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Production of Formaldehyde From Methanol PDF
Production of Formaldehyde From Methanol PDF
Production of Formaldehyde
from Methanol
Integrated Final Report
Done by team 3:
PAGE
I
4. PROCESS SIMULATION................................................................................................................…................52
4.1. VALIDATION...................……………….………………………………………...................................................53
4. EQUIPMENT SIZING………………………………………………………………………….................……………70
EQUIPMENT & LINING LIST……………...........................................................................................……….71
REACTION DESIGN……....................................................................................................................................72
6.1. Reactor Design Equation……..………………………………….........………...........................................72
6.2. Mole BALANCE…………………………………………….........………………………………………….…….73
6.3. Net Rate Law………………………………………………………………………………….........……….…….74
6.4. Rate Law..........................................................................................................................................….........74
6.5. Stoichiometry…………………………………………………………………………….........……………….…76
6.6. Combination.....................................................................................................................................…........77
6.7. Pressure Drop...............................................................................................................................…..........78
6.8. Energy Balance….......................................................................................................................................80
6.9. Heat Exchanger inside the reactor…………………………………………………………........……….83
6.10. Arrangement of The Tubes..............................................................................................................., 88
6.11. Other Parameters Evaluation……………………………………………........………………………….89
6.12. Results....………………………………………………………………………..................,,,,,,,,,,,,.............……90
II
6.12.1.2. Explicit equations…………………………………………………........................…90
6.12.1.3. The result of the differential and explicit equations…..........................93
6.12.1.4. Graphs...................................................................................................…..................94
6.12.2. HEAT EXCHANGER RESULTS........................................................................…..................96
6.13. Selection of The Material…………….........………………………………………………………………97
6.14. COMPARING THE PRODUCTS...................................................................................................…...98
6.15. Summary Table ……………………………………………........……………………………………………98
5. ABSORBER DESIGN………………………………….................................……………................………………..99
7.1. Packed Bed Absorber...............................................................................................................................99
7.2. Sizing of Packed Tower........................................................................................................................100
7.3. Control Loop System .......................................................................................................................105
7.4. Design Summary....................................................................................................................................106
III
8.H.DESIGN SIMULATION............................................................................................................................131
Sample Calculation.........................................................................................................................................132
Design of E-101................................................................................................................................................140
Design of E-102................................................................................................................................................142
Design of E-103................................................................................................................................................143
Design of E-106................................................................................................................................................144
Design of Condenser and Reboiler..........................................................................................................145
Design of Condenser E-104........................................................................................................................146
Design of Reboiler E-105 .......................................................................................................................147
Pinch Analysis for E-101 .......................................................................................................................148
Pinch Analysis for E-102 ....................................................................................................................., 149
Pinch Analysis for E-103 .......................................................................................................................150
Pinch Analysis for E-106 .......................................................................................................................151
Pinch Analysis for Condenser .......................................................................................................152
Pinch Analysis for Reboiler .......................................................................................................................153
PUMP P-101.............................................................................................................................................................154
PUMP P-102.............................................................................................................................................................155
PUMP P-103.............................................................................................................................................................156
COMPRESSOR C-101 .......................................................................................................................................157
VISCOSITY ESTIMATION...................................................................................................................................158
DENSITY ESTIMATION.......................................................................................................................................160
PIPING SCHEMATICS..........................................................................................................................................163
HAZOB ANALYSIS..............................................................................................................................…................172
A. Carbon Steel...........................................................................................................................................179
B. Stainless Steel.......................................................................................................................................183
CONCLUSION...........................................................................................................................................…............187
REFERENCES.......................................................................................................................................…................188
IV
EXECUTIVE SUMMARY
This work is a fully integrated and detailed report for the senior design
project on the PRODUCTION OF FORMALDEHYDE FROM METHANOL. The
compilation of this report was done gradually and chronologically over
a period of four months taking into account every aspect of design from
a chemical engineering point of view. The starting point of the design
project was a background research for the process literature. This
research included a summary of the project, problem information and
kinetics, physical and chemical properties of the participating materials
in the plant, literature review of alternative production routes, safety
precautions and environmental preservation for the process. The
second report was a quantitative analysis for the mass and energy
balances of the plant. Detailed calculations were performed in this
report for all equipment and streams in the plant, taking into account
the required process conditions to achieve a production capacity of
60000 ton/year of formalin. The third task was to simulate the plant’s
units and operations by utilizing the chemical simulation software
Aspen Hysys to gain an optimized view of the process conditions. Design
and sizing for all units and equipment in the plant were performed in
the fourth task. The designed units included the reactor, the absorber,
the distillation column, the compressor, heat exchangers and pumps. A
piping sizing of the plant’s layout and connections is presented at the
end of end of the design chapter. Operability, efficiency and economic
feasibility were the basis of the design and sizing of these units. The
final task of this project covered the estimation of the capital costs of the
production process and its profitability. Cumulative cash flow diagrams
were the introduced in the analysis to demonstrate these costs in
relation to the production revenues and returns.
