55
Evaporative Concentration of a Thermally Sensitive Chemical Chen 4450 Process Safety Auburn University November 27, 2006 Guest Speaker Robert D’Alessandro, P.E. Director of Process Engineering Degussa Corporation

Evaporative Concentration of a Thermally Sensitive Chemicalchambro/Chen 4450 Lecture Presentation Rev B... · Factor 10,840 Bottom Line = Heat Loss Small Scale Has It Large Scale

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  • Evaporative Concentration of a Thermally Sensitive Chemical

    Chen 4450 Process SafetyAuburn UniversityNovember 27, 2006

    Guest SpeakerRobert D’Alessandro, P.E.Director of Process EngineeringDegussa Corporation

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Introduction

    Five Main Principles of Inherently Safer Chemical Plants:

    Limitation of Effects

    Use equipment fit for its service

    Webster: Existing in something as an inseparable element.

    Synonyms: Innate, native, inbred, ingrained

    Substitution

    Use safer chemicals

    Simplification

    Use less complexity

    An Integral Part Of

    Attenuation or Moderation

    Use the least hazardous conditions

    Intensification or Minimization

    Use less hazardous chemicals

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Lecture Objectives

    Recognizing potential reactivity problems

    Safety aspects of connected equipment

    Safety instrumented systems

    Adiabatic calorimeters for obtaining proper data

    Gassy systems versus tempered systems

    Vapor-liquid disengagement in vessels

    Two-phase venting versus “all vapor” venting

    Introduction to the following process safety related concepts:

    Reactive System

    Pressure Relief

    ExampleEvaporative

    Concentration of a

    Thermally Sensitive ChemicalIntegrating process safety into process design

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Process Flow Diagram - RA 2nd Stage Concentration

    Steam60 psig

    Z-100Three Stage Steam

    Jet Vacuum System

    Chilled Water5 C

    T

    70 wt% RAFrom 1st StageConcentration

    Steam150 psig

    Process OffgasTo Thermal Oxidizer

    90 wt% RATo Crystalazer Chilled Water

    5 C

    Process CondensateTo Treatment

    Note 1: Barometric LegNote 2: Equilization LineNote 3: 3 Barometric Legs

    P

    L

    L

    RO

    F

    T

    R-100

    P-100

    A-100X-100

    V-101

    P-101

    X-101

    83 C

    70 C

    15 C

    20 C

    20mmHgA

    2,500 PPH

    1,944 PPH

    Cond.

    250 PPH

    806 PPH

    10mmHgA

    16.7psia

    16.7psia

    1 32

    575,200Btu/hr

    308,800Btu/hr

    21.7 C

    15.2 C

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Signs of Inherent Trouble

    “70 wt% RA begins, at what the chemists describe as, a slow decomposition when temperatures exceed 120 °C.”

    Be suspicious of “normal” laboratory data

    “The chemists also noted some foaming when this slow decomposition occurred.”

    Hints from Chemists or Operators

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Signs of Inherent Trouble

    MSDS – Material Safety Data Sheet:Excellent source of general safety information

    OSHA type data is good – hygiene, PPE, medical, fire fighting, etc.

    Physical property data is usually good

    “MSDS for 70 wt% RA also indicates this temperature limit.”

    However, my experience indicates:Reactivity data is lacking and sometimes wrong

    Better now then in the past, but still needs improvement

    Better for common petrochemicals then for specialty chemicals

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Signs of Inherent Trouble

    The hints from the chemists tell us that additional data is needed.

    What kind of data?

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Laboratory Scale Data

    Consider:A typical organic fluid at 80 °C in some container

    Surrounded by still air at 20 °C

    Factor 10,840

    Bottom Line = Heat Loss

    Small Scale Has It

    Large Scale Doesn’t

    ?? WHY ??

