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MINIMIZING FOULING AND CORROSION: Equipment Operation and Troubleshooting- Volume One

Minimizing Fouling Vol One

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Corrosion and fouling can wreak havoc in many chemical process operations, and can negatively impact process operations, depress chemical-conversion rates and product yield, reduce energy efficiency and incur excess costs associated with maintenance and repairs. Meanwhile, corrosion-related damage, and uncontrolled fouling or buildup in process equipment can lead to unscheduled downtime for maintenance, and in extreme cases, catastrophic failure of process equipment. All of this can create safety issues for plant personnel and neighboring communities, and reduce the overall profitability of the process.

This Chemical Engineering Guidebook contains practical engineering articles related to corrosion-related issues in specific types of equipment. The articles were originally published in Chemical Engineering from 2010 to 2018. Several articles provide practical guidance for managing and monitoring corrosion in pressure vessels and reactors, heaters, boilers, pumps, condensers, gas turbines, flares and more. Others focus on fouling and corrosion issues in aboveground and buried piping and storage tanks.

This guidebook is 198 and delivered in a PDF format.

Topics include:

Column Revamps: From Outside to Inside

• Some of the many things to consider for this complex task are presented here

Microreactors: Lessons Learned From Industrial Applications

• Implementing microreactors in chemical production is quite a challenge. How these challenges can be met is described here

Steam Concepts

Heat Exchanger Standards for Shelland- Tube Equipment

• Reliable operation of shell-and-tube heat exchangers begins with an appropriate standard. This article provides an overview of those that are applicable

Crossflow Membrane Filtration Essentials

• Several aspects of crossflow membrane filtration, including process design, equipment selection and control, are detailed here

Gas-Phase Filtration Media Properties: What to Know

• There are many physical properties that can impact the ultimate performance of adsorbent media in gas-phase filtration applications

Thermowell Installation

Polymer-based Piping

Controlling Membrane Fouling

Wet Scrubbers

Point-Level Switches for Safety Systems

• Industries that manufacture or store potentially hazardous materials need to employ point-level switches to protect people and the environment from spills

Design Underground Piping for Safety

• Buried systems bear a number of unique risks and require special considerations, including those related to soil characteristics and seismic loads

Inspecting Underground Piping

• First consider noninvasive methods to determine where excavation is — and isn’t — necessary

Flare Consolidation Considerations

• Consolidating multiple flares can help mitigate emissions and maintenance

Thermal Design Guidelines for Optimizing Shell-and-Tube Heat Exchangers

• Ensuring optimal performance of shell-and-tube heat exchangers requires knowledge of the controlling fluid, correct exchanger geometry and configuration, as well as proper fluid placement

Superheater Problems in Steam Generators

• Knowing the features of a good boiler will prevent problems associated with a poor design

Pressurized Piping: Sampling Steam and Water

• Without proper systems, analysis of steam and water chemistry can provide erroneous results —with costly implications

Flooded Condenser Controls: Principles and Troubleshooting

• Flooded condensers are the prime tower pressure-control methods for total condensers that generate only liquid products, and although these control methods can be troublesome, a good understanding of their principles will help achieve improved, trouble-free operations

Enclosed Combustion Equipment and Technology

• A thorough understanding of enclosed combustion technologies will help engineers to select the proper equipment to balance emissions-control performance with efficiency, costs and complexity

Operating Strategies for Gas Dehydration Units

• The presence of certain contaminants can wreak havoc on gas dehydration systems and other similar separation processes, but there are design measures that can help to minimize the issues caused by these substances

The Shotgun Approach

• Removal of Fouling Deposits on heat transfer surfaces in Coal-Fired Process Heaters & Boilers

Gas Turbines: Design and Operating Considerations

• Follow these engineering recommendations to improve gas turbine operation and performance while reducing operating costs

Filtration and Separation During Chemical Process Operations: Avoid Common Errors

• The seven commonly made mistakes discussed here often lead to poor filtration and separation performance and many associated problems

An Up-Close Look at Electropositive Filtration

• Electropositive filters take advantage of surface-charge effects to filter nanometer-sized particles. Provided here is an overview of how they work and where they can be used

Getting the Most from Severe Service Valves

• Severe service valves (SSVs) differ from general purpose valves in important ways. Presented here is guidance on how to increase service life, reduce costs and improve safety and environmental performance of SSVs

Implementing a Corrosion-Under-Insulation Program

• CPI facilities need to put in place a systematic program for preventing and mitigating corrosion under insulation

Rotating Machinery: What You Should Know About Operational Problems

• Follow this guidance to improve the operation, safety and reliability of rotating machinery in chemical process plants

Shell-and-Tube Heat Exchangers: The Design Cycle

• Following this step-by-step approach will ensure that the heat exchanger will perform as required when finally fabricated

Piping-System Leak Detection and Monitoring for the CPI

• Eliminating the potential for leaks is an integral part of the design process that takes place at the very onset of facility design

Unlocking the Secrets of Plate-and-Frame Heat Exchangers

• An understanding of the design, sizing, specification and installation of plate-and-frame heat exchangers is necessary to evaluate vendors’ proposed designs

Reliable Operation and Sealing of Agitators

• Mechanical seals, as required by most vessel agitators, are systems sufficiently complex to warrant a good understanding by engineers and appropriate training for operators

Piping Design for Potentially Lethal Chemicals

• Integrity and reliability are critical for piping and equipment that handle chemicals with extreme health hazards

Optimizing Flare Operation Through Proper Design

• Flare problems are often caused by the seal systems that are designed to control air ingress. Follow these troubleshooting guidelines to improve design and ensure safe, reliable flare operation

Heat-Transfer Fluid Selection

Magnetically Driven Pumps: An overview

• Understanding sealless pump technologies and their potential applications

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