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D= 184.54 Kmol

= 11448.8616 kg

MEG = 184.355kmol

F = 188.306 Kmol (0.999.high purity)

= 11766.873 kg HG = 0.18454kmol

MEG refining column

MEG = 186.218kmol

=11545.545kg Pressure = 10 mmHg

HG =2.088kmol Temp = 93.2 oC

= 221.328kg

W = 3.766 Kmol

= 317.664 kg

MEG = 1.8523kmol

HG = 1.9136kmol

Assuming 99% recovery, of total MEG feed to distillation column, is obtained in the

distillate.

Kmol of MEG in Distillate = 188.306 0.99 x 0.98891

= 184.355 Kmol / hr.

= 11431.0818 Kg/hr.

Kmol of Distillate ( D ) = 184.355 / 0.999

= 184.54 Kmol / hr.

Avg. M.W. of distillate = (0.999 x 62) + (0.001 x 106)

= 62.044 kg / Kmol.

33

Amt. of Distillate (D) = 184.54 x 62.04

= 11448.8618 kg / hr.

Amt. of HG in Distillate = 184.54 x 0.001

= 0.18454 Kmol / hr.

= 0.18454 x 106

= 19.561 kg / hr.

Kmol of feed (F) = 188.306 Kmol / hr.

= 11766.873 kg/hr

TAKING OVER ALL M.B.

F=D+W

188.306 = 184.54 + W

W = 3.766 Kmol /hr.

M.B. ON MEG

F x (Xf MEG) = D x (Xd MEG) + W x (Xb MEG)

188.306 x 0.9889 = 184.54 x 0.999 + 3.766 x Xb MEG

Xb MEG = 0.4918 (mol.fr.of MEG in Bottoms)

XbHG = (1- 0.4918)

= 0.5081 (mol.fr.of HG in Bottoms)

Kmol of MEG in Bottoms = 0.4918 x 3.766

= 1.8521 Kmol / hr

Mol. Weight of MEG = 62 kg/Kmol

= 114.831 kg/hr.

Kmol of HG in Bottoms = 0.5081 x 3.766

= 1.9135 Kmol / hr.

Mol. Weight of HG =106 kg/Kmol

= 1.9135 x 106

= 202.83 kg/hr.

Component In, Kg Out, Kg

Liquid phase Vapor phase

MEG 11545.545 114.8426 11430.01

HG 221.328 202.8416 19.56124

D= 1881.97kmol

= 11766.873 kg

34

MEG =1.88kmol

H2O =1880.08kmol

6.3.5 MEG recovery column (Plate column):

F = 1900.451kmol

= 35021.339 kg

MEG = 18.481kmol

MEG recovery column

=1145.844kg

= 33875.496kg.

W = 18.481kmol

=1205.55 kg

MEG = 17.122kmol

H2O = 1.3584kmol

distillate.

Kmol of Water in Distillate = 1881.97 x 0.999

= 1880.08 Kmol / hr

Kmol of Distillate ( D ) = 1880.08 / 0.999

= 1881.97 Kmol / hr.

Avg. M.W. of distillate = (0.999 x 18) + (0.001 x 62)

= 18.044 kg / Kmol.

Amt. of Distillate (D) = 1881.97 x 18.044

= 33958.266 kg /hr

Amt. of MEG in Distillate = 1881.97 x 0.001

= 1.88 Kmol / hr

= 1.88 x 62

= 116.56 kg/ hr.

Amount of feed ( F ) = 1900.451 Kmol/hr

= 35021.339 kg/hr.

TAKING OVERALL M.B.

F = D+ W

1900.451 = 1881.47 + W

35

W = 18.481kmol / hr

M.B. ON WATER

F x (Xf H) = D x (Xd H) + W x (Xb H)

1900.451 x 0.99 = 1881.97 x 0.999 + 18.481 x Xb W

Xb W = 0.0735 (mol.fr.of Water in

Bottoms) Xb MEG = 1- 0.0735

= 0.9264 (mol.fr.of MEG in

Bottoms) Amount of MEG in Bottoms = 18.481 x 0.9264

= 17.122 Kmol / hr

= 17.122 x 62

= 1061.56 kg/hr.