    Laboratory Heat LossEquipment Btu / Hour / Lb

    Test Tube10 ml

    Beaker100 ml

    Cooling Rate°C / Minute

    0.09

    0.06

    542

    341

    Full Scale Heat LossEquipment Btu / Hour / Lb

    Reactor660 gallons

    Reactor6600 gallons

    0.048

    0.004

    4.6

    0.05

    Cooling Rate°C / Minute

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Surface Area to Volume Ratio

    0.0

    1.0

    2.0

    3.0

    4.0

    5.0

    6.0

    7.0

    8.0

    0.001 0.010 0.100 1.000 10.000 100.000 1000.000

    Volume (Gallons)

    Surf

    ace

    Are

    a / V

    olum

    e (S

    F/G

    allo

    n)

    L / D = 1

    L / D = 4

    3.8 ml 38 ml 380 ml 3800 ml (S/V)Lab Scale >>> (S/V)Commercial Scale

    Heat Generation ~ Volume of Contents

    Heat Loss ~ Surface AreaSmall Scale Experiments Must

    Eliminate Heat Loss

    Surface AreaVolume Volume Ratio

    10ml

    100ml

    1000gallons

    5000gallons

    124

    57

    2

    1

    10.5

    4.9

    0.145

    0.085

    Laboratory Scale Data

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Laboratory Scale Data

    Two Forms of Heat LossBoth are magnified by large surface to volume ratios

    Heat loss to the sample container caused by thermal capacity of test cell.

    CapacityCarryingHeatSampleCapacityCarryingHeatSystem

    ≡Φ Phi Factor

    tpftf

    pbb

    tpftf

    pbbtpftf

    CmCm

    CmCmCm

    +=+

    ≡Φ 1

    If ThenTUAQ Δ=

    Heat loss to surroundings caused by temperature difference .

    0=ΔT 0=Q

    Decrease Test Cell Mass

    Increase Sample Mass

    Commercial Vessel Phi Factor = 1.05 to 1.10Goal for Small

    Scale Equipment

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic Calorimeters

    ARC – Accelerating Rate Calorimeter

    Invented by D.I. Townsend at Dow Chemical in the late 1970s

    Solved the ΔT problem

    But not the thermal inertia problemHeavy Wall Test Cell

    Containment T

    Sample T

    Heating Elements

    Containment Vessel

    Can not track very fast reactions

    Very sensitive at low reaction rates

    Still has important applications

    High Thermal Inertia Adiabatic Calorimeter

    Phi Factor: 2.0 ≤ Φ ≤ 4.0

    Heavy wall test cell

    Built to withstand internal pressure

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic CalorimetersLow Thermal Inertia Adiabatic Calorimeters

    Invented by DIERS in the early 1980s

    Solved the ΔT problem

    Solved the thermal inertia problem

    Can track very fast reactions

    Not sensitive at low reaction rates

    Phi Factor: 1.05 ≤ Φ ≤ 1.15

    Thin wall test cell

    Pressure compensation prevents test cell rupture

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic CalorimetersLow Thermal Inertia Adiabatic Calorimeters

    Containment vessel isolation ball valve

    Containment Vessel Pressure Transducer

    Test Cell Pressure Transducer

    “Super”Magnetic Stirrer

    Auxiliary Fill Line

    Rupture Disk(1900 psig)

    3-Way ValveFilling Test Cell

    or Pressure Equalization

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic CalorimetersLow Thermal Inertia Adiabatic Calorimeters

    Thin Walled Low Thermal Inertia Test Cell

    Insulation for Maintaining Adiabatic Conditions

    A View of the InsidePressure Containment

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    The type of data that is needed is now known!

    The experiment must now be specified.

    Evaporative Concentration

    Data from a Low Thermal Inertia Adiabatic Calorimeters

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Tempered Versus Gassy SystemsTempered Liquid Phase Systems:

    T & P related directly to each other via the vapor pressure of components

    In Open Systems:Heat generation or addition causes vaporization of components

    Vaporization provides liquid phase cooling

    When vapor removal is sufficient, T (and P) stops increasing

    In Closed Systems:Essentially no vaporization occurs

    Pressure increases in step with increasing temperature

    Examples of Tempered Systems:Styrene polymerization

    Methanol vessel under fire

    Blowdown of a vessel containing liquid propane

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Tempered Versus Gassy SystemsGassy Liquid Phase Systems:

