PETRO PROJECT ENGINEERING, INC.

Serving Petroleum Refineries & Petrochemical Plants Worldwide Since 1980

 

Chemical Process Design Assignments

In 1980, Petro’s first job was to revamp Sooner Refining Company’s Egan Refinery in Louisiana. Petro used Simsci’s “PROCESS” to simulate crude oil distillation and designed adequate overhead cooling capability.  As a result the refinery was able to increase crude throughput from 7,500 BPD to 12,500 BPD.

In 1985, Petro provided complete engineering for Celeron Oil’s Jennings Ethanol Plant. Petro developed process design from scratch using Simsci’s “PROCESS” and then implemented the design into a new plant which was built in Jennings, Louisiana.  This was the first complete plant engineered by Petro. The plant concentrated aqueous ethanol (12%) from corn for use as automotive fuel—gasohol.  Celeron was a wholly-owned subsidiary of Goodyear. Jennings, Louisiana, is 200 miles east of Houston.

In 1987, Petro under took to simulate FCCU debutanizer at a Convent, Louisiana refinery. Petro used Simsci’s “PROCESS” for the job.

In 1992, Petro developed a process to manufacture dimethyl ether for use as an aerosol propellant. We used “DESIGN II” for simulating the process.

In 1993, Petro engineers completed work on developing Aerosol Propellant Technology.  We were granted U.S. Patent (No. 5,191,146) for a process to refine LPG into aerosol propellants. Heat and material balance for the process was developed using ChemShare (“DESIGN II”). Using this process you can produce eco friendly, stable alkane (propane, n-butane and i-butane) propellants for personal care products like hair sprays, deodorants  etc.

In 1994, Petro completed a “DESIGN II” model of carbon black manufacturing process.

In 1995, Petro engineered an Aerosol Propellant Plant, which was built in China. The process was hydro de-sulfurization followed by advanced extraction. These are disclosed in the U. S. Patent application. This was another complete plant engineered by Petro. Petro used “DESIGN II” process simulator.

In 2002, Petro was involved in a revamp at a turbo-expander plant in Cote d’Ivoire.  Wet inlet gas from oil wells is cooled to cryogenic temperatures and ethane and heavier petroleum fractions are separated.  Petro delivered a process design package, cost estimate and a 3-D layout of a new de-propanizer. All process work was done using “DESIGN II” simulator.

In 2003, Petro developed a simulation model of Wet Gas Recycle Process to produce formaldehyde from methanol.  Petro is now ready to provide complete design of formaldehyde plants. “DESIGN II” was the process simulator.

Petro has ready designs to manufacture hydrogen sulfide, methyl mercaptan, dimethyl sulfide, ethyl mercaptan. Simulation models are ready in “DESIGN II”.

In 2004 Petro addressed flow assurance issues of about twenty five Zafiro offshore wells in Equatorial Guinea. Petro performed hydraulic analysis of multiphase flow using Invensys’ PIPEPHASE.

In 2005, we developed a process for the reduction of NOx from furnaces. 

We continue of find opportunities in separation using distillation.  We will obtain vapor—liquid equilibrium data from published sources (or the client). Then regress this data into an Equation of State (NRTL, Wilson etc.) using “DESIGN II” (ChemShare) and finally use “DESIGN II” to design a complete distillation plant.

In 2006, we were retained by the law firm Abrams, Scott & Bickley (Houston) to assist in litigation on a turboexpander plant built in Geismar, Louisiana.

In 2007, we developed an engineering design to concentrate ethanol for a plant which was to be built in Fairmont, Minnesota. We performed process simulation using “DESIGN II”, developed 3-D layout using CadWORX.

In 2007, we studied Marathon Oil’s Oletha Field in Texas and developed a PIPESIM model for flow assurance analysis.

In 2007 we analyzed an evaporator for concentrating glycol, which is used for deicing aeroplanes.

Activities in 2008 consisted of simulation of a process to manufacture tetramethyl ammonium chloride.  We performed simulation using “DESIGN II”.

Environmental Assignments  

Petro recognizes that our clients’ need for environmental guidance and consultation services are frequently unscheduled, unbudgeted and last minute surprises.

Petro will coordinate periodic testing services to meet permit requirements.  We will review records and consult on environmental control system performance and operating procedures.

Petro will respond to specific situations and assist in problem definition, identifying corrective alternatives and recommending a course of action to pursue. Sometimes, situations under study may be an unanticipated problem caused by manufacturing process change, control system malfunction oversight in a regulation requirement or a misguided public or government opinion.

We have prepared air permitting applications for clients in Louisiana and Texas.  We have also completed air emissions inventory for large and complex chemical plants:

           Mobil Oil, Chalmette Refinery, Chalmette, Louisiana        

           Murphy Oil, Meraux Refinery, Meraux, Louisiana

           Quantum Chemical, Deer Park, Texas

 

We have prepared waste water permitting applications for clients in Louisiana and Texas.  Petro has prepared NPDES Permit Applications for:

           Sooner Refining Co., Egan, Louisiana

           Ingleside Properties, Ingleside, Texas

           Celeron Oil, Jennings, Louisiana                 

           Calgon Corp., Pasadena, Texas       

 

Petro’s engineers conducted a concept design to recover acrylonitrile from a wastewater stream at  a chemical plant near Bay Minnette, Mississippi.  The evaluation considered various processing conditions at the plant.

Petro was retained to study high BOD/COD levels in wastewater at a chemical manufacturing plant located forty miles north of Mobile, on Highway 43  in 1988. Constituents of concern were alcohols, ketones and oil & grease. Petro studied the process and recommended changes to process to avoid contamination. 

In compliance to 40 CFR  Part II2  Petro has prepared and certified SPCC for refineries and chemical plants in Louisiana and Texas. Representative clients for whom Petro has prepared SPCC are:

           Mt. Airy Refining Co., Mt. Airy, Louisiana   

           Sooner Refining Co., Egan, Louisiana

           Ingleside Properties, Ingleside, Texas

           Celeron Oil  Co., Jennings, Louisiana

           Kaneka, Pasadena, Texas

           SQM, Pasadena, Texas

 

Forensic Assignments  

 

We have provided consultation to law firms on litigation support and have testified as Expert Witness on chemical processing, petrochemical manufacture and related cases. 

 

Recent forensic work includes:

 

Cause No. 2001-48088; Gulsby—Bay Partners v. Gulf Liquids New River Project LLC in the 215th Judicial Court of Harris County, Texas (2006).

 

Case No. 04-Cl-01449; Process Construction v. Kenton County Air Board & URS; Commonwealth of Kentucky, Boone County Court (9546-1).

construction of manufacturing plants. (2006—2008) 

 

American Arbitration Association; Lurgi, Inc. v. Thermal Kinetics Systems, LLC, Case No. 30 154 Y 00454 08.  (2009)

 

From our forty years of service, Petro has gained extensive experience in oil refineries, chemical and petrochemical plants, basic metal plants, and air and water pollution abatement.

PETRO—2010

 

Raj  D. Kulkarni, P. E.

Petro Project Engineering, Inc.

P. O. Box 890343

Houston, TX 77289

Tel: (281) 470-2121

E: raj.kulkarni@petroproject.com