V
IV
LITERATURE REVIEW OF
THE PRODUCTION
PROCESS
1
SUMMARY OF THE PROJECT
The main purpose of this project is to conduct a comprehensive study that would
lead ultimately to an integrated design, in a chemical engineering point of view, of a
plant that produces formaldehyde with a production capacity specified in advance.
This study will take into consideration aspects including the entire plant’s process
unit design, process flow diagrams, cost estimations, operation parameters,
equipment sizing, construction materials and environment/safety precautions. This
project requires the theoretical and practical application of mass transfer, heat
transfer, fluid dynamics, unit operations, reaction kinetics and process control. There
are several tasks that are crucial to the completion of the project outlines including
mass and energy balances, Hysys simulation of the Process Flow Diagrams, design of
the reactor, design of heat exchangers, design of the absorber and distillation
column, energy optimization, economic analysis and hazard analysis.
CH 3 OH 12 O2 HCHO H 2O (1)
The desired reaction is the first which is exothermic with a selectivity of 9, while the
second is an endothermic reaction. The project’s target is to design a plant with a
capacity of 60,000 tons formalin/year. This plant is to include three major units; a
reactor, an absorber and a distillation column. Also it includes pumps, compressors
and heat exchangers. All are to be designed and operated according to this
production capacity.
2
PROBLEM INFORMATION
(4) −676
(6) −314
3
The reactor in this project’s problem (designed for 87.4% methanol
conversion) is to receive two streams; the first is a mixture of fresh
methanol (25oC, 1 atm) and recycled methanol (68.3 oC, 1.2 atm) pumped to
3 atm and vaporized to 150oC. The second stream to the reactor mixed with
the first is compressed fresh air (25 oC, 1 atm). The absorber receives the
reactor’s outlet (343oC) and afresh stream of water (30oC, 138 kpa).
Absorption of 99% is expected where the liquid outlet is heated to 102oC.
The distillation column receives the liquid then separates the overhead
methanol stream (68.3 oC, 1.2 atm) then recycles it back to methanol fresh
feed mixing point. The bottom formaldehyde stream is pumped and mixed
with deionized water forming (37 wt. % formaldehyde) formalin stream
which sent for storage. The mixing is presented as follows:
4
PHYSICAL & CHEMICAL PROPERITIES
This section includes all the major participating materials to the
production plant. These properties are based upon operating conditions
of the plant’s design.
Boiling
Molecular ΔHv
Name Formula point
weight (g/mol) oC
kJ/mole
Methanol CH3OH (g) 32.042 64.7 35.27
Oxygen O2 (g) 31.999 -183 6.82
Air Gas 28.851 -194.5 ---
Formaldehyde HCHO (g) 30.026 -19.3 24.48
Hydrogen H2 (g) 2.016 -252.7 0.904
Water H2O (l) 18.015 100 40.656
Formalin HCHO (l) 30.03 96 ---
Silver Ag (s) 107.8682 1950 1950
5
LITERATURE REVIEW OF PRODUCTION PROCESS
Formaldehyde was discovered in 1859 by a Russian chemist named
Aleksandr Butlerov. Then in 1869, it was ultimately identified by the
German chemist August Hofmann. The manufacture of formaldehyde
started in the beginnings of the twentieth century. Between 1958 and
1968, the annual growth rate for formaldehyde production averaged to
11.7%. In the mid-1970s, the production was 54% of capacity. Annual growth
rate of formaldehyde was 2.7% per year from 1988 to 1997. In 1992,
formaldehyde ranked 22nd among the top 50 chemicals produced in the
United States. The total annual formaldehyde capacity in 1998 was estimated
by 11.3 billion pounds. Since then and the production capacity around the
globe is expanding exponentially reaching a world’s production of 32.5
million metric tons by 2012. Due to its relatively low costs compared to
other materials, and its receptivity for reaching high purities,
formaldehyde is considered one of the most widely demanded and
manufactured materials in the world. It is also the center of many
chemical researches and alternative manufacture methods. This also
explains the vast number of applications of this material including a
building block for other organic compounds, photographing washing,
woodworking, cabinet-making industries, glues, adhesives, paints,
explosives, disinfecting agents, tissue preservation and drug testing.