    Non-condensable gases are present or formed by reaction

    T & P are not simply related by the vapor pressure of the components

    In Open Systems:Heat generation or addition does not cause vaporization

    Cooling effects from vaporization do not occur

    Instead, the sensible heat content (temperature) of the liquid increases

    Examples of Gassy Systems:Decomposition of some organic peroxides

    Decomposition of some polymers

    Blow-down of a subcooled liquid containing dissolved gas

    In Closed Systems:Pressure increases almost without bounds

    Rossonic Acid Decomposition

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Experimental Specification

    Testing 90 wt% RA in a Low Thermal Inertia Adiabatic Calorimeter:Stainless Steel Open Test Cell

    Containment Backpressure = 300 psig

    Charge = 90 g (Fill ~ 75%) (Phi Factor ~ 1.1)

    Hold at 70 °C

    Test Normal Operating Condition

    Heat (4 °C Increments) and

    Search (5 minute holds)

    Until self-heating is observed

    Convert to adiabatic mode

    Allow test cell to self cool

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic Calorimeter Data

    Temperature Versus Time

    50

    75

    100

    125

    150

    175

    200

    225

    250

    0 2000 4000 6000 8000 10000 12000 14000

    Time (seconds)

    Tem

    pera

    ture

    (C)

    Heat & Search

    Normal Operating Condition

    Self-Heating Detected

    ∆T ~ 120 °C

    Adiabatic Operation

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic Calorimeter Data

    Pressure Versus Time

    250

    275

    300

    325

    350

    375

    400

    425

    0 2000 4000 6000 8000 10000 12000 14000

    Time (seconds)

    Pres

    sure

    (psi

    a)

    Containment Pressure

    Self-Heating Detected

    Pressure Rise ~ 90 psiClosed Test Cell ~ 12,000 psi

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic Calorimeter Data

    Self Heat Rate Versus Recipricol Temperature

    0.01

    0.10

    1.00

    10.00

    100.00

    -3.0 -2.9 -2.8 -2.7 -2.6 -2.5 -2.4 -2.3 -2.2 -2.1 -2.0 -1.9 -1.8 -1.7 -1.6 -1.5

    Recipricol Temperature

    Self

    Hea

    t Rat

    e (C

    /min

    )

    110 C

    94 C

    Heat & Search

    Based on Lab Data

    Onset Temperature

    Maximum Self-Heat Rate 80 °C/minute

    Second Reaction

    ArrheniusKinetics

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Adiabatic Calorimeter Data

    Pressure Rise Rate Versus Recipricol Temperature

    0.01

    0.10

    1.00

    10.00

    100.00

    1000.00

    -2.6 -2.5 -2.4 -2.3 -2.2 -2.1 -2.0 -1.9

    Recipricol Temperature

    Pres

    sure

    Ris

    e R

    ate

    (psi

    /min

    )

    Maximum Pressure Rise Rate

    180 psi/minute

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Now the proper data is known and available!

    So lets examine the Auburnite design concept

    Evaporative Concentration

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Process Flow Diagram - RA 2nd Stage Concentration

    Steam60 psig

    Z-100Three Stage Steam

    Jet Vacuum System

    Chilled Water5 C

    T

    70 wt% RAFrom 1st StageConcentration

    Steam150 psig

    Process OffgasTo Thermal Oxidizer

    90 wt% RATo Crystalazer Chilled Water

    5 C

    Process CondensateTo Treatment

    Note 1: Barometric LegNote 2: Equilization LineNote 3: 3 Barometric Legs

    P

    L

    L

    RO

    F

    T

    R-100

    P-100

    A-100X-100

    V-101

    P-101

    X-101

    83 C

    70 C

    15 C

    20 C

    20mmHgA

    2,500 PPH

    1,944 PPH

    Cond.

