Abstract: Storage tank farms are essential industrial facilities to accumulate oil, petrochemicals and gaseous products. Since tank farms contain huge mass of fuel and hazardous materials, they are always targets of serious accidents such as fire, explosion, spill and toxic release which may cause severe impacts on human health, environmental and properties.
Although having a safe layout is not able to prevent initiating accidents, however it effectively controls and reduces the adverse impact of such accidents.
The aim of this paper is to determine the optimal layout for a storage tank contains different type of hydrocarbon fuels. A quantitative risk assessment is carried out on a selected tank farm in Jaipur, India, with particular attention given to both the consequence modeling and the overall risk assessment using PHAST Software. Various designs of tank layouts are examined taking into consideration several issues of plant operations and maintenance. In all stages of the work, standard guidelines specified by the industry are considered and recommendations are substantiated with simulation results and risk quantification.
Abstract: Vibration analysis is the most important factor in preventive maintenance. Gas turbine vibration analysis is also one of the most challenging categories in most critical equipment monitoring systems. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of this kind of equipment developed too much in recent years. On the other hand, too much operation condition consideration in this kind of equipment should be adjusted properly like inlet and outlet pressure and temperature for both turbine and compressor. In this paper the most important tools and hypothesis used for analyzing of gas turbine power plants discussed in details through a real case history related to an Alstom Typhoon gas turbine power plant in Iran oil industries. In addition, the basic principal of vibration behavior caused by mechanical unbalance in gas turbine rotor discussed in details.
Abstract: Biopolymers have gained much attention as ecofriendly alternatives to petrochemical-based plastics because they are biodegradable and can be produced from renewable feedstocks. One class of biopolyester with many potential environmentally
friendly applications is polylactic acid (PLA) and polycaprolactone (PCL). The PLA/PCL biodegradable copolyesters were synthesized by bulk ring-opening copolymerization of successively added Llactide (LL) and ε-caprolactone (CL) in the presence of toluene, using 1-hexanol as initiator and stannous octoate (Sn(Oct)2) as catalyst. Reaction temperature, reaction time and amount of catalyst were evaluated to obtain optimum reaction conditions. The results showed that the %conversion increased with increases in reaction temperature and reaction time, but after a critical amount of catalyst was reached the %conversion decreased. The yield of PLA/PCL biopolymer achieved 98.02% at the reaction temperature 160 °C, amount of catalyst 0.3 mol% and reaction time of 48 h. In addition, the thermal properties of the product were determined by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA).
Abstract: This research involves the design and analysis of pinch-based water/wastewater networks to minimize water utility in the petrochemical and petroleum industries. A study has been done on Tehran Oil Refinery to analyze feasibilities of regeneration, reuse and recycling of water network. COD is considered as a single key contaminant. Amount of freshwater was reduced about 149m3/h (43.8%) regarding COD. Re-design (or retrofitting) of water allocation in the networks was undertaken. The results were analyzed through graphical method and mathematical programming technique which clearly demonstrated that amount of required water would be determined by mass transfer of COD.
Abstract: Owing to extensive use of hydrogen in refining or
petrochemical units, it is essential to manage hydrogen network in
order to make the most efficient utilization of hydrogen. On the other
hand, hydrogen is an important byproduct not properly used through
petrochemical complexes and mostly sent to the fuel system. A few
works have been reported in literature to improve hydrogen network
for petrochemical complexes. In this study a comprehensive analysis
is carried out on petrochemical units using a modified automated
targeting technique which is applied to determine the minimum
hydrogen consumption. Having applied the modified targeting
method in two petrochemical cases, the results showed a significant
reduction in required fresh hydrogen.
Abstract: The present study was performed in Musa bay (northern part of the Persian Gulf) around the coastal area of Bandare-Imam Khomeini and Razi Petrochemical Companies. Sediment samples and effluent samples were collected from the selected stations, from June 2009 to June 2010. The samples were analyzed to determine the degree of hydrocarbon contamination. The average level of TPH concentration in the study area was more than the natural background value at all of the stations, especially at station BI1 which was the main effluent outlet of Bandar-e- Imam Khomeini petrochemical company. Also the concentration of total petroleum hydrocarbon was monitored in the effluents of aforementioned petrochemical companies and the results showed that the concentration of TPH in the effluents of Bandar-e- Imam Khomeini petrochemical company was greater than Razi petrochemical company which is may be related to the products of Bandar-e- Imam Khomeini petrochemical company (aromatics, polymers, chemicals, fuel).