6
by-products such as carbon monoxide and dimethyl ether forms. In 1921,
the oxidation of methanol to formaldehyde with vanadium pentoxide
catalyst was introduced to and patented. Then in 1933, the iron-
molybdenum oxide catalyst was also patented and used till the early
1990’s. Improvements to the metal oxide catalyst were done through
the metal composition, inert carriers and preparation methods. The first
commercial plant for the production of formaldehyde using the iron-
molybdenum oxide catalyst was put into action in 1952. Unlike the
silver based catalyst in this project, the iron-molybdenum oxide catalyst
makes formaldehyde from the exothermic reaction (1) entirely. Under
atmospheric pressure and 300 – 400 oC, methanol conversion inside the
reactor could reach 99% and a yield of 88% - 92%.
7
passed to the absorber. The composition of formaldehyde in the
absorber outlet is controlled by the amount of water addition. An almost
methanol-free product can be achieved on this process design. The
advantage of this process over the silver based catalyst is the absence of
the distillation column to separate unreacted methanol and
formaldehyde product. It also has a life span of 12 to 18 months, larger
than the sliver catalyst. However, the disadvantage of this process
design is the need for significantly large equipment to accommodate the
increased flow of gases (3 times larger) compared to the original silver
catalyst process design. This increase in equipment sizing clashes with
economic prospect behind the design costs.
8
KINETIC DATA FOR THE PROBLEM
Kinetic information for the methanol oxidation reaction:
CH3 OH 21 O2 HCHO H2O
ln k1 12.50 8774
T
ln k 2 17.29 7439
T
Where T is in Kelvin, the rate data as follows for the side reaction:
CH 3OH HCHO H 2
k1' p m
0.5
rm2 [mole / g catalyst / hr ]
1 k 2' p m
0.5
Standard enthalpies of reaction (298 K, 1 atm) for the two reactions are
given as:
9
SAFETY & ENVIRONMENT PRECAUTIONS
The main concern is mainly with precautions and protocols that are to
be followed while handling materials in the plant. Safety equipment
includes: splash goggles, protective coats, gloves and safety shoes are all
required in dealing with these materials regardless of the their
reactivity and stability. These documentations will include the two
target materials and compounds encountered and utilized in the plant
as follows:
METHANOL
10
EXPOSURE
Exposure to methanol can be treated fast and efficiently. If the contact
was to the eyes or skin, flushing with water for 15 minutes would be the
first course of action. Contaminated clothing or shoes are to be removed
immediately. If the contact is much more series, use disinfectant soap,
then the contaminated skin is covered in anti-bacteria cream. Inhalation
of methanol is much more hazardous than mere contact. If breathing is
difficult, oxygen is given, if not breathing at all artificial respiration.
REACTIVITY
Methanol has an explosive nature in its vapor form when in contact with
heat of fires. In the case of a fire, small ones are put out with chemical
powder only. Large fires are extinguished with alcohol foam. Due to its
low flash point, it forms an explosive mixture with air. Reaction of
methanol and Chloroform + sodium methoxide and diethyl zinc creates
an explosive mixture. It boils violently and explodes.
STORAGE
The material should be stored in cooled well-ventilated isolated areas.
All sources of ignition are to be avoided in storage areas.
11
This material is a highly toxic material that the ingestion of 30 ml is
reported to cause fatal accidents to adult victims. Formaldehyde ranges
from being toxic, allergenic, and carcinogenic. The occupational exposure
to formaldehyde has side effects that are dependent upon the composition
and the phase of the material. These side effects range from headaches,
watery eyes, sore throat, difficulty in breathing, poisoning and in some
extreme cases cancerous. According to the International Agency for
Research on Cancer (IARC) and the US National Toxicology Program:
‘’known to be a human carcinogen’’, in the case of pure formaldehyde.