    250 PPH

    806 PPH

    10mmHgA

    16.7psia

    16.7psia

    1 32

    575,200Btu/hr

    308,800Btu/hr

    21.7 C

    15.2 C

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Jacket Jacketor or

    Total Working Tubes Tubes

    R-100 2nd Stage ConcentratorPressure Vessel

    476 gallons

    395 gallons 4'0" ID x 4'0" TT 30 psig & FV 100 psig & FV

    316L Stainless

    Steel

    316L Stainless Steel

    A-1002nd Stage Concentrator Agitator

    Pitched Blade Turbine NA NA

    2 - 18" Impellers 50 RPM x 5 HP NA NA

    316L Stainless

    SteelNA

    X-1002nd Stage Concentrator Overhead

    Shell & Tube Exchanger NA NA 630,000 Btu/hr 30 psig & FV 100 psig & FV

    Carbon Steel Carbon Steel

    P-1002nd Stage Concentrator Bottoms Pump

    Centrufugal NA NA 10 GPM x 50' TDH 100 psig NA316

    Stainless Steel

    NA

    Z-1002nd Stage Concentrator Vacuum System

    Steam Jets & Direct Contact Condensers

    NA NA 15 PPH @ 10 mmHgA 3 Stages 200 psig & FV NACarbon Steel NA

    V-1012nd Stage Concentrator Distillate Receiver

    Pressure Vessel

    264 gallons

    172 gallons 3'0" ID x 4'0" TT 15 psig & FV NA

    Carbon Steel NA

    X-1012nd Stage Concentrator Distillate Receiver

    Shell & Tube Exchanger NA NA 340,000 Btu/hr 100 psig & FV 100 psig & FV

    Carbon Steel Carbon Steel

    P-1012nd Stage Concentrator Distillate Receiver

    Centrifugal NA NA 60 GPM x 100' TDH 100 psig NADuctile

    Iron NA

    Characteristics Shell ShellVolume

    Service TypeItem

    N

    umbe

    r Design PressureEquipment List - 2nd Stage Concentration

    Materials of Construction

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Steam60 psig

    T

    70 wt% RAFrom 1st StageConcentration

    90 wt% RATo Crystalazer

    L

    RO

    F

    T

    R-100

    P-100

    A-100

    83 C

    70 C

    20mmHgA

    2,500 PPH

    1,944 PPH

    Cond.

    70 C556 PPH

    Water Vaporto OverheadCondenser

    Saturated Steam @ 60 psig

    Temperature = 153 °C

    Onset Temperature = 94 °C

    This doesn’t look good!

    Inventory ~ 395 gallons

    Mass ~3,300 pounds

    Wetted Area ~ 62 ft2

    Normal Operating T = 70 °C

    Onset Temperature = 94 °C

    Close, but OK

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Steam60 psig

    T

    70 wt% RAFrom 1st StageConcentration

    90 wt% RATo Crystalazer

    L

    RO

    F

    T

    R-100

    P-100

    A-100

    83 C

    70 C

    20mmHgA

    2,500 PPH

    1,944 PPH

    Cond.

    70 C556 PPH

    Water Vaporto OverheadCondenser

    Quick Calculation

    Perry’s Handbook

    For stainless steel, jacketed vessels with organics and condensing steam

    OHT Coefficient = 50 -150 Btu/h/sf/F

    U ∆T T condBtu/h/sf/F °C °C

    80 62 132100 50 120120 42 112

    ( ) ( )

    UAQTTUAQ

    ftAhBtu

    lbBtuhlbQ

    =Δ⇒Δ=

    =

    ==

    22.62/000,559

    /1005/556

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Inventory Concerns:Inventory is relatively large for such a potentially energetic material.

    Reducing inventory doesn’t work…………. Why?

    Wall Temperature Concerns:Inside wall temperature is probably higher than decomposition onset T

    No choice at the required capacity with the current configuration

    Single Failure Upset Cases of Concern:Loss of agitation

    Failed open steam valveResults in Increasing wall temperature

    Are there any others?

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    Multiple Sequential Failure Upset Cases of Concern:Loss of cooling + stuck open steam valve

    Loss of vacuum + stuck open steam valve

    Failed closed pressure valve + stuck open steam valve

    And others!

    CONCLUSIONS:An uncontrolled exothermic decomposition appears plausible

    The concentrator relief device should be sized for this case

    Fortunately, the necessary data is available!

    But should sizing be based on “all vapor” venting or two-phase flow?

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Why Does Two-Phase Venting Occur

    Results of Water Blowdown Experiments:

    Final Liquid Volume

    For “All Vapor” Venting

    485 Gallons

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Why Does Two-Phase Venting Occur

    Valve Opens

    Pressure Falls

    If Rate of Bubble Generation is High Enough Liquid Swells to the Top of the Vessel

    Liquid Swell Caused by Volume Generation

    Not Liquid Entrainment

    Highly Dependent on Physical Characteristics of Components

    Volumetric Generation

    LiquidSwell

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Rossonic Acid Decomposition

    Volumetric Generation of Non-Condensable Gas

    Evaporative Concentration

    “The chemists also noted some foaming when this slow decomposition occurred.”

