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Your problem starts with your reactors. To answer your question first, You didn't do as good of a chemical wash as you could have. I would be willing to bet that this exchanger has been cleaned before with better results. Make sure to use an organic and inorganic solvent in the wash. You will...

Check to see If your heater box temperature is tied to your fuel gas. If it is, as you reduce your O2 you may bog the heater which will cool the heater box off and the fuel gas usage will increase. This would only be an issue if you had flame inpingment on the heater tubes. Other than that...

A good source for determining proper location of noncondensible lines is "Troubleshooting Refinery Processes" 2nd edition by Norm Lieberman. You would likely see some benefit by adding a non consensible line on your reboiler to remove CO2. However if your are using 35# steam and not 135# you...

I have about 6 years of refinery process engineering experience. Some of the previous post range from the funny side to being just scary. It's interesting to read peoples experience from the project design/CAD stand point. Most of my bread and butter is made from improving designs in the...

I have found that it is possible to simulate an amine contactor in Hysys but minor variations will throw your results off dramatically. I have had better luck using Promax the updated version of T-sweet.

There is an API spec on sizing the demister pad. The calculation is based on an average particulate size (150 microns?)