FIRE HAZARDS
Formaldehyde is flammable in the presence of sparks or open flames.
EXPOSURE
Exposure to methanol can be treated fast and efficiently. If the contact was
to the eyes or skin, flushing with water for 15 minutes would be the first
course of action. If the contact is much more series, use disinfectant soap,
then the contaminated skin is covered in anti-bacteria cream. Inhalation of
methanol is much more hazardous than mere contact. The inhalator should
be taken to a fresh air.
12
PRELIMINARY COSTS OF MATERIALS
This table gives an approximate cost (in 2012) for the major plant
materials that are utilizes frequently including*:
13
MASS AND ENERGY
BALANCES
This is a full detailed chapter presenting the Mass and Energy Balances
for the project’s plant of producing formaldehyde from methanol. The
analysis and calculations were done manually and collectively by the
project team #3. All process streams and unit operation were accounted
for in this chapter. These calculations are based upon the team’s
previous and current Chemical Engineering courses. All required
parameters from the problem statement including; conversion,
selectivity, temperature, pressure and production capacity were
implemented in the mass and energy balance. The following process
flow diagram (PFD) of the formaldehyde plant is the reference for unit
designation and stream numbering.
14
1. MASS BALANCE
15
1.1. First Run
1.1.1. Mass balance around the reactor:
n8 = 282.26 kmol/hr.
xM = 0.3465
xO = 0.1363
xW= 0.0046
xN = 0.5126
Reactor
n9 = 329.21 kmol/hr.
xM = 0.0374
xF = 0.2596
xW= 0.2376
xH = 0.0258
xN = 0.4395
– – ①
– ②
Conversion = 0.874 =
⑥
Selectivity = 9 =
– ⑦
From ⑥& ⑦:
16
ξ1 = 7.866 kmol/h
ξ2 = 0.874 kmol/h
xM = xO2 = xN2 =
Σ xi 1
nM, 9 = 1.26 , nO2, 9 = 0 , nH2O, 9 = 7.866
17
Stream 9 (n9) = Σ ni = 33.536
yM = yO2 = yH2O =
yH2 = yF = yN2 =
Σ yi 1
ABS.
n10 = 329.21 kmol/hr
xM = 0.0374 n13 = 228.43 kmol/hr
xF = 0.2596 xM = 0.0539
xW= 0.2376 xF = 0.3704
xH = 0.0258 xW= 0.5756
xN = 0.4395
Solubility of formaldehyde
18
0.468 kmol F =====================> 1 kmol water
Solubility of Methanol
Thus,
19
Assuming that all N2 ,H2 are streamed out through off gas:
nN2, 12 = nN2, 10 = 14.796
Additionally,
( )
So,
20
xH2O = 1 , xM = 0 , xF = 0 , xN2 = 0, xH2 = 0 , xO2 = 0
Thus,
yM = , yO2 = , yH2O =
yH2= , yF = , yN2 =
Σ yi 1
Thus,
yM = , yO2 = , yH2O =
yH2= , yF= , yN2 =
Σ yi 1
n13 = 23.29 kmol/h, nM, 13 = 1.26 kmol/h, nH2O, 13 = 13.378 kmol/h, nF,
13 = 8.6526 kmol/h
Thus,
yM = , yH2O = , yF =
Σ yi 1
21
1.1.3. Mass balance around the distillation column:
Assumptions:
Fractional Recovery 1 = 99 %
Bx, H2O = frac.2 * n14 * xH2O, 14 = 0.99 * 23.29 * 0.5744 = 13.244 kmol
water/h
22
Bx, F = 0.3715 * 23.29 = 8.65224 kmol Formaldehyde/h
Mole
ni = Molecular Mass Fraction
Material Fraction mi = niMW
yintot Weight (xi = mi/mtot)
yi
0.00017
Methanol 0.0038 32.042 0.12176 0.000244
4
Formalde 8.65223
0.60475 30.026 259.792 0.52135
hyde 5
Water 0.39508 13.244 18 238.392 0.4784
Sum =
498.306
52 wt. % of Formaldehyde.