    Remember this clue!

    Concentrator Fill ~ 83 %

    CONCLUSION: Design for Two-Phase Flow

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Larger Relief Devices Are NeededWhen Two-Phase Flow OccursVolume Balance Concept – Closed System

    Gas Generating

    Exothermic Reaction

    T & P

    Increase

    Wouldn’t It Be NiceVOLUME

    GENERATIONRATE

    VOLUMEEXPANSION

    RATE=

    CONSTANT

    PRESSURE

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Larger Relief Devices Are NeededWhen Two-Phase Flow OccursVolume Balance Concept – Open System

    A More Realistic

    System

    VOLUMEGENERATION

    RATE

    VOLUMEDISCHARGE

    RATE=

    CONSTANT

    PRESSURE

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Larger Relief Devices Are NeededWhen Two-Phase Flow OccursVolume Balance Concept – Open System

    Definition of a Successful Emergency Relief Device:

    Provides a balance between volume generation and volume dissipation

    For the “Worst Credible” case conditions

    At a pressure no greater than the maximum allowable pressure

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Larger Relief Devices Are NeededWhen Two-Phase Flow OccursVolume Balance Concept

    Vg = Volume Generation Rate = Volume Discharge Rate = Vd

    ⎭⎬⎫

    ⎩⎨⎧

    ====ρρρGAGAWVV dg

    Mass Flow Through Relief Device

    Two-Phase Density

    Two-Phase Mass Flux

    Relief Device X-Sectional Area

    2

    3

    3

    2

    ftsft

    ftlbfts

    lbG

    ==⎭⎬⎫

    ⎩⎨⎧ρVolumetric Flux =

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Larger Relief Devices Are NeededWhen Two-Phase Flow OccursVolume Balance Concept Saturated Hexane at 320 °F & 132.8 psia

    Two Phase Density

    0

    10

    20

    30

    40

    0.0 0.2 0.4 0.6 0.8 1.0

    Inlet Void Fraction

    Two

    Phas

    e D

    ensi

    ty (l

    b/cf

    )

    Increasing Vapor Content

    Critical Mass Flux

    500

    600

    700

    800

    900

    0.0 0.2 0.4 0.6 0.8 1.0

    Inlet Void Fraction

    Crit

    ical

    Mas

    s Fl

    ux (l

    b/sf

    /s)

    Increasing Vapor Content

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Larger Relief Devices Are NeededWhen Two-Phase Flow Occurs

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

    Inlet Void Fraction

    Volu

    met

    ric F

    lux

    (cf/s

    /sf)

    ALL LIQUID ALL VAPOR

    ⎭⎬⎫

    ⎩⎨⎧

    ====ρρρGAGAWVV dg

    Volume Balance Concept Saturated Hexane at 320 °F & 132.8 psia

    Increasing Vapor Content

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Simple Ideal Vent Sizing Results

    Inside Diameter = 4’0” T-T Length = 4’0” Total Volume = 475 gallons

    Fill Volumes = 428 gallons (90 %), 333 gallons (70 %), 238 gallons (50 %)

    Design Pressure (DP) = 50, 75, 100, 150 psig

    Maximum Pressure = (1.1) DP (10% accumulation)

    Maximum Pressure Rise Rate = 180 psi per minute

    Consider the following cases:

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Simple Ideal Vent Sizing Results

    Concentrator475 Gallon Vessel

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    25 50 75 100 125 150 175

    Design Pressure (Psig)

    Vent

    Are

    a (S

    q In

    )

    Fill Ratio = 90%

    Fill Ratio = 70%

    Fill Ratio = 50%

    ~ 12” Vent

    ~ 23” Vent

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    A large vent is required due to two-phase flow

    Can two-phase flow be avoided?

