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PROJECT PROPOSAL 2003-2004 (RAS/8/091) 1. Title: Process Diagnostics and Optimization in petrochemical Industry 2. Project Description: a) Specific problem to be addressed: Petroleum and petrochemical industries are fast modernizing in the Region. Many new petrochemical complexes are being established. The need of the hour is troubleshooting in existing plants and deciding on the optimum parameters for the new plants. The modern industry is sufficiently aware of the role isotope techniques can play in meeting the above needs and indigenous availability of such technology can go a long way in helping the industry. Radioisotope techniques include NDT, tracer technology and sealed source applications. It is well recognized that a synergistic application of all these methods is the best way to provide the right answer for troubleshooting as well as for optimization of the process parameters. The project aims to provide an integrated indigenous capability in isotope techniques in each of the participating RCA countries for troubleshooting and optimization of process parameters in petroleum and petrochemical industries. The proposed project is related to promotion and applications of radioisotope technology for troubleshooting and process optimization in industry. Most commonly encountered problems in industry are leak detection, malfunctioning of the process vessels and columns. The proposed project mainly addresses the application of radiotracer and sealed sources for problem solving in oil, petroleum, and petrochemical and chemical process industries. Relevant target areas for radioisotope applications in RCA developing countries are already defined. Though the technology is applicable across a broad industrial spectrum, the petroleum industry, petrochemical and chemical process industries, sectors are identified as the most appropriate target beneficiaries of radioisotope applications within RCA Region: these industries are widespread internationally and are of considerable economic and environmental importance. b) Nature, magnitude, causes and effects of the problems Radioisotopes continue to play an important role for better management of natural resources, industrial growth and environmental preservation. Considerable progress has already been made in promoting the industrial applications of radiotracers, sealed sources and nucleonic gauges in RCA developing countries. Looking into trends in industrialization of RCA developing countries there is evidence that the radioisotope technology will continue to play an important role in industry for many years to come. The economic benefits of the technology have been amply demonstrated. There is now a need to consolidate, refine and systematize existing know-how, and to extend further the capabilities of the technology through on-job demonstrations for problem solving and case studies, and to develop the quality control of data and results. c) End users The major end users’ problems in RCA developing countries are inspection and troubleshooting detection of columns, reaction vessels and pipes in petroleum refineries and other chemical process industries. d) Regional approach to the problem identified The appropriate way to develop further radioisotope technology is through regional co-operation. The existing regional projects RCA played an important role to develop the personnel expertise and skills of national tracer and sealed sources groups. Viable tracer groups are well established in RCA developing countries. Regional resource units could be created in these RCA developing countries to accelerate technical co-operation among the developing countries. e) Technical justification including objectives, methods proposed for solving the problem The competition with alternative methods shows that radioisotope techniques have survived and prospered in the past because of their superiority in certain areas to competitive methods, or in many cases to solve a problem where there were no alternative methods. The general objective of this project proposal is to upgrade the capability of radiotracer and sealed source groups in RCA developing countries, to consolidate and systemize existing know-how, and to extend further the potential of the radioisotope technology using new techniques and applications which are beneficial for problem solving in industrial processes. The objective for the cycle 2003-2004 is the following: To maximize the radioisotope technology transfer to end users, to implement and sustain the commercial routine application of radiotracers for problem solving of technology in priority industrial sectors: in petroleum industry and chemical process industry increasing the productivity and reducing the environmental impact. f) Results expected The following outputs are expected to be achieved: Outputs : The expected results from the project will be ; Setting up in-house tracer groups in two different petroleum refining and process equipment manufacturing public sector companies. Establishing links with academic institutions involved in research on design of different process vessels Widening the applications of radioisotopes in industry by three folds in the next five years The results of the applications will lead to optimise the design of various process systems at design stage and improvement in process efficiency of full scale industrial systems. the end users’ industrialists will be informed on the technology, through: i. Regional workshops and Expert group meetings, ii. Expert missions and fellowships. iii. Regional/ National Executive management seminars to promote the adoption of the technology by industry. iv. Supply of equipment. The technical, social and economic benefits from the routine applications of radioisotopes in industry and environment are known as relevant due to the process optimization, saving in raw materials, energy and reducing of industrial pollution. g) Project duration The project long-term objectives could be meet in five-year time, but the short and medium term objectives can be met for two years duration 2003-2004 The main phase of implementation of the project is 2003-2004. The further implementation