23
1.2. Second Run
x3, M = x6, M =
x3, water = x6, water =
From first run we got n1O2 and n1N2
n1O2=
n1N2=
n8 = n6 + n7=10.13387+18.729=28.86287
24
1.2.3. Mass balance around the reactor:
25
1.2.4. Mass balance around the absorber:
From solubility:
0.78 kg F = 0.468 kmol F ==============> 1 kmol water
From vapor pressure for water, the temperature of the column is 89.31
oC which was derived from energy balance around the absorber and the
procedure of calculating the temperature will be shown in the energy
balance.
So,
( )
26
n12, H2O = (18.657 + 7.99947) * 0.496 = 13.23
n12 = nG1,F+ nG1, N2 + nG1, H2+ nG1, H2O= 0.0874 + 14.796 + 0.874 + 13.23 =
28.988
nL1, H2O = n10 + n9, water (second run)– n12, H2O = 18.675 + 7.99978 – 13.23 =
13.445
Assumptions:
5- Light Key : methanol
6- Heavy key: H20
7- Non-heavy key: formaldehyde
8- Constant Molal Overflow (CMO)
27
BxF= 0.37 * 23.358= 8.6425
Mol Mass
nj = y i * Molecular mi = ni *
Component fraction faction xi =
ntot weight M
(yi) mi/Mtot
Methanol 0.00173 0.0038 32.042 0.12176 0.006244
Formaldehyde 0.39345 8.6425 30.026 259.5 0.51965
Water 0.60637 13.3194 18 239.73 0.4801
28
1.3 Mass Balance Data Sheet
1- Initial mass balance (before Scaling) on 10 kmol methanol/hr. basis:
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0 8.7466 10 10 0 10 0 10 1.26 1.26 0 0 1.26 1.26 1.25755 0.0038 0.0038 0 0.0038 0.0038
oxygen 3.933 0 0 0 3.933 0 3.933 3.933 0 0 0 0 0 0 0 0 0 0 0 0
formaldehyde 0 0 0 0 0 0 0 0 8.74 8.74 0 0.0874 8.6526 8.6526 0 8.6425 8.6425 0 8.6425 8.6425
water 0 0 0.13378 0.13378 0 0.13378 0 0.13378 7.99978 7.99978 18.675 13.23 13.445 13.445 0.13454 13.3197 13.3197 11.16667 24.48637 24.48637
hydrogen 0 0 0 0 0 0 0 0 0.874 0.874 0 0.874 0 0 0 0 0 0 0 0
nitrogen 14.796 0 0 0 14.796 0 14.796 14.796 14.796 14.796 0 14.796 0 0 0 0 0 0 0 0
summation kmol/hr 18.729 8.7466 10.13378 10.13378 18.729 10.13378 18.729 28.86278 33.66978 33.66978 18.675 28.9874 23.3576 23.3576 1.39209 21.966 21.966 11.16667 33.13267 33.13267
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0 280.2586 320.42 320.42 0 320.42 0 320.42 40.37292 40.37292 0 0 40.37292 40.37292 40.29442 0.12176 0.12176 0 0.12176 0.12176
oxygen 125.856 0 0 0 125.856 0 125.856 125.856 0 0 0 0 0 0 0 0 0 0 0 0
formaldehyde 0 0 0 0 0 0 0 0 262.4272 262.4272 0 2.624272 259.803 259.803 0 259.4997 259.4997 0 259.4997 259.4997
water 0 0 2.40804 2.40804 0 2.40804 0 2.40804 143.996 143.996 336.15 238.14 242.01 242.01 2.42172 239.7546 239.7546 201 440.7546 440.7546
hydrogen 0 0 0 0 0 0 0 0 1.748 1.748 0 1.748 0 0 0 0 0 0 0 0
nitrogen 414.288 0 0 0 414.288 0 414.288 414.288 414.288 414.288 0 414.288 0 0 0 0 0 0 0 0
summation kg/hr 540.144 280.2586 322.828 322.828 540.144 322.828 540.144 862.972 862.8322 862.8322 336.15 656.8003 542.1859 542.1859 42.71614 499.3761 499.3761 201 700.3761 700.3761
29
3- Mass balance (after Scaling) on ton/year mass unit:
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0 24009.26 27449.82 27449.82 0 27449.82 0 27449.82 3458.678 3458.678 0 0 3458.678 3458.678 3451.953 10.43093 10.43093 0 10.43093 10.43093
