Harmonizing Efficiency and Stability: An Improved Approach to Phosgene Reactor Energy and Stress Management

Identifier:  TFM:2081

Handle: https://hdl.handle.net/20.500.11797/TFM2081

Authors:  Escudero Solà, Erik

Abstract:
Energy costs related to utility usage in a chemical plant is a big slice of the yearly total operating costs. This thesis is part of an effort to improve the energy recovery system in the phosgene synthesis section in the COVESTRO’s site in Tarragona. This study will explain how this task was approached and its discoveries. Due to restrictions in what can be and what cannot be done by an internship student, the project has been focused on solutions that do not involve any purchase, costs or changes in conditions that could affect the production or its quality. Once an introduction to the nature of the process and their chemicals is made, a brief summary of the situation is discussed. Later on, the path followed is described as clearly as possible while censoring what could be sensitive data (by having empty axis in plots, talking in percentages, referencing documentation by their unofficial name, etc…). If there is any doubt regarding any of that data, more information can provided with prior authorization of COVESTRO. Finally, conclusions and results could be catalogued in two different parts: troubleshooting and optimization. The troubleshooting part was discovered during the creation of this work and it does not fulfil the mentioned objective but prevents future problems and increase the reliability of the system. The optimization gives as a result a change of operational control (conditioned by process, economical or strategic reasons) that takes the form of an EXCEL® file that is being used by the control panellists. The project has been considered an overall a success leading to important savings in operational costs, when the collected results are extrapolated to a year basis, reaching the six figures number.