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    04 Process Monitoring

    Uploaded by

    Kvspavan Kumar
    johnsn matthew

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    04 Process Monitoring

    Uploaded by

    Kvspavan Kumar
    69 views22 pages
    johnsn matthew

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

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    johnsn matthew

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    69 views22 pages

    04 Process Monitoring

    Uploaded by

    Kvspavan Kumar
    johnsn matthew

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 22

    Process monitoring

    A Ramaragavan
    25 Mar 2015
    Westin Hotel Gurgaon, India

    Process monitoring

    Normal
    deactivation

    Reasons for process monitoring


    Abnormal
    deactivation

    Optimize
    performance

    Measurable parameters

    SOR
    activity

    Loading
    issues

    Poisoning

    Conversion
    Bed
    movement

    Poor
    mixing

    Sintering

    Gas
    distribution

    Thermal
    cycles

    Pressure drop
    Support
    failure
    Wetting/
    fouling

    Purification
    Hydrodesulphurizer
    Monitor conversion of organic sulphur and pressure drop
    Fouling can lead to loss in activity and pressure drop
    increase

    Desulphurizer
    Once saturated, sulphur slip will rise rapidly
    Assessing saturation level

    Mass balance, inlet sulphur flow


    Intermediate bed sample points (single bed)
    Inter-bed sampling (lead lag)
    Online density measurements

    Online ZnO saturation analysis


    Accurate analysis of low
    S levels difficult
    Scan across ZnO bed
    online
    TRACERCO DiagnosticsTM Maximizer

    Detects difference
    between ZnO and ZnS
    density
    Optimize change-out in
    turnarounds and
    maximize ZnO utilization

    Reforming
    Main deactivation mechanism
    Sintering

    Key performance indicators:


    ATE at catalyst exit temperature
    Pressure drop

    Considerations

    Methane slip sensitive to operating conditions


    Heat loss
    Radiation effect
    Failure of thermocouple
    Gas distribution

    Reformer survey toolbox


    LOTIS and
    MANTIS tube
    inspection

    Gold Cup TWT


    measurements

    Pressure surveys

    Thermal Imager

    Remnant tube life


    calculations

    Design philosophy
    review

    Computational
    fluid dynamics

    Tube failure
    analysis

    Maldistribution
    checks

    CatTracker Intube temperature


    measurements

    Assessment of
    burners

    Combustion air
    survey

    Optical pyrometer

    Benchmarking

    Process
    Simulation

    Corrosion
    investigations and
    analysis

    CatTrackers - process gas profile

    Multipoint thermocouple installed in central of catalyst tube


    Validation of process modelling
    Avoiding carbon formation
    Minimizing steam:carbon ratio
    Sulphur poisoning

    CatTrackers - process gas profile

    Reformer Imager - TWT measurement

    Reformer Imager - TWT measurement

    Reformer survey report


    Statistical and graphical analysis of TWT
    Hot zone

    Cold zone

    Benchmarking against other reformers


    Troubleshoot operational issues

    Benchmarking reformer performance


    Database captured results of reformer surveys
    Allows for benchmarking of reformer
    Compare against similar reformers

    Water gas shift


    Main deactivation mechanism
    HTS = sintering
    LTS = poisoning

    Key performance indicator


    CO slip and ATE
    Pressure drop
    Temperature profile

    Considerations

    Shrinkage on reduction
    Variable inlet temperature
    Kinetically limited at lower T, equilibrium limited at higher T
    Heat loss

    WGS temperature profiles

    Methanator
    Deactivation due to carry over from CO2 removal section
    Key performance indicator
    COX slip
    Temperature profile
    Pressure drop

    CatTracker temperature monitoring

    Synthesis catalyst
    Main deactivation mechanism
    Pressure drop

    Key performance indicators


    Catalyst bed temperatures
    Inlet/exit % ammonia
    Pressure drop

    Considerations

    Inlet flow
    Bed temperatures
    Inlet gas analysis
    Catalyst size
    Production rate

    Pressure
    Bed

    volumes

    Monitoring & optimisation


    Simple heat & mass balances
    To check measured vs calculated ammonia make

    Determine catalyst activity


    To assess current and future performance

    Optimise bed temperatures/loop purge to


    Maximise NH3 make and catalyst life
    Minimise synthesis compressor power
    Make (te/day)

    T3 (degC)
    T2 (degC)

    Remote monitoring

    JOHNSON MATTHEY OFFICE


    DCS

    CLIENT DATA
    HISTORIAN

    PLANT ENGINEERS

    CLIENT
    FIREWALL

    SECURE
    VPN LINK

    JM
    FIREWALL

    PLANT
    MANAGERS
    CLIENT SITE

    DEDICATED
    JM SERVER
    JM SUPPORT STAFF
    AUTOMATED
    ANALYSIS
    TOOLS

    Summary
    Common measurements

    Analysis
    Mass balance
    Bed temperature rise
    Bed temperature profile
    Pressure drop

    Advanced measurements

    Radioactive tracer scans


    Multipoint thermocouples
    Thermal imaging
    Remote monitoring

    Thank you

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