Kmol of Water in Bottoms = 18.481 17.130

= 1.3584 Kmol / hr

= 1.3584 x 18

= 143.99 kg/ hr.

Table 6.5 Material balance over Recovery plate column

Component In, Kg Out, Kg

Liquid phase Vapor phase

Water 33875.496 24.4512 33841.44

MEG 1145.844 1061.546 116.56

ENERGY BALANCE

D= 184.54 Kmol

7.4 MEG REFINING COLUMN: = 11448.8616 kg

MEG = 184.355kmol

(0.999.high purity)

HG = 0.18454kmol

F = 188.306 Kmol

= 11766.873 kg

MEG refining column

MEG = 186.218kmol Pressure = 10 mmHg

=11545.545kg

Temp = 93.2 oC

HG =2.088kmol

= 221.328kg

W = 3.766 Kmol

= 317.664 kg

MEG = 1.8523kmol

HG = 1.9136kmol

43

7.4.1 for top:

T = 66.8 oC

Poperating = 10 mmHg

L = 0.71D

= 0.71D + D

= 0.71 x 184.355 V =

315.247 kmol / hr

Reflux L = 0.71D

= 0.71 x 184.355 L

= 130.89 kmol / hr

= m + (mCpT)

44

QV = [(315.247 x 68.58 x 103) + (315.247 x 188.298 x 66.8)]

= 25.58 x 106 kJ / hr

= 1.6485 x106 kJ / hr

Condenser load, QC :

= QV ( QReflux + QD )

= 21.595 x 106 kJ / hr

Assuming cooling water enters the condenser at 25oC & leave at 45oC

= 83.34 x 106 kJ / hr

Reboiler Load:

system QB + QFeed = QD + QW + QC

QFeed

= 2.252 x 106 kJ / hr

45

QB = (21.595 x 106 + 83.34 x 106 - 2.252 x 106 + 2.341 x 106 )

= 21.794 x 106 kJ / hr

QB = m steam

= 11448.8616 kg

MEG = 184.355kmol

(0.999.high purity)

HG = 0.18454kmol

F = 188.306 Kmol

= 11766.873 kg MEG recovery column

MEG = 186.218kmol

=11545.545kg Plate column

HG =2.088kmol

= 221.328kg

W = 3.766 Kmol

= 317.664 kg

MEG = 1.8523kmol

T = 169 oC

Cpmean of H2O = 76.55 kJ / kmol oK

46

QD = 24.40 x 106 kJ / hr

L = 0.51D

= 0.51D + D

= 0.51 x 1881.97 V =

2841.77kmol / hr

Reflux L = 0.71D

= 0.51 x 1881.97 L

= 959.80 kmol / hr

= m + (mCpT)

= 12.43 x106 kJ / hr

Condenser load

QC = QV ( QReflux + QD )

47

= 172.12 x 106 kJ / hr

Assuming cooling water enter the condenser at 25oC & leaves at 45oC

Tbottom

QResidue

T = 173 oC

= ( mCpT )liq

= 603.39 x 103 kJ / hr

Reboiler Load:

QB + QFeed = QD + QW + QC

= 143.71x 103 kJ / hr

Reboiler load

196.97 x 106 kJ / hr

48

Consider the steam enter at 2 kg/cm2 & 118.719oC

steam =2037.51 kJ / kg

QB = m steam

D= 184.54 kmol

= 11448.8616 kg

MEG =

184.355kmol

D (0.999.high purity)

I HG = 0.18454kmol

S

T

F = 188.306 kmol I

= 11766.873 kg L

MEG = 186.218kmol L

=11545.545kg A

T

HG =2.088kmol I

= 221.328kg. O W = 3.766 kmol

N

= 317.664 kg

MEG = 1.8523kmol

HG = 1.9136kmol

Steam

Condensate

PROCESS DESIGN:

Let ,

Mole fraction of MEG XF= 0.9889

XD = 0.999

XW = 0.4918

9.2.1 Nos of theoretically stages

Use McCabe Theile method for determining the

theoretical stages. McCabe Theile Method: [17,21]

59

Assumption:

Binary mixture separation between MEG & DEG.

