To meet environmental accounting regulations, the key for petrochemical plants is precise management of emissions data. The complexities of integrating market-based regulations with a plant control network are described here  
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The LNG  terminal is an important link in the liquefied natural gas chain, accounting for 20 per cent or more of the total project cost.  It also has potential for cost reduction.  The author discusses various strategies for cutting cost and their impact on terminal design.
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With advancing automobile engine design, a major Russian gas processing complex was faced with the need to produce unleaded, high octane gasolines, which meant replacing existing monometallic Russian catalyst with a new breed of catalyst.  This is an account of how the change was accomplished.
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Hybrid catalysts made by combining zeolites with platinum-promoted tungstate-modified zirconia provide a promising way to obtain higher catalytic activity and higher selectivity for desired fuel products.
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A case study showing how asset life extension helped a leading manufacturer of ammonia and urea to assess the condition of its plants and put in place effective asset strategies that support the achievement of business objectives



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Five types of on-purpose propylene production are available, including propane dehydrogenation, metathesis, olefins cracking and interconversion, high severity FCC, and gas-to-olefins. Each one is discussed in detail



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A Hungarian ethylene producer has identified more than a $30 per ton increase in profit.  The initial phases of a profitabiltiy programme show what can be achieved in a collaborative effort with the right tools and methodologies.

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One solution to the logistical constraints seen in ethylene plant furnace scheduling is technology that automatically generates multiple optimised schedules for schedulers to analyse and quickly select the best one to be executed.

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An integrated refining and petrochemical approach to paraxylene manufacture from various feedstocks, such as excess aromatics in reformate or pyrolysis gasoline. A paraxylene production complex is reviewed and its component units described


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An insight into the R&D, optimisation and engineering activities needed to take Fischer-Tropsch pilot plant data through all development stages, from “ballpark” scoping to the more detailed levels of engineering definition



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A selection of profitable contracting strategies for capital-intensive GTL projects. The author reviews how GTL projects have evolved, from their inception through the various stages of engineering and study to the award of an EPC contract



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A description of modifying pressure control strategies to avoid n-hexane solvent loss in a process unit’s intermediate storage vessels. A new control philosophy was implemented to improve the existing split-range pressure control strategy



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An implicity approach-based method for calculating distillation column dynamics has been used to model time-dependent effects of independent disturbances with a demethaniser column.  Startup and shutdown sequences can be tested in this way.
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A review of the use of chloride guard beds to treat liquid phase and gas phase streams to prevent operational problems from hard-to-detect organic chlorides, while at the same time avoiding side reactions and high partial pressures.
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A close examination of natural gas preconditioning and final conditioning processes, including the associated chemical, physical and hybrid solvents involved. The author also looks at the various Claus tailgas-treating technologies


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Conventional and new approaches to the control of fouling in vinyl monomer processes are discussed in this article, which describes the fouling characteristics of three vinyl monomer processes: acrylic acid, vinyl acetate and vinyl chloride


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A review of diagnostic tests that are used for identifying the causes of caustic system fouling. The author also looks at methods of monitoring the onset of fouling and some of the ways by which the problem can be minimised


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Recent developments in methanol-to-propylene conversion are based on a simple fixed-bed reactor system and common processing elements, providing an economic route to dedicated propylene independent of petroleum-based processes


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A number of naphtha simulation options are available. The four scenarios that form the basis of these simulations can lead to the best options for cracking less conventional streams such as LSR and FCC naphtha, while also producing propylene




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Catalysts have a significant impact on steam-reforming plant rate and reliability. Catalyst selection depends on feedstocks, operating conditions and reformer design. Important criteria include activity, shape and size of the catalyst


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Transalkylation catalysts are able to convert heavy aromatics into high-quality petrochemicals at lower recycle rates and with increased run lengths without the need for a solvent-extraction unit.
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A two-step reaction process for upgrading low-value aromatics to high-value steamcracker feedstock uses optimised catalyst formulations in each reactor.
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Among the subjects in this second article on the place of human factors in project planning, the project business is analaysed - discussing how ergonomic principles should be integrated - and the framework of a warranted quality system, including management monitoring tools and system auditing.
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Processes now used in the new generation of hydrogen plants make a wide choice of catalysts necessary in order to meet the requirements of particular systems.  This article describes the capabilities of some of these catalysts.
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Although homogeneous catalysis is not as widely used in hydrocarbon processing as heterogeneous catalysis there are industrial applications where the former, in liquid phase, has many advantages, including relatively high selectivity and product purity, low investment and mild operating conditions.
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The growing demand for polyvinylchloride (PVC) and its raw material vinychloride monomer (VCM) means expansion of capacity in the coming years.  New plants will need to have low capital and operating costs and be aware of environmental issues.
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Deep catalytic cracking was developed by the Research Institute of Petroleum Processing (RIPP), Beijing, and employs the Institute's propietary FCC catalyst.  High yields of propylene, butylenes and amylenes are obtained, which serve as feedstocks for the RFG blendstocks, alkylate and oxygenates.
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Gas chromatology continues to be the most significant analytical tool used in the petrochemical and refining industries, but downsizing has meant the loss of some of the most experienced people who could pass on their knowledge to those having to deal with increasingly sophisticated equipment.
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Improved PE/PP-polymerisation technology requires more feedstocks free of poisoning components.  Most of these can be removed catalytically.  A system of noble metal and copper catalysts makes it possible to take out components like acetylenes, dienes, As and S compounds, oxygen, CO and hydrogen.
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To reduce the cost of recovering olefins, Stone & Webster and BP Chemicals have jointly developed a chemical absorption technology, commercially ready for recovering light olefins from vents from ethylene oxide and synthetic ethanol units, and from streams located within olefin plants.
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By eliminating a tubular fired furnace, the Kellogg Reforming Exchanger System (KRES), used in the production of methanol, is proving to be profitable and energy efficient against conventional steam reforming.
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Two surveys were organised by the Amine Best Practices Group in order to build a database to compare the operating efficiency of different amine units.  This article reports the findings of the latest survey, which focused on the question of operating costs and some of the design features affecting them.
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The preferred method of removing acetylene from ethylene and propylene in olefin polymerisation catalysts is by selective hydrogenation, and modern methods involve palladium catalysts.  An experiment to learn more about the acetylene removal process under different feed conditions is described here.