Abstract: The equilibrium chemical reactions taken place in a converter reactor of the Khorasan Petrochemical Ammonia plant was studied using the minimization of Gibbs free energy method. In the minimization of the Gibbs free energy function the Davidon– Fletcher–Powell (DFP) optimization procedure using the penalty terms in the well-defined objective function was used. It should be noted that in the DFP procedure along with the corresponding penalty terms the Hessian matrices for the composition of constituents in the Converter reactor can be excluded. This, in fact, can be considered as the main advantage of the DFP optimization procedure. Also the effect of temperature and pressure on the equilibrium composition of the constituents was investigated. The results obtained in this work were compared with the data collected from the converter reactor of the Khorasan Petrochemical Ammonia plant. It was concluded that the results obtained from the method used in this work are in good agreement with the industrial data. Notably, the algorithm developed in this work, in spite of its simplicity, takes the advantage of short computation and convergence time.
Abstract: In this work, we treat the problems related to chemical and petrochemical plants of a certain complex process taking the centrifugal compressor as an example, a system being very complex by its physical structure as well as its behaviour (surge phenomenon). We propose to study the application possibilities of the recent control approaches to the compressor behaviour, and consequently evaluate their contribution in the practical and theoretical fields. Facing the studied industrial process complexity, we choose to make recourse to fuzzy logic for analysis and treatment of its control problem owing to the fact that these techniques constitute the only framework in which the types of imperfect knowledge can jointly be treated (uncertainties, inaccuracies, etc..) offering suitable tools to characterise them. In the particular case of the centrifugal compressor, these imperfections are interpreted by modelling errors, the neglected dynamics, no modelisable dynamics and the parametric variations. The purpose of this paper is to produce a total robust nonlinear controller design method to stabilize the compression process at its optimum steady state by manipulating the gas rate flow. In order to cope with both the parameter uncertainty and the structured non linearity of the plant, the proposed method consists of a linear steady state regulation that ensures robust optimal control and of a nonlinear compensation that achieves the exact input/output linearization.
Abstract: This study investigated the presence of polycyclic
aromatic hydrocarbons (PAHs) in the sediments of the Musa Bay
(around the PETZONE coastal area) from Feb 2010 to Jun 2010.
Concentrations of PAHs recorded in the Musa Bay sediments ranged
from 537.89 to 26,659.06 ng/g dry weight with a mean value of
3990.74 ng/g. the highest concentration of PAHs was observed at
station 4, which is located near the aromatic outlet of Imam
Khomeini petrochemical company (station 4: BI-PC Aromatic
effluent outlet) in which its concentration level was more than the
NOAA sediment quality guideline value (ERL= 4022 ng/g dry
weight). Owing to the concentration of PAHs in the study area, its
concentration level was still meet the NOAA sediment quality
guideline value (ERL: 4022 ng/g dry weight); however, according to
the PELq factor, slightly adverse biological effects are associated
with the exposure to PAHs levels in the study area (0.1< PELq= 0.24
> 0.5).
Abstract: Pyrolysis of waste tire is one of alternative technique
to produce petrochemicals, such as light olefins, mixed C4, and monoaromatics.
Noble metals supported on acid zeolite catalysts were
reported as potential catalysts to produce the high valuable products
from waste tire pyrolysis. Especially, Pd supported on HBeta gave a
high yield of olefins, mixed C4, and mono-aromatics. Due to the high
prices of noble metals, the objective of this work was to investigate
whether or not a non-noble Ni metal can be used as a substitute of a
noble metal, Pd, supported on HBeta as a catalyst for waste tire pyrolysis.
Ni metal was selected in this work because Ni has high activity
in cracking, isomerization, hydrogenation and the ring opening of
hydrocarbons Moreover, Ni is an element in the same group as Pd
noble metal, which is VIIIB group, aiming to produce high valuable
products similarly obtained from Pd. The amount of Ni was varied as
5, 10, and 20% by weight, for comparison with a fixed 1 wt% Pd,
using incipient wetness impregnation. The results showed that as a
petrochemical-producing catalyst, 10%Ni/HBeta performed better
than 1%Pd/HBeta because it did not only produce the highest yield of
olefins and cooking gases, but the yields were also higher than
1%Pd/HBeta. 5%Ni/HBeta can be used as a substitute of
1%Pd/HBeta for similar crude production because its crude contains
the similar amounts of naphtha and saturated HCs, although it gave
no concentration of light mono-aromatics (C6-C11) in the oil. Additionally,
10%Ni/HBeta that gave high olefins and cooking gases was
found to give a fairly high concentration of the light mono-aromatics
in the oil.