P = total pressure of the system = 10 mmHg

Psat DEG = 0.1331 KPa

= 1.334 / 0.1333

= 10.077

Now at bottom Psat MEG = 1.4757 KPa

Psat DEG = 0.1673 KPa

So, bottom = Psat MEG / Psat DEG

= 1.4757 / 0.1673

= 8.8174

Thus, average = { top x bottom }0.5

= {10.007 x 8.8174}0.5

average = 9.3933

Now we have the equation

Y = X / {1+ (-1)}

From the above eqn we can generate the vapor- liquid equilibrium data given as

follow.

Now plotting x-y diagram & Using McCabe Theile method for determining the

theoretical stages.

no. of theoretical stages = 18

9.2.2 Packed Column Diameter And Column Height:

The necessary data required is as follows :

60

Reflux Ratio = 0.71

Feed = saturated liquid (assume)

Kmol of Feed F = 188.306 kmol

Kmol of Distillate D = 184.54 kmol

Kmol of Bottom W = 184.54 kmol

Vapor Density rG = 2.099Kg/m3

Liquid Viscosity m = 2.2 x 10-3 Kg/m s

No. of theoretical stages = 18 ( from vapor liquid Equilibrium diagram)

Owing to its low pressure drop per theoretical stage metal Pall Ring is often preffered

to other packings for vacuum distillation.

Here, L/D =0.71

L = 131.0234 Kmol / hr

Vapor rate = V = L+D

= 184.54 + 131.0234

= 375.5634 Kmol / hr.

Mass flow rate of vapor

(375.5634 x 62.044)

Mg =

(3600)

M g = 6.4726 Kg /s

Mass flow rate of liqid

131.0234 x62.044

Ml =

3600

M l = 2.2581 Kg /s

Flow parameter

Ml g

X= Mg gl

--------------------------- (2)

Where, X = flow parameter

Ml = Mass flow rate of liquid = 2.2581 Kg/s

Mg = Mass flow rate of vapor = 6.4726 Kg/s

rl = Density of liquid =954 Kg/m3

61

From equation (2)

= 2.25812.099

6.4726 (954 2.099)

X = 0.01638

By using plot of flooding and Pressure drop.

Ml g G2 f P l0.1

X= Mg

gl

Y = ggl

V/S

DP N

Take, = 50 m2 ref.

Z m

We get Y = 0.0125

G2 f P l0.1

Y = ggl ----------------------------------------- (3)

Owing to its low-pressure drop, the metal pall ring is used as a packing for

vacuum distillation,

Size: 38 mm (1.499)

Packing Factor fp (m-1) = 131

Deigned H.E.T.P. (m) = 0.5425

m = Viscosity of liquids = 2.2 x 10-3 Kg/m

s rg = Density of gas = 2.099 kg / m3

rl = Density of liquid = 954 kg / m3

G' in kg / m2. s

G2 f P l0.1

Y = ggl

G'2 = [(0.0125 x 2.099 x (954 2.099)] / [131 x (2.2 x 10-3) 0.1 ]

G'2 = 0.3515 kg / m2 s

G = 0.5929 kg / m2 s

Taking vapor mass velocity as 60% if flooding velocity.

62

Hence, Area of tower =

At M

g

0.6 G

= 18.19 m2

A D2

t

4 = 18.19

Diameter of tower = D = 4.81 5 m

Total height of packed bed,

Z = No.of theoretical stages x H.E.T.P.

HETP = height equivalent to one theoretical plate

For pall ring metal (1.5) H.E.T.P. = 0.5425

Z = No .of theoretical stages x H.E.T.P. Z =

18 x 0.5425

Z = 9.765

m = 10 m

In packed tower, height of each bed is approximately its diameter.

Hence, 2 beds of 5 m heights are provided.

