Procedural Automation of Ethane Recovery to Rejection in NGL Trains

This paper is based on successful implementation of procedural automation of Ethane (C2) recovery - rejection mode change using Yokogawa's Exapilot software, wherein ADNONC Gas Processing Habshan 5 & Sulphur management approved the implementation based on similar success of the Sulphur Recover Unit start-up/shutdown procedural automation & company's drive for digitalisation. Scope was to develop modules for automating C2 Recovery /Rejection change over procedure in NGL unit using M/s Yokogawa Exapilot software. These automated procedures aimed to standardize said mode change over operations by incorporating the operating know how and the expertise of skilled-experienced operators into the Exapilot system as a set of Standard Operating Procedures (SOPs) that are executed in right operating sequence for enhanced operating efficiency. Two main procedures & associated modules were designed, engineered and built using Exapilot to enable single-click change over automation for NGL units. Those were validated with operation and deployed in the Exapilot Server and were integrated with the Operator Consoles (HIS) for access, and was supplemented with operator training. Ethane Recovery to Rejection Mode Change Ethane Rejection to Recovery Mode Change Besides standardization and reduced change over time, this improved the critical asset integrity and lifespan of NGL section equipment by advocating systematic operations. Following benefits including major take away from this project: ➢ Standardized the mode change-over procedures & minimized human error by the digitalization of paper documentation procedures into electronic workflow process. Procedural Automation like Exapilot is powerful tool for digital transformation of batch/discrete operation like unit/equipment start-up/shutdown or grade/mode change over. ➢ Reduced inherent delay due to manual change over. Hence, minimizing the loss-opportunities & operating cost. Besides this tool can be used as training tool (when used in offline mode) which help operator succession plan & effective knowledge transfer ➢ Automated critical operation such as temperature/flow ramping, improved equipment integrity and prolonged equipment life. Procedural Automation using Exapilot thus can improve operation efficiency, asset integrity, equipment or material life span This paper presents a success story of procedural automation of batch operation in continuation of similar success in SRU start-up & shutdown automation. This tool along with proper integration work with DCS, has opened door for automation/digitalization in batch operation in continuous process not only in other sites of ADNOC Gas Processing and other ADNOC Group Companies but also in other industries that helps companies to enhance efficiency and fulfil their digitalization journey. Though Exapilot software belongs to M/s Yokogawa, however other DCS systems have similar software such as Honeywell DCS EPKS has E-procedure for procedural automation.

A Short Review on the Utilization of Incense Sticks Ash as an Emerging and Overlooked Material for the Synthesis of Zeolites

The traditional hydrothermal synthesis methods are mainly performed under batch operation, which generally takes few days to weeks to yield a zeolite with the desired properties and structure. The zeolites are the backbone of the petrochemical and wastewater industries due to their importance. The commercial methods for zeolite synthesis are expensive, laborious and energy intensive. Among waste products, incense sticks ash is a compound of aluminosilicates and could act as a potential candidate for the synthesis of zeolites for daily needs in these industries. Incense sticks ash is the byproduct of religious places and houses and is rich in Ca, Mg, Al and Si. As a result, incense sticks ash can be proven to be a potential candidate for the formation of calcium-rich zeolites. The formation of zeolites from incense sticks ash is an economical, reliable and eco-friendly method. The application of incense sticks ash for zeolite synthesis can also minimize the problem related to its disposal in the water bodies, which will also minimize the solid waste in countries where it is considered sacred and generated in tons every day.

Optimization of Hydrolysis-Acidogenesis Phase of Swine Manure for Biogas Production Using Two-Stage Anaerobic Fermentation

The traditional pig manure wastewater treatment in Taiwan has been low in methane production efficiency due to unstable influent concentration, wastewater volume, and quality. Two-stage anaerobic systems, in contrast, have the advantage of buffering the organic loading rate in the first stage (hydrolysis-acidogenesis phase), allowing a more constant feeding rate to the second stage (methanogenesis phase). Response surface methodology was applied to optimize the operational period (0.5–2.0 d) and initial operational pH (4–10) for hydrolysis and acidogenesis of the swine manure (total solid 5.3%) at 35 °C in batch operation mode. A methanogenesis verification experiment with the optimal condition of operational period 1.5 d and pH 6.5 using batch operation resulted in peak volatile acid production 7 g COD/L, methane production rate (MPR) 0.3 L-CH4/L-d, and methane yield (MY) 92 mL-CH4/g-CODre (chemical oxygen demand removed). Moreover, a two-stage system including a hydrolysis-acidogenesis reactor with the optimal operating condition and a methanogenesis reactor provided an average MPR 163 mL/L-d and MY 38 mL/g volatile solids, which values are 60% higher than those of a single-stage system; both systems have similar dominant methane-producing species of Firmicutes and Bacteroidetes with each having around 30%–40%. The advantages of a two-stage anaerobic fermentation system in treating swine manure for biogas production are obvious.

Challenges in transfer of gas-liquid reactions from batch to continuous operation: dimensional analysis and simulations for aerobic oxidation

The transfer of gas-liquid reactions from conventional batch processes into continuous operation using milli and micro reactors is claimed as an important step towards process intensification. Importantly, this transfer step should be realized in an early phase of process development, already, in order to minimize research efforts towards the undesired operation strategy. The main challenge of this approach, therefore, arises from lack of knowledge in the early stage of process development and the resulting system with high degrees of freedom. This contribution presents an approach to tackle this challenge by means of mathematical modelling and simulation for the aerobic oxidation of 9,10-dihydroanthracene (DHA) catalyzed by polyoxometalates (POMs) being used as example for gas-liquid reactions. The reaction was chosen as it provides sufficient complexity, since it consists of three consecutive oxidation steps of DHA and a parallel catalytic redox-cycle according to a Mars-van-Krevelen mechanism. It also provides the challenge of unknown reaction kinetics, which have been estimated in this contribution. The dimensionless balance equations for reactor modeling are derived and parametrized based on early stage experimental results obtained in batch operation mode. The discrimination between batch and continuous operation was performed by means of characteristic dimensionless numbers using the identical mathematical model for comparability reasons. The model was used to perform sensitivity studies with emphasis on the interplay between mass transfer characteristics and reaction kinetics for both the batch and continuous operation mode. The simulation results show that the performance of both operation modes mainly depend on the oxidation state of the POM catalyst, which is caused by the differences in oxygen availability. Therefore, results obtained in batch operation mode are prone to be masked by mass transfer issues, which affects catalyst and reactor development at the same time and may thus cause maldevelopments. With respect to process development it can thus be concluded that the transfer from batch to continuous operation together with mathematical modeling is important in an early phase, already, in order to detect limitations misleading the development. Finally, even simple models with roughly estimated parameters from preliminary experiments are shown to be sufficient in the early phase and can systematically be improved, in the subsequent phases. Graphical abstract