2 weeks ago, Professor Silveston from Waterloo University Canada came to Universiti Teknologi Malaysia for an assignment. While he was around, he gave a workshop on problem solving. It was really a very interesting workshop and we learnt how to think critically on how to solve problems (it can be any problem including chemical engineering operation problems).
I would like to share one problem that he gave us and I want to see some ideas. Please feel free to gave your opinion on the answer for the problem.
Flash Fire ProblemHeavy naphtas are converted into high octane gasoline in platformer. By products of the reaction include LPG and hydrogen rich gas containing 6-80% by volume hydrogen. The products from the platformer reactor (at 700 psig and 500 oC) are heat-exchanged with the naptha feed to the reactor. This preheats the feed. The platforming catalyst is rapidly fouled and must be generated by blowing with steam or waste gas. Thus the process is cyclic. A battery of reactors maintains a steady flow.
In three weeks since the startup, there have been four flash fires along the flanges of the heat exchanger. The plant manager claims that because of the differential expansion within the heat exchanger, because of the diameter of the exchanger and the stream hydrogen is rich these flash fires are bound to occur. The maintainance mean have broken 6 bolts trying to get the flange tighter, but they just cannot get it tight enough. The excahanger costs $200,000 and the whole plant costs #39 million. The technical manager says that the plant must be safe in 3 days.
What will you do?
What are the actions?
Can you think and share with us your action plan...
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