Safe Design and Operation of Process Vents and Emission Control Systems creates an increasingly complex systems for more effective treatment, dispersal, or disposal of process gases.

Features:

• Preventing fires, explosions, and toxic releases
• Maintaining safe vent conditions
• Understanding normal process operations, such as intentional routine controlled venting and emergency operations, like overpressure relief
• Mitigating the impacts of end-of-line treatment devices, such as scrubbers, flares, and thermal oxidizers, on the vent header system
• Complying with regulations

Contents

Introduction

• Relationship to Other CCPS Publications.
• Industries and Operations Covered.
• Intended Audience.
• How to Use this Book

Management Overview

• Impact on Vent Header Systems

Normal Process and Emergency Systems

• Types of Vent Header Systems.
• Normal Process Vent Header Systems.
• Emergency Vent Header Systems.
• Combined Vent Header Systems.
• Considerations.
• Design Philosophy.
• Design Sequence.
• Hazards Associated with Combining Vent Streams.
• Inherent Safety.
• Flammability and Combustibility.
• Toxicity.
• Reactivity.
• Regulatory Issues

Combustion and Flammability

• Flammable Limits.
• Mixture Stoichiometry.
• Factors Influencing Flammable Limits.
• Flammable Limit Variability.
• Effects of Temperature on Flammable Limits.
• Effects of Pressure on Flammable Limits.
• Flammable Limits of Combined Gas Streams.
• Cool Flame.
• Hybrid Mixtures.
• Limiting Oxidant Concentration.
• Deflagrations.
• Pressure Piling.
• Detonation Phenomena.
• Deflagration to Detonation Transition (DDT) and Run-Up Distance.
• Overdriven and Stable Detonations.
• Detonation Cell Size

Understanding Requirements

• Understanding the Sources.
• Identify Vent Sources.
• Identify Normal Process Vent Streams.
• Normal Process Vent System, Design Case Scenario.
• Define Interface Requirements.
• Identify Hazard Scenarios That Could Result in Emergency Venting.
• Vent Gas Characteristics for Emergency Venting.
• Emergency Venting Design Case Scenario.
• Liquid Entrainment or Condensation in Normal Process Vent Headers.
• Two-Phase Venting.
• Flammable Gases and Vapors.
• Toxic and Noxious Materials.
• Reactive Systems.
• Regulatory Issues.
• Historical Background.
• Brief Review of Laws and Regulations.
• Improved Air Quality.
• At-Source Treatment Options.
• Combining Vent Streams.
• End-of-Line Treatment Systems.
• Specify Design Requirements

Design Approach

• Design Basis.
• Merging Vent Streams.
• Features Favorable for Merging Steams.
• Features that do not Favor Merging Streams.
• Vent Header Systems Handling Flammable Materials.
• Explosion Prevention.
• Operating Fuel Lean.
• Operating Inerted.
• Operating Fuel Rich.
• Oxidizers Other Than Oxygen.
• Explosion Protection.
• Ignition Sources.
• Vent Header Systems Handling Toxic Gases.
• Operating Principles for Header Systems Handling Toxic Gases.
• Piping Design.
• Combined Relief Valve and Rupture Disk Devices.
• Reactive Systems.
• Reactive Systems Design Considerations.
• Mechanical Design Considerations.
• Vent Header Pipe Specifications.
• Vent Header Supports.
• Stresses on Vent Header Piping.
• Shock Waves Downstream of Rupture Disks.
• Corrosion.
• Header Operating Pressure and Pressure Drop.
• Thermal Stresses and Low Temperature Embrittlement.
• Liquid Knock-Out and Drainage.
• Expansion Joints and Flexible Connections.
• Valves in the Vent Header System

Treatment and Disposal Systems

• Selection of Treatment and Disposal Methods.
• Collection.
• Containment.
• Collection with Venting.
• Dump and Catch Tanks.
• Blowdown Drums and Tanks.
• Quench Drums.
• Quench Pools.
• Advantages and Disadvantages ? Collection Systems.
• Physical Separation.
• Vapor-Liquid Gravity Separators.
• Knock-Out Tanks and Drums.
• Mist Eliminators.
• Cyclones.
• Advantages and Disadvantages ? Physical Separators.
• Absorption.
• Spray Towers.
• Tray Towers.
• Packed-Bed Scrubber.
• Venturi Scrubbers.
• Advantages and Disadvantages -- Absorption Systems.
• Adsorption 156.
• Advantages and Disadvantages -- Carbon Adsorption.
• Recovery.
• Condensing Systems.
• Gas Recovery Systems.
• Advantages and Disadvantages -- Recovery Systems.
• Thermal Destruction.
• Flares.
• Thermal and Catalytic Oxidizers.
• Process Heaters Used for Thermal Destruction.
• Advantages and Disadvantages -- Thermal Destruction Systems.
• Dispersion of Vent Gas.
• Design and Safety Considerations.
• Atmospheric Dispersion Design.
• Advantages and Disadvantages -- Dispersion to Atmosphere

Hazard Analysis and Consequence Assessment

• Hazard Analysis Methods.
• Hazard Analysis Process.
• Identification of Causes.
• Development of Consequences.
• Estimation of Hazard Scenario Risk.
• Consequence Assessment Techniques

Operations and Maintenance

• Daily Inspections.
• Scheduled Inspections and Maintenance.
• Materials Build-Up.
• Pressure Relief Valves and Rupture Disks.
• Conservation Vents.
• Explosion Prevention Systems.
• Fast Acting Valves and Chemical Isolation Systems.
• Explosion Relief Panels.
• Inerting Systems.
• Instrument and Controls.
• Low Point Drains.
• Corrosion and Erosion.
• Structural Supports for Vent Headers.
• Insulation and Heat Tracing.
• Management of Change

Index

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