermal profile through the reactor will in most circumstances be carefully optimized to maximize selectivity, extend catalyst life, etc. Because of this, direct heat integration with other process streams is almost never carried out. The heat transfer to or from the reactor is instead usually carried out by a heat transfer intermediate. For example, in exothermic reactions, cooling might occur by boiling water to raise steam, which, in turn, can be used to heat cold streams elsewhere in the process. 

Given a network structure, it is possible to identify loops and paths for it, as discussed in Chap. 7. Within the context of optimization, it is only necessary to consider those paths which connect two different utilities. This could be a path from steam to cooling water or a path from high-pressure steam used as a hot utility to low-pressure steam also used as a hot utility. These paths between two different utilities will be designated utility paths. Loops and utility paths both provide degrees of freedom in the optimization. ... 

In a single stage, without liquid recycle, the conversion can be optimized between 60 and 90%. The very paraffinic residue is used to make lubricant oil bases of high viscosity index in the range of 150 N to 350 N the residue can also be used as feedstock to steam cracking plants providing ethylene and propylene yields equal to those from paraffinic naphthas, or as additional feedstock to catalytic cracking units. 

Single-reaction-step processes have been studied. However, higher selectivity is possible by optimizing catalyst composition and reaction conditions for each of these two steps (40,41). This more efficient utilization of raw material has led to two separate oxidation stages in all commercial faciUties. A two-step continuous process without isolation of the intermediate acrolein was first described by the Toyo Soda Company (42). A mixture of propylene, air, and steam is converted to acrolein in the first reactor. The effluent from the first reactor is then passed directiy to the second reactor where the acrolein is oxidized to acryUc acid. The products are absorbed in water to give about 30—60% aqueous acryUc acid in about 80—85% yield based on propylene. 

The first-stage catalysts for the oxidation to methacrolein are based on complex mixed metal oxides of molybdenum, bismuth, and iron, often with the addition of cobalt, nickel, antimony, tungsten, and an alkaU metal. Process optimization continues to be in the form of incremental improvements in catalyst yield and lifetime. Typically, a dilute stream, 5—10% of isobutylene tert-huty alcohol) in steam (10%) and air, is passed over the catalyst at 300—420°C. Conversion is often nearly quantitative, with selectivities to methacrolein ranging from 85% to better than 95% (114—118). Often there is accompanying selectivity to methacrylic acid of an additional 2—5%. A patent by Mitsui Toatsu Chemicals reports selectivity to methacrolein of better than 97% at conversions of 98.7% for a yield of methacrolein of nearly 96% (119). 

The efficiency of the Rankine cycle itself can be increased by higher motive steam pressures and superheat temperatures, and lower surface condenser pressures in addition to rotating equipment selection. These parameters are generally optimized on the basis of materials of constmction as well as equipment sizes. Typical high pressure steam system conditions are in excess of 10,350 kPa (1500 psi) and 510 °C. 

Thermal isomerization of a-pinene, usually at about 450°C, gives a mixture of equal amounts of dipentene (15) and aHoocimene (16) (49,50). Ocimene (17) is produced initially but is unstable and rearranges to aHoocimene, which is subject to cyclization at higher temperatures to produce a- and P-pyronenes (18 and 19). The pyrolysis conditions are usually optimized to give the maximum amount of aHoocimene. Ocimenes can be produced by a technique using shorter contact time and rapid quenching or steam dilution (51). 

Whereas polyisobutylene and butyl mbber exhibit chain cleavage on free-radical attack, halobutyls, particulady bromobutyl and CDB, are capable of being cross-linked with organic peroxides. The best cure rate and optimal properties are achieved using a suitable co-agent, such as y -phenjiene bismaleimide. This cure is used where high temperature and steam resistance is required. 

While process design and equipment specification are usually performed prior to the implementation of the process, optimization of operating conditions is carried out monthly, weekly, daily, hourly, or even eveiy minute. Optimization of plant operations determines the set points for each unit at the temperatures, pressures, and flow rates that are the best in some sense. For example, the selection of the percentage of excess air in a process heater is quite critical and involves a balance on the fuel-air ratio to assure complete combustion and at the same time make the maximum use of the Heating potential of the fuel. Typical day-to-day optimization in a plant minimizes steam consumption or cooling water consumption, optimizes the reflux ratio in a distillation column, or allocates raw materials on an economic basis [Latour, Hydro Proc., 58(6), 73, 1979, and Hydro. Proc., 58(7), 219, 1979]. 

A range of industrial steam turbines with a ehoiee of reaetion and impulse blading are available to satisfy these needs. They virtually guarantee an optimal solution to the various problems eneountered when eombining eompressors, expanders, and turbines to form an effieient, reliable nitrie aeid train. A typieal train is depieted in Figure 4-26. 

The great dependenee of NO formation on temperature reveals the direet effeet of water or steam injeetion on NOx reduetion. Reeent researeh showed an 85% reduetion of NOx by steam or water injeetion with optimizing eombustor aerodynamies. 

Once the highest steam level is set, then intermediate levels must be established. This involves having certain turbines exhaust at intermediate pressures required of lower pressure steam users. These decisions and balances should be done by in-house or contractor personnel having extensive utility experience. People experienced in this work can perform the balances more expeditiously than people with primarily process experience. Utility specialists are experienced in working with boiler manufacturers on the one hand and turbine manufacturers on the other. They have the contacts as well as knowledge of standard procedures and equipment size plateaus to provide commercially workable and optimum systems. At least one company uses a linear program as an aid in steam system optimization. 

Process steam requirements and driver steam requirements can be optimized. 

Optimization of the pressing process, e.g. by increasing the effect of the steam shock by (1) increased press temperatures, (2) additional steam injection, or (3) an increased gradient in the moisture content difference between surface and core layer. 

A common process task involves heating a slurry by pumping it through a well-stirred tank. It is useful to know the temperature profile of the slurry in the agitated vessel. This information can be used to optimize the heat transfer process by performing simple sensitivity studies with the formulas presented below. Defining the inlet temperature of the slurry as T, and the temperature of the outer surface of the steam coil as U then by a macroscopic mass and energy balance for the system, a simplified calculation method is developed. 

Determine the optimal steam ratio (kg steain/kg ethylbenzene) that should be used in the styrene reactor in order to maximize the economic potential of the process. 

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