(187e) Safely Overcoming Capacity Constraints Challenges Using UOP Process Equipment and Callidus Flares

Distillation column diameters have increased significantly over the past 20 years as plant nameplate capacities have grown at an accelerated pace. Column diameters exceeding 10 meters in new propylene and aromatics separations are becoming more commonplace. Large column diameters pose new challenges for the fabrication, transportation and erection of the column shell as well as the design, supply, and installation of the associated column internals. This paper will discuss how UOP has addressed these challenges through continuous evolution of mechanical improvements to UOP trays over the past forty (40) years. These design improvements are utilized today to ensure mechanical integrity and address isometric concerns with columns employing multiple reboiler and condenser shells. UOP tray designs able the operator to intuitively and easily install the trays safely even under constrained turnaround schedules.

Multi-point Ground Flares (MPGF) are the preferred technology for pressure relief in many ethylene plants. Like elevated flares, they provide a safe means of depressurizing the plant should an upset occur. Unlike elevated flares, proper design criteria have not been widely disseminated or discussed within the industry. Based on a series of performance studies conducted at the UOP Callidus multi-point flare test facility, engineering calculations, and computational fluid dynamics (CFD) models have been developed to provide greater insight into the design of MPGF. Various design inputs are discussed including physical test data and calculations, burner head design, plot space requirements, fence height requirements, and the number of stages required for correct operation. The resulting impact of the MPGF design on capital equipment cost, operating cost, environmental impact, and safety are highlighted.