    Evaporative Concentration

    Yes

    By allowing enough room for vapor disengagement

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Vessel DisengagementBubbly Flow Regime

    Co = 1.2

    0.00

    0.10

    0.20

    0.30

    0.40

    0.50

    0.60

    0.70

    0.80

    0.90

    1.00

    0.1 1.0 10.0 100.0

    Dimensionless Superficial Vapor Velocity

    Vess

    el A

    vera

    ge V

    oid

    Frac

    tion

    Onset/Disengagement Boundary

    Vessel Condition

    Vapor Venting Region

    Two Phase Venting Region

    Inside Diameter = 4’0”

    T-T Length = 4’0”

    Total Volume = 475 gallons

    DP = 50 psig & FV

    Disengagement

    Maximum Fill ~ 17 %

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Evaporative Concentration

    With less inventory, how can the heat needed for the normal evaporation be added?

    Decrease the concentrator inventory

    Avoid two-phase flow

    Size the relief device for “all vapor” venting

    Basis for New Concentrator Design Concept

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    New Concentrator Design

    Inside Diameter = 4’0”

    T-T Length = 5’0”

    Total Volume = 535 gallons

    DP = 50 psig & FV

    DT = 500°F 70 wt% RA

    Emergency Water

    Water Vapor

    90 wt% RA

    20 mmHg

    70°C

    LC On Upstream Vessel

    5 psig Saturated

    Steam

    Tube Side

    Condensation

    Conditions

    11.5 psia

    93°C

    Pumping

    TrapSide View Top View

    Baffles

    Working Volume = 70 gallons

    Maximum Volume = 100 gallons

    Relief Device = 6” PSE based on vapor flow only

    Minimization, Moderation, Limitation of Effects

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Is This Enough?

    Shutdown Based On:

    Redundant High Level

    Redundant Process Temperature

    Redundant Tube Side Steam Pressure

    Quench water addition triggered by high process temperature only.

    Shutdown

    Feed & Steam

    Safety Instrumented Systems (SIS) - Interlocks

    Independent of the Basic Process Control System (BPCS)

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Concentrator – Top View

    Emergency Vent Line

    Normal Vent Line

    Car Seal Open

    Full Port Block Valve

    Rupture Disk

    (hidden)

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Concentrator – Bottom View

    Process Outlet Pipe

    Steam

    Condensate Line

    Stab-In

    Tube Bundle

    SIS Redundant

    Temperature

    Transmitters

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Concentrator – Bottom View

    SIS Redundant Level Switches

    Process Outlet Pipe

    BPCS Level Transmitter

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    What Could Have Been Done Differently?

    Conduct a high phi factor calorimeter test to better understand reaction mechanism.

    Conduct calorimeter tests to determine if the reaction system tempers at the maximum allowable working pressure of the vessel.

    Conduct a blowdown test to obtain a better feeling for disengagement dynamics.

    Use more sophisticated tools to analyze the possibility of utilizing smaller vent sizes.

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Alternate Schemes to Consider