Spacing between each bed is = 2 m

Hence, total spacing = 0.5 x 3 = 1.5 m

Taking both disengaging space and distribution space = 2 m

Hence total height of tower = 10 + 2 + 2

= 14 m

MECHANICAL DESIGN [23, 24, 26]

9.2.3 Shell Design:

Shell Thickness (based on external pressure):

Diameter of tower = Di = 5m

Height of column = 14 m Pressure

inside column is vacuum.

Outside pressure is 1 atm = 0.1 MN /m2

Hence design pressure = Pd = 0.1 x 1.05

= 0.105 MN /m2

Shell is I.S. 2825-1969

63

Allowable stress = f = 98.1 MN /m2

Welding joint efficiency factor = J = 0.85

Thickness of shell,

The inside depth of the end can be calculated from the following correlation,

Ri = 5m

Di = Do =5m (initial

approximation) ri = 0.1 x Ro

= 0.5m

hi = 5 - (5 5 / 2)x(5 5 / 2

2x0.5) = 0.9686 m

Effective length of tower W/O stiffner = (Tangent to Tangent length + 2/3 x hi)

= 12 + 2/3x 0.9688

= 12.6459m

Do / L = 5/ 12.6459

= 0.3953

K value corresponding to this = 0.246 & m =2.43

Modulus of elasticity E = 1x 105 MN/m2

Corroded shell thickness,

P = KxE x (t/Do)m

0.105 = 0.246 x 1 x 105

(t/4)2.43 t = 0.02467 m

Take standard thickness = 26 m t

= 26 m

Checking for plastic deformation,

1

P = 2x f x t/Do x

1 [1.5U (1 0.2Do / l) /100x(t / Do)]

U = 1.5 % (take for new vessel)

1

P = 2 x 98.1 x 4.82 x10-3 x

1 [1.5x1.5(1 0.2x0.3953/100x0.00482)]

= 0.2446 0.105 MN/m2

9.2.4 Head Design:

Selecting Torispherical head

64

Outside diameter of shell,

Do = Di + 2 ts

= 5 + 2 (0.026) = 5.052 m

So, Ro = 0.9 Do

= 0.9 x 505.2

= 454.68 cm

Temperature = Td = T + 50 oC

= 95 + 50

= 145 oC

Table-9.3 Head thickness

t(cm) Ro / t Ro / 100t Factor B factB

(assumed) P = 14.22xRo / t

1.2 378.9 3.78 4400 0.7402

1.3 349.75 3.49 4500 0.8201

1.4 324.77 3.24 4800 0.9421

1.5 303.2 3.03 5000 1.051 Pdesign

Consider 2mm corrosion allowance,

th = 1.5 +0.2

th = 17 mm

Standard thickness available th = 18 mm

DATA:

Vessel Type = Class 1

Pdesign =1.05 MN/m2

Total Column height = 14 m

Column Diameter = 5m

Skirt height = 4 m

Packing Type = 38mm Metal Pall ring

Column MOC = SS304

Wind Pressure = 1000 N/m2

Weight of attachments (ladder + pipes + liquid distributor) = 1373.4N

65

Head = Torispherial

Head thickness =18mm

Tdesign = 145o C

Permissible Stress =91.8 MN/m2

s = 78480 N/m3

Insulation = Asbestos

in = 5.64*103 N/m3

tin =50 *10-3 m

Shell thickness without corrosion allowance = 26

= 0.026m

Do = 5.052m

Vessel is Located in non seismic zone

Determination Of Longitudinal Stresses:

Axial Stress due to pressure

p = P x Do / 4 x ts

= 1.05 x 5.052 / 4 x 0.026

= 51.005 MN/ m2

(a) Stress due to Shell weight s

fs = Ws / x D x ts

Ws = weight of shell = x D x t x s x X

fs = x D x t x s x X / x D x ts

= s x X

= 0.7848 X MN / m2

( b) Stress due to insulation in

in = tin x in x X/ ts

= 0.05 x ( 5.64*103 ) x X /

0.026 in = 0.01084 X MN / m2

(c ) Stress due to liquid and packing load in column

Volume of bed = x D2x H /4

= x 52 x 10

= 196.3495 m3

66

Consider void fraction for packing = 0.5

Liquid hold up = Vb x

= 196.3495 x 0.5

= 98.1747 m3

Weight of liquid = Vl x l

= 137.44 x 954

= 93658 kg

= 918.511 x 103 N

Total weight of packing = packed bed volume x density of packing

= x D2x H /4 x p

= x52x 10 /4 x 430

= 83.43 x 103 kg

= 824.08 x 103 N

l = Weight of (liquid + packing) / p x D x ts

( liquid + packing)

of packing

= 1.7465MN

l = 1.7465 x X / p x ( 5.052) x( 0.026 )