Abstract: Accurate demand forecasting is one of the most key
issues in inventory management of spare parts. The problem of
modeling future consumption becomes especially difficult for lumpy
patterns, which characterized by intervals in which there is no
demand and, periods with actual demand occurrences with large
variation in demand levels. However, many of the forecasting
methods may perform poorly when demand for an item is lumpy.
In this study based on the characteristic of lumpy demand patterns
of spare parts a hybrid forecasting approach has been developed,
which use a multi-layered perceptron neural network and a
traditional recursive method for forecasting future demands. In the
described approach the multi-layered perceptron are adapted to
forecast occurrences of non-zero demands, and then a conventional
recursive method is used to estimate the quantity of non-zero
demands. In order to evaluate the performance of the proposed
approach, their forecasts were compared to those obtained by using
Syntetos & Boylan approximation, recently employed multi-layered
perceptron neural network, generalized regression neural network
and elman recurrent neural network in this area. The models were
applied to forecast future demand of spare parts of Arak
Petrochemical Company in Iran, using 30 types of real data sets. The
results indicate that the forecasts obtained by using our proposed
mode are superior to those obtained by using other methods.
Abstract: Greenhouse gases (GHG) emissions impose major
threat to global warming potential (GWP). Unfortunately
manufacturing sector is one of the major sources that contribute
towards the rapid increase in greenhouse gases (GHG) emissions. In
manufacturing sector electric power consumption is the major driver
that influences CO2 emission. Titanium alloys are widely utilized in
aerospace, automotive and petrochemical sectors because of their
high strength to weight ratio and corrosion resistance. Titanium
alloys are termed as difficult to cut materials because of their poor
machinability rating. The present study analyzes energy consumption
during cutting with reference to material removal rate (MRR).
Surface roughness was also measured in order to optimize energy
consumption.
Abstract: Conventional materials like glass, wood or metals
replacement with polymer materials is still continuing. More simple
thus cheaper production is the main reason. However due to high
energy and petrochemical prices are polymer prices increasing too.
That´s why various kinds of fillers are used to make polymers
cheaper. Of course target is to maintain or improve properties of
these compounds. In this paper are solved rheology issues of
polymers compounded with vegetal origin fibers.
Abstract: The presence of toxic heavy metals in industrial
effluents is one of the serious threats to the environment. Heavy
metals such as Cadmium, Chromium, Lead, Nickel, Zinc, Mercury,
Copper, Arsenic are found in the effluents of industries such as
foundries, electroplating, petrochemical, battery manufacturing,
tanneries, fertilizer, dying, textiles, metallurgical and metal finishing.
Tremendous increase of industrial copper usage and its presence in
industrial effluents has lead to a growing concern about the fate and
effects of Copper in the environment. Percolation of industrial
effluents through soils leads to contamination of ground water and
soils. The transport of heavy metals and their diffusion into the soils
has therefore, drawn the attention of the researchers.
In this study, an attempt has been made to delineate the
mechanisms of transport and fate of copper in terrestrial
environment. Column studies were conducted using perplex glass
square column of dimension side 15 cm and 1.35 m long. The soil
samples were collected from a natural drain near Mohali (India). The
soil was characterized to be poorly graded sandy loam. The soil was
compacted to the field dry density level of about 1.6 g/cm3. Break
through curves for different depths of the column were plotted. The
results of the column study indicated that the copper has high
tendency to flow in the soils and fewer tendencies to get absorbed on
the soil particles. The t1/2 estimates obtained from the studies can be
used for design copper laden wastewater disposal systems.
Abstract: There have been widespread applications of fluidized beds in industries which are related to the combination of gas-solid particles during the last decade. For instance, in order to crack the catalyses in petrochemical industries or as a drier in food industries. High capacity of fluidized bed in heat and mass transfer has made this device very popular. In order to achieve a higher efficiency of fluidized beds, a particular attention has been paid to beds with pulsating air flow. In this paper, a fluidized bed device with pulsating flow has been designed and constructed. Size of particles have been used during the test are in the range of 40 to 100μm. The purpose of this experimental test is to investigate the air flow regime, observe the particles- movement and measure the pressure loss along the bed. The effects of pulsation can be evaluated by comparing the results for both continuous and pulsating flow. Results of both situations are compared for various gas speeds. Moreover the above experiment is numerically simulated by using Fluent software and its numerical results are compared with the experimental results.