    Falling Film EvaporatorA very good alternative

    Usually have low heat transfer coefficients

    Probably more expensive then vessel/tube bundle combination

    Agitated Thin Film EvaporatorNot the best for low viscosity liquids

    Considerably more expensive then vessel/tube bundle combination

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Connected Equipment

    Jacket Jacketor or

    Total Working Tubes Tubes

    R-100 2nd Stage ConcentratorPressure Vessel

    476 gallons

    395 gallons 4'0" ID x 4'0" TT 30 psig & FV 100 psig & FV

    316L Stainless

    Steel

    316L Stainless Steel

    A-1002nd Stage Concentrator Agitator

    Pitched Blade Turbine NA NA

    2 - 18" Impellers 50 RPM x 5 HP NA NA

    316L Stainless

    SteelNA

    X-1002nd Stage Concentrator Overhead

    Shell & Tube Exchanger NA NA 630,000 Btu/hr 30 psig & FV 100 psig & FV

    Carbon Steel Carbon Steel

    P-1002nd Stage Concentrator Bottoms Pump

    Centrufugal NA NA 10 GPM x 50' TDH 100 psig NA316

    Stainless Steel

    NA

    Z-1002nd Stage Concentrator Vacuum System

    Steam Jets & Direct Contact Condensers

    NA NA 15 PPH @ 10 mmHgA 3 Stages 200 psig & FV NACarbon Steel NA

    V-1012nd Stage Concentrator Distillate Receiver

    Pressure Vessel

    264 gallons

    172 gallons 3'0" ID x 4'0" TT 15 psig & FV NA

    Carbon Steel NA

    X-1012nd Stage Concentrator Distillate Receiver

    Shell & Tube Exchanger NA NA 340,000 Btu/hr 100 psig & FV 100 psig & FV

    Carbon Steel Carbon Steel

    P-1012nd Stage Concentrator Distillate Receiver

    Centrifugal NA NA 60 GPM x 100' TDH 100 psig NADuctile

    Iron NA

    Characteristics Shell ShellVolume

    Service TypeItem

    N

    umbe

    r Design PressureEquipment List - 2nd Stage Concentration

    Materials of Construction

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Summary

    Critical information often comes from inconspicuous place.

    Keep your eyes and ears wide open!!

    Guessing is unacceptable

    In God we trust, everyone else bring the right data!!

    Avoid two-phase emergency venting where possible

    Its always easier to ride your bicycle down-hill

    Be weary of lab scale data when exothermic reactions are involved.

    Scale-up is usually not included in a chemistry curriculum!!

    A safety concept can not be realized without having the proper data

    Don’t go skydiving without reading the parachute instructions

    Chemistry knowledge is a key ingredient for process safety.

    Don’t sell your Morrison & Boyd on eBay!!

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Summary

    What can happen, will happen.

    Remember Murphy’s Law.

    Keep the “stuff” in the pipes

    Once you start skidding, you are out of control.

    Integrate the safety concept and the process design

    Avoid problems by changing the basic process and/or equipment

    Pressure relief should be the last line of defense

    But not the only line of defense.

    Use the right equipment.

    Don’t try to fix your car without the right tools.

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Closing Remarks

    Contact Information – Call or Write Anytime !!

    Email: [email protected] (best method)

    Phone: 251-443-2420 (I travel allot, so be patient)

    Address:

    Robert D’Alessandro

    Degussa Corporation

    4301 Degussa Road

    Theodore, AL 36590-0606

    I will be glad to help in anyway I can !!

    mailto:[email protected]

  • Auburn University Chen 4450 Process Safety Robert D‘Alessandro, P.E.

    Closing Remarks

    Thank you !!

    Auburn University

    Professor Chambers, Professor Eden, and Professor Roberts

    Degussa Corporation

    Professor Riemenschneider, Dr. Kemnade

    Students in Chen 4450

    Evaporative Concentration of a Thermally Sensitive Chemical IntroductionLecture ObjectivesEvaporative ConcentrationSigns of Inherent TroubleSigns of Inherent TroubleSigns of Inherent TroubleLaboratory Scale Data Laboratory Scale Data Laboratory Scale Data Adiabatic CalorimetersAdiabatic CalorimetersAdiabatic CalorimetersAdiabatic CalorimetersEvaporative ConcentrationTempered Versus Gassy SystemsTempered Versus Gassy SystemsExperimental SpecificationAdiabatic Calorimeter DataAdiabatic Calorimeter DataAdiabatic Calorimeter DataAdiabatic Calorimeter DataEvaporative ConcentrationEvaporative ConcentrationEvaporative ConcentrationEvaporative ConcentrationEvaporative ConcentrationEvaporative ConcentrationEvaporative ConcentrationWhy Does Two-Phase Venting OccurWhy Does Two-Phase Venting OccurEvaporative ConcentrationLarger Relief Devices Are Needed�When Two-Phase Flow OccursLarger Relief Devices Are Needed�When Two-Phase Flow OccursLarger Relief Devices Are Needed�When Two-Phase Flow OccursLarger Relief Devices Are Needed�When Two-Phase Flow OccursLarger Relief Devices Are Needed�When Two-Phase Flow OccursLarger Relief Devices Are Needed�When Two-Phase Flow OccursSimple Ideal Vent Sizing ResultsSimple Ideal Vent Sizing ResultsEvaporative ConcentrationVessel DisengagementEvaporative ConcentrationNew Concentrator DesignIs This Enough? Concentrator – Top ViewConcentrator – Bottom ViewConcentrator – Bottom ViewWhat Could Have �Been Done Differently? Alternate Schemes to Consider Connected EquipmentSummarySummaryClosing RemarksClosing Remarks