= 4.243 x X MN/m2

( d ) Stress due to attachments

Whead =0.02831 MN

Total dead load stress

dead = s + in + l + a

= 0.7848 X + 0.01084 X + 4.243 X + 0.06931 + 0.003362 X

67

dead =0.06931 +4.3246 xX N/m2

The axial Stress due to wind load in self supporting tall vessel,

The total load due to wind acting on the bottom and upper part of thr vessel are

determined by

Pw = K1 x K2 x Pwindpress x H x Do ( insulated )

Where,

Pw = wind pressure = 1000 n/m2

K1 = coefficient depending upon the shape factor = 0.7 for cylindrical surface

K2 = coefficient depending upon the period of vibration of the vessel

= 1 if period of vibration is 0.5 sec or less

=2 if period of vibration is exceed 0.5

Do( insulated ) = Di + 2 tin

H = L + Skirt height

W = total weight

Now,

Weight of shell

Ws = p x Dits x L x s

= (3.14) x (5) x (0.026) x ( 14 ) x (78480)

Ws = 0.4487 M N

Weight of insulation

Win = p x D x tin x L x in

= ( 3.14 ) x ( 5 ) ( 0.05 ) x ( 14 ) x ( 5.64*103 )

Win = 0.06266 MN

Weight of attachment = Weight of two heads + Weight of ladder, pipes, liq distributor

= 2 (0.02831) + 1.3734 x 10-3

Wa = 0.058 N

= 0.4487 + 0.06266 + 1.7465 + 0.058

W = 2315.86 KN

H = L + Skirt height

68

= 14 +

4 H = 18 m

a) Period of Vibration

T = 6.35 x 10-5 x ( 18 / 5.052 )1.5 x ( 2315.86 / 0.026) 0.5

T = 0.127 sec < 0.5 sec

K2 =1

K1 = 0.7 for cylindrical vessel

b) Wind load

Pw = K1 x K2 x Pwindpress x H x Do ( insulated )

= 5 + 2 (0.05)

Pw = 3.571 x X KN / m

Bending moment

i.e Wind moment at the base of the vessel due to wind load is given by

Mwind = { Pwmd x H }/2

= 3.571 x X x X /2

Mwind = 1.785 x X2 KN m

Resulting bending stress

i.e Wind Stress in axial direction is given by

wind = 4 x Mwind / p x ts x D2

f (max) = f x J

= 98.1 x 0.85

= 83.385 MN/m2

69

Solving this equation

0 ax2 + bx + c =0

By Solving equation

X = 1496.59 >>> 18m

So This design is Ok

Down wind side ,

f compression =p + dead +wind

compressive = 0.125 x E x ( t / Do )

= 0.125 x ( 2 x 105) x ( 0.026 / 5.052 ) =

128.661 MN/m2

Equating maximum value of f comp.

ax2 + bx + c = 0

X = 18.683 >>> 18 m

The minimum weight of vessel with two head and the shell is given by

Wmin = Ws + 2 Whead

= 0.4487 + ( 2x

0.03831) Wmin =0.50532 MN

The maximum weight of vessel with two head and the shell is given by

= 0.50532 + 0.062665 + 0.058 + 1.74657

Wmax = 2.37248 MN

At minimum dead weight

Tmin = 6.35 * 10-5 x ( H / D )1.5 x ( Wmin / ts )0.5

= 6.35 * 10-5 x ( 18 / 5.052 )1.5 x ( 505.32 / 0.026 )0.5

Tmin = 0.059 sec < 0.5 sec

\ K2 =1

K1 = 0.7 for cylindrical vessel

At maximum dead weight

70

Tmax = 6.35 x 10-5 x ( H/ D )1.5 x ( Wmax / ts )0.5

= 6.35 x 10-5 x ( 18 / 5.052 )1.5 x ( 2372.48 / 0.026 )0.5

Tmax = 0.13 sec < 0.5 sec

\ K2 = 1

K1 = 0.7 for cylindrical vessel

Maximum and minimum Wind load

Pw = K1 x K2 x ( Pw ) x H x Do (based on insulation thickness)