of some techniques for routine applications should continue beyond 2004. h) Estimated budget of the project States participating in RCA programme must contribute to the implementation of the project to the maximum extent possible, given that RCA's main objective is not to set up an infrastructure in the participating States, but to enable them to share their facilities and the know-how existing in the region. Their contribution may be in local currency or in kind and may be in the form of logistical support for the activities being carried out in their respective countries, the provision of cost-free experts and standard equipment. The radioisotope provision or sample irradiation in nuclear reactors should be promoted considering the lack of irradiation facilities for radioisotope production in some RCA countries. The Agency will support to the extent possible the project by means of organization of training courses, of expert missions for on job demonstrations and problem solving, of guidebooks and software, and of provision of some components and spare parts and some standard data loggers and simple devices. i) Relation with ongoing projects - NEW PROJECT- 3. Proposed work plan and schedule of major project activities for the first two years. 3.1 Preparation of regional standards for assessment and certification of competency in the application of radioisotopic techniques for: Column scanning Blockage detection Detections of leaks 3.2 Transfer of knowledge and extension of industrial use of radiotracers applications for: Routine services for troubleshooting and process optimisation in petrochemical, and petroleum refining industries . Modeling of hydrodynamic behaviour of different process vessels like Fluid Catalyst Cracking Units (FCCU), of trickle bed reactors at high pressure, Design optimization of vacuum pan crystallizers in sugar industries etc. Leak Detection industrial systems. Vadidation of CFD models using RTD data. Use of TLA techniques for corrosion monitoring. Blockage location techniques. 3.3 Transfer of knowledge and extension of industrial use of sealed radioisotopic sources for: Automated systems for gamma scanning for columns. Gamma scanning of large diameter columns [up to 10 meters ] using 3 – 4 detectors and high intensity sources. Detection of corrosion in heat exchanger tubes using miniature detector and Am-241 gamma source. On - line thickness monitoring of pipelines with / without insulation using Ir - 192 source. Evaluation of computed tomographic imaging systems for industrial process columns to determine liquid/vapour phases at given locations. Determination of flow velocity of liquids in oil/water/gas mixture by dual energy gamma transmission techniques. Gap meter gauge utilising low activity 252Cf neutron source in backscatter geometry for inspection of the gap between the foundation and the bottom plate of oil-storage tanks in petroleum industry is very useful tool and needs to be popularised. Evaluation of neutron backscattering techniques for interface and level location . Tracers in oil field investigations. Summary of Activities Year/month 2003 Jan - Dec Jan - Dec Jan - Dec May October November 2004 Jan - Dec Jan - Dec Jan - Dec April July November Activities Budget Expert assignments, 3mm Fellowships, 6mm Supply of equipment (to be specified) $45,000 $20,000 $35,000 RW on Applications of tracers in oilfields, 1 weeks in CPR EGM on Quality assurance and accreditation on gamma scanning, leak detection and blockage location, 1 week in MAL RW on Process diagnostics using radioisotope techniques in petroleum/chemical industries, 2 weeks, IND $25,000 $25,000 Expert assignments, 3mm Fellowships, 6mm Supply of equipment to be specified RW on Process optimisation using tracers in petroleum/chemical industries, 2 weeks, KOR EGM on Quality assurance and accreditation on gamma scanning, leak detection and blockage location, 1 week, VIE EGM and PCM on Advances in Radioisotopes techniques in Petroleum Industry, 1 week in IND $45,000 $20,000 $30,000 $35,000 $35,000 $25,000 $35,000 4. The national plan of activities a) National seminars and on job demonstration for problem solving For promotion of radioisotope technologies, one national seminar should be executed in each RCA developing countries for end users. One full scale demonstration of gamma and neutron backscatter column scanning techniques should be demonstrated in each country. One full scale demonstration of tracers in oil field should be carried out in a few countries. b) Expert missions: RCA 2003-2004, Expert missions (To be decided after consultations between MSS) 5. List of RCA Member States The RCA Member States that have indicated their intention to participate in the project are the following: Bangladesh, China, India, Indonesia, Korea, Malaysia, Mongolia, Myanmar, Pakistan, Philippines, SriLanka, Thailand, Vietnam 6. National infrastructure Within the RCA Region the following is the status of radiotracers and sealed sources applications in industry: countries, such as China, India, Malaysia, where radioisotope technology has been exploited satisfactorily; countries, such as Bangladesh, Indonesia, Korea, Pakistan, Philippines, Sri Lanka, Thailand, Vietnam where some progress has been done; countries, such as Mongolia and Myanmar now commencing to make use of this technology. 11 out of 13 RCA developing countries have the infrastructure and capabilities, which are available for the activities proposed to be implemented in this project. Mongolia and Myanmar have not facilities, manpower and financial resources available to participate in this project. Some techniques can be implemented in these countries as well through on job demonstration, provision of simple detection systems and regional training events. 7. In -kind contribution For demonstration workshop, availability of cost free lecturers, internal travel and local logistics. 8. Description of inputs sought from the Agency The inputs sought from the Agency are: Regional events: 180,000 USD Expert missions 6 m/m and fellowships 12m/m =130,000 USD Equipment provision = 65, 000 USD Total: 375, 000 USD Order of priority: Regional Events Expert Missions Equipment Fellowships ----------------------