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Tubular reactors, used in many processes, have been limited in capacity and scope by practical and economic constraints.  A new technology to overcome many of these shortcomings has been developed.  This article addresses its advantages for both endothermic and exothermic reaction systems.

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Advances in computer technology have made it possible for dynamic process simulation to be used in a wide range of applications.  This article describes the Trainer system and its use as a training simulator for LNG plant operators.

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Ethylene producers are seeking ways to upgrade the mixed C4 stream from ethylene plants to improve operating economics.  Various technologies have been commercialised, including butadiene extraction, MTBE, and several others that can be combined to produce or recover various C4 products.
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Methyl-isobutyl-ketone (MIBK) is a widely used solvent in the medium pressure boiling range.  Over 30 years, the single-stage MIBK process, using acetone as a feedstock, has been developed to a state-of-the-art technology.  This article examines the process.
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A new crystallisation process for paraxylene, which is a parent material for PET, is based on Sulzer Chemtech's heat pump crystalliser technology, and features two crystallisers and a refrigeration plant.  Energy consumption and investment costs are claimed to be lower than with conventional systems.
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Integrating a human factors engineering strategy in the early phases of preparations for a new project has been shown to produce significant financial and work-related benefits, not least in reduced capital expenditure.
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Some of the new technologies associated with para-xylene production are discussed in this article, particularly developments that have overcome previous limitations to productive capacity.
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A global shortage of n-paraffins, and the consequent rise in prices, presents an opportunity to refiners and petrochemical producers to add value to their kerosene by diversifying into normal paraffins, says the author.  The technology for doing so is illustrated by operating data.

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The authors describe the thinking and practical aspects behind building a 10000 tonnes/day methanol plant, employing the proven technologies already in use in commercial scale production.

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Description of a means of using low-grade feedstock to supply both a competitively priced synthetic chemical and low cost and reliable peaking electricity, without the need to develop any new processes or equipment.

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The authors describe a post reactor process, downstream from the main reactor, for eliminating detrimental byproducts from the catalytic PA reactor.

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The author sees the future for polypropylene expanding as new materials, some of which are described here, rejuvenate existing applications and create new opportunities based on competition between materials and product differentiation.

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A recently built petrochemical complex has been working on a programme to predict the yield patterns for a variety of feeds and operations, using case studies to determine how actual performance compares with the plant's potential.

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Agreement between the simulated and the experimental results in an exercise involving three reactors at a petrochemical plant established the accuracy of the proposed model and the simulation programme.
   

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Efficient utilisation of refinery offgases can prove to be attractive for hydrogen production by employing hybrid or integrated systems.  But attention must be given to specific operational requirements to achieve flexibility and reliability.

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Recently introduced technologies are offering para-xylene producers the option of lowering production costs by reducing feedstock requirements and, says the author, enabling para-xylene production increases without hardware modifications.

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A detailed review of a proprietary technology that reduces methanol production costs wherever low cost natural gas is available.  With rising oil prices, low cost methanol is seen as a profitable feedstock for conventional petrochemical processes.

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An overview of ethylene recovery and processing, outlining low temperature/cryogenic processes for recovery of ethylene from refinery offgases and from polyethylene plants offgas streams, and the purification of recovered ethylene.

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This article looks at examples of commercial columns used in CO2 removal and selective H2S treating, comparing performance test data to demonstrate benefits of modelling actual column internals using mass transfer rate process simulation.

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A reliable and cost effective asset management strategy can increase hydrogen plant throughout as well as optimise operating conditions and energy efficiency.  This article looks at the way current operations may be optimised.

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Optimisation of operating conditions requires an in-depth study of the hydrogen plant, say the authors.  They consider the optimisation of catalyst and absorbent to maximise hydrogen output beyond the capabilities of operations strategies.

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How fully automated thermal oxidiser units containing energy and byproduct recovery systems are able to resolve operational concerns over organic wastes, and can be the most economic way to dispose of chlorinated hydrocarbon residues.

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The extended application of Coriolis meters for measuring natural gas minimises the uncertainties associated with volumetric flow measurement.  Installation requirements and overall cost can also be simplified and reduced.

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Application of computational fluid dynamics in the design of a high-flux ethylene furnace equipped with ultra-low NOx vortex burners.  The fundamental kinetics mechanisms that are important in NOx formation under combustion are described.        

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An extractive distillation process provides direct recovery of aromatics from FCC gasoline to rebalance refinery production towards higher levels of petrochemicals.

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Maximising the use of natural gas in a refinery-petrochemicals complex offers higher margins and lower carbon emissions
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