Do = Di + 2 x tin

= 5+ 2 x ( 0.05 )

= 5.1 m

For minimum Weight condition Do = 5.052 m

For maximum Weight condition Do = 5.1 m ( insulated )

Pwmin = 0.7 x ( 1 ) x ( 1000 ) x ( 18 ) x ( 5.052 )

= 63.665KN

Pwmax = ( 0.7 ) x ( 1 ) x ( 1000 ) x ( 18 ) x ( 5.1 )

= 64.26 K N

Wind moment

Mwind = Pw x H / 2 Mwindmi

= 63.665 x 18 / 2

= 572.89 KN m

Mwinsmax = 64.26 x 18 /2

= 578.34 KN

Wind stress

wind = 4 x Mwind / p x Di2 x tsk

wind min = 4 x 572.89 / 3.14 x ( 5 )2 * tsk

= 30.277 / tsk KN / m2

wind max = 4 x 578.34 / 3.14 x ( 5 )2 tsk = 29.4821 / tsk

KN / m2

dead,min = Wmin / p x Di x tsk

= 0.50532 / 3.14 x 5 x tsk

= 0.0328 / tsk M N / m2

dead max = Wmax / p x Di x tsk

= 2.37248 / ( 3.14 ) x ( 5) x tsk = 0.151 / tsk MN /

m2

Maximum tensile stress without any eccentric load is given by

tensile = windmin - deadmin

71

Take J = 0.7 for double weld joint

\ tensile = permissible x J

= 98.1 x 0.85

= 83.385 MN/m2

tensile = windmin - deadmin

83.385 = windmin - deadmin

tsk = 3.11 x10 5 m

Maximum tensile stress without any eccentric load is given by

compressive in skirt wall = 0.125 E tsk / Do

= 0.125 (2 x105) tsk / 5.052

= 4948.53 tsk

compressive in skirt wall = windmax + deadmax

tsk = 6.054 mm

1969) \ Skirt thickness tsk = 8

SR.

PARAMETER DESCRIPTION

NO.

1 Tower MOC SS304

2 Tower ID 5m

3 Tower OD 5.052 m

4 Shell thickness 26 mm

5 Shell head thickness 18mm

6 Height of tower(Without support) 14m

7 Height of packed Bed 10 m

8 Type of Head Torrispherical

9 No. of Beds of packing 2 , each of height 5 m

10 DP/Z Selected 50 N/M2/m

11 Tower Support Skirt Support

12 Skirt MOC SS304

13 Skirt Height 4m

14 Skirt thickness 8 mm

15 Type Pall Ring

16 MOC Metal (S S)

17 Bulk Density 430 kg/m3

18 HETP 0.5425m

72

ximum operating temperature.

Use safety over design factor of 15 20 %.

14.1 ESTIMATION CAPITAL COST:

Table-14.1 Purchase Cost of equipments

Equip- Unit (Rs. Cost

Ments Thusd) (Rs. Thusd)

MEG STORAGE

1 TANK 2 200 400

HG STORAGE

2 TANK 1 200 200

ETHYLENE OXIDE

3 STORAGE 2 200 400

TANK

PLUG FLOW

4 REACTOR 1 500 500

TRIPPLE EFFECT

5 EVAPORATOR 1 85 85

VACUUM

DISTILLATION

6 COLUMN (PACKED 1 70 70

COLUMN)

DISTILLATION

7 COLUMN (PLATE 1 75 75

COLUMN)

8 DRYING COLUMN 1 50 50

9 CENTRIFUGAL 6 10 60

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