Flaring is crucial to chemical plant safety. However, excessive flaring, especially the intensive flaring during the chemical plant start-up operation, emits huge amounts of volatile organic compounds (VOCs) and highly reactive VOCs, which meanwhile results in tremendous industrial material and energy loss. Thus, the flare emission should be minimized if at all possible. This paper presents a general methodology on flare minimization for chemical plant start-up operations via plantwide dynamic simulation. The methodology starts with setup and validation of plantwide steady-state and dynamic simulation models. The validated dynamic model is then systematically transformed to the initial state of start-up and thereafter virtually run to check the plant start-up procedures. Any infeasible or risky scenarios will be fed back to plant engineers for operation improvement. The plantwide dynamic simulation provides an insight into process dynamic behaviors, which is crucial for the plant to minimize the flaring while maintaining operational feasibility and safety. The efficacy of the developed methodology has been demonstrated by a real start-up test.

Epoxy resin nanocomposites reinforced with three different ionic liquid functionalized carbon nanotubes (f-CNTs) were fabricated by an in situ polymerization method. The influence of the anions on the curing process was studied through differential scanning calorimetry (DSC) and normalized Fourier transform infrared (FTIR) spectroscopy. The composition of the nanocomposites was analyzed by X-ray photoelectron spectroscopy. Two different mechanisms are proposed to explain the curing process of the neat epoxy and its composites. The electric conductivity and mechanical properties of the nanocomposites are also reported. The tensile strength was increased dramatically due to the insertion of f-CNTs. Scanning electron microsopy fracture surface analysis indicates a strong interfacial bonding between the carbon nanotubes and the polymer matrix.

Multistage compression systems (MSCS) are the most important and valuable facilities in chemical plants, whose failure may cause severe accidents and/or tremendous economic loss. Thus, operation for MSCS needs sufficient care under various situations, especially during plant startup. This paper employs rigorous pressuredriven dynamic simulations to examine and improve operation safety of the cracked gas compression system during an ethylene plant startup. For safety consideration, antisurge process design and control strategies are dynamically evaluated along with startup procedures. Operating point trajectory for each compressor and their potential safety problems are identified. Assisted by the rigorous dynamic simulation, the plant startup procedure is improved with better safety performance.

Flaring is an important but passive method in ethylene plants to protect plant personnel, facilities, and the ambient environment. However, excessive flaring emits huge amounts of CO, CO2, NOx, and hazardous volatile organic compounds (VOCs), which may cause locally transient air pollution problems and negative societal impacts. Flaring may also cause high losses of raw material and energy that could generate more desired products for the industry. Thus, flare minimization has great benefits to environmental, societal, and industrial sustainability. Based on current industrial practices, a general strategy for flare minimization under various ethylene plant events is presented.

Ethylene plant upsets usually lead to flaring of off-spec products, resulting in significant losses of raw material and energy as well as to air emission problems. Under the premise of plant safe operation, establishing process recycles connecting off-spec streams to their upper-stream process can help to reduce flaring during plant upsets. Operational strategies for recycling the potential flaring sources, i.e., effluents from the acetylene reactor and ethylene tower overhead, under various process upsets are developed and analyzed based on rigorous plant-wide dynamic simulations. Safety considerations on the compressor system performance have been addressed by quantitative comparison of the effectiveness of various recycling strategies. Case studies demonstrate that the safety-considered flare minimization strategies can proactively reduce the flaring emission amount and upset time and thus have great potentials of economical and environmental benefits to ethylene plants.

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Ethylene oxide (EO) is an important chemical intermediate for the production of various chemical products. The manufacturing of EO involves critical exothermic reactions at high temperature and high pressure, whose failure may cause catastrophic personal injury, severe air pollution, and tremendous economic loss. Thus, an EO plant must be well controlled under various situations, especially during its start-up operations. In this paper, a general methodology for improving chemical plant start-up operations through plant-wide dynamic simulation has been developed. It undergoes modeling and validations for steady-state, dynamic, and historian start-up operations. On the basis of the validated dynamic simulation model, the original plant start-up strategy is further examined and optimized to speed-up the plant start-up operation with enhanced safety considerations. A case study on an EO plant start-up has demonstrated the significant operational and economic benefits of the proposed methodology.

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