Abstract: Programmable logic controllers are the main controllers in the today's industries; they are used for several applications in industrial control systems and there are lots of examples exist from the PLC applications in industries especially in big companies and plants such as refineries, power plants, petrochemical companies, steel companies, and food and production companies. In the PLCs there are some functions in the function library in software that can be used in PLC programs as basic program elements. The aim of this project are introducing and implementing a new function block of a neural network to the function library of PLC. This block can be applied for some control applications or nonlinear functions calculations after it has been trained for these applications. The implemented neural network is a Perceptron neural network with three layers, three input nodes and one output node. The block can be used in manual or automatic mode. In this paper the structure of the implemented function block, the parameters and the training method of the network are presented by considering the especial method of PLC programming and its complexities. Finally the application of the new block is compared with a classic simulated block and the results are presented.
Abstract: Explosion occurs due to sudden release of energy.
Common examples of explosion include chemical, atomic, heat, and
pressure tank (due to ignition) explosions. Petroleum, gas, and
petrochemical industries operations are threatened by natural risks
and processes. Fires and explosions are the greatest process risks
which cause financial damages.
This study aims at designing a single-floor structure for the control
room of a petroleum refinery to be resistant against gas explosion
loads, and the information related to the structure specifications have
been provided regarding the fact that the structure is made on the
ground's surface. In this research, the lateral stiffness of single pile is
calculated by SPPLN.FOR computer program, and its value for
13624 KN/m single pile has been assessed. The analysis used due to
the loading conditions, is dynamic nonlinear analysis with direct
integration method.
Abstract: There was a high rate of corrosion in Pyrolysis
Gasoline Hydrogenation (PGH) unit of Arak Petrochemical Company
(ARPC), and it caused some operational problem in this plant. A
commercial chemical had been used as anti-corrosion in the
depentanizer column overhead in order to control the corrosion rate.
Injection of commercial corrosion inhibitor caused some
operational problems such as fouling in some heat exchangers. It was
proposed to replace this commercial material with another more
effective trouble free, and well-known additive by R&D and
operation specialists.
At first, the system was simulated by commercial simulation
software in electrolytic system to specify low pH points inside the
plant. After a very comprehensive study of the situation and technical
investigations ,ammonia / monoethanol amine solution was proposed
as neutralizer or corrosion inhibitor to be injected in a suitable point
of the plant. For this purpose, the depentanizer column and its
accessories system was simulated again in case of this solution
injection.
According to the simulation results, injection of new anticorrosion
substance has no any side effect on C5 cut product and
operating conditions of the column. The corrosion rate will be
cotrolled, if the pH remains at the range of 6.5 to 8 . Aactual plant
test run was also carried out by injection of ammonia / monoethanol
amine solution at the rate of 0.6 Kg/hr and the results of iron content
of water samples and corrosion test coupons confirmed the
simulation results.
Now, ammonia / monoethanol amine solution is injected to a
suitable pint inside the plant and corrosion rate has decreased
significantly.
Abstract: The main objective of this study is to test the
relationship between numbers of variables representing the firm
characteristics (market-related variables) and the extent of voluntary
disclosure levels (forward-looking disclosure) in the annual reports of
Egyptian firms listed on the Egyptian Stock Exchange. The results
show that audit firm size is significantly positively correlated (in all
the three years) with the level of forward-looking disclosure.
However, industry type variable (which divided to: industries,
cement, construction, petrochemicals and services), is found being
insignificantly association with the level of forward-looking
information disclosed in the annual reports for all the three years.
Abstract: In the present research, steam cracking of two types of
feedstocks i.e., naphtha and ethane is simulated for Pyrocrack1-1 and
2/2 coil configurations considering two key parameters of coil outlet
temperature (COT) and coil capacity using a radical based kinetic
model. The computer model is confirmed using the industrial data
obtained from Amirkabir Petrochemical Complex. The results are in
good agreement with performance data for naphtha cracking in a
wide range of severity (0.4-0.7), and for ethane cracking on various
conversions (50-70). It was found that Pyrocrack2-2 coil type is an
appropriate choice for steam cracking of ethane at reasonable
ethylene yield while resulting in much lower tube wall temperature
while Pyrocrack1-1 coil type is a proper selection for liquid
feedstocks i.e. naphtha. It can be used for cracking of liquid
feedstocks at optimal ethylene yield whereas not exceeding the
allowable maximum tube temperature.