oxygen 10781.865 0 0 0 10781.86 0 10781.86 10781.86 0 0 0 0 0 0 0 0 0 0 0 0
formaldehyde 0 0 0 0 0 0 0 0 22481.69 22481.69 0 224.8169 22256.87 22256.87 0 22230.89 22230.89 0 22230.89 22230.89
water 0 0 206.2926 206.2926 0 206.2926 0 206.2926 12335.89 12335.89 28797.39 20401.04 20732.58 20732.58 207.4645 20539.36 20539.36 17219.32 37758.68 37758.68
hydrogen 0 0 0 0 0 0 0 0 149.7481 149.7481 0 149.7481 0 0 0 0 0 0 0 0
nitrogen 35491.333 0 0 0 35491.33 0 35491.33 35491.33 35491.33 35491.33 0 35491.33 0 0 0 0 0 0 0 0
summation ton/yr 46273.198 24009.26 27656.12 27656.12 46273.2 27656.12 46273.2 73929.31 73917.33 73917.33 28797.39 56266.94 46448.12 46448.12 3659.417 42780.68 42780.68 17219.32 60000 60000
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0 749306 856682.6 856682.6 0 856682.6 0 856682.6 107942 107942 0 0 107942 107942 107732.1 325.5394 325.5394 0 325.5394 325.5394
oxygen 336933.27 0 0 0 336933.3 0 336933.3 336933.3 0 0 0 0 0 0 0 0 0 0 0 0
formaldehyde 0 0 0 0 0 0 0 0 748740.6 748740.6 0 7487.406 741253.2 741253.2 0 740388 740388 0 740388 740388
water 0 0 11460.7 11460.7 0 11460.7 0 11460.7 685327.2 685327.2 1599855 1133391 1151810 1151810 11525.81 1141076 1141076 956628.9 2097704 2097704
hydrogen 0 0 0 0 0 0 0 0 74279.82 74279.82 0 74279.82 0 0 0 0 0 0 0 0
nitrogen 1267547.6 0 0 0 1267548 0 1267548 1267548 1267548 1267548 0 1267548 0 0 0 0 0 0 0 0
summation kmol/year1604480.9 749306 868143.3 868143.3 1604481 868143.3 1604481 2472624 2883837 2883837 1599855 2482706 2001005 2001005 119257.9 1881789 1881789 956628.9 2838418 2838418
30
5- Mass balance (after Scaling) on kmol/hr. mass unit:
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0.00 85.54 97.79 97.79 0.00 97.79 0.00 97.79 12.32 12.32 0.00 0.00 12.32 12.32 12.30 0.04 0.04 0.00 0.04 0.04
oxygen 38.46 0.00 0.00 0.00 38.46 0.00 38.46 38.46 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
formaldehyde 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 85.47 85.47 0.00 0.85 84.62 84.62 0.00 84.52 84.52 0.00 84.52 84.52
water 0.00 0.00 1.31 1.31 0.00 1.31 0.00 1.31 78.23 78.23 182.63 129.38 131.49 131.49 1.32 130.26 130.26 109.20 239.46 239.46
hydrogen 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 8.48 8.48 0.00 8.48 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
nitrogen 144.70 0.00 0.00 0.00 144.70 0.00 144.70 144.70 144.70 144.70 0.00 144.70 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
summation kmol/hr 183.16 85.54 99.10 99.10 183.16 99.10 183.16 282.26 329.21 329.21 182.63 283.41 228.43 228.43 13.61 214.82 214.82 109.20 324.02 324.02
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0 2740.783 3133.542 3133.542 0 3133.542 0 3133.542 394.8262 394.8262 0 0 394.8262 394.8262 394.0585 1.190746 1.190746 0 1.190746 1.190746
oxygen 1230.8065 0 0 0 1230.806 0 1230.806 1230.806 0 0 0 0 0 0 0 0 0 0 0 0
formaldehyde 0 0 0 0 0 0 0 0 2566.402 2566.402 0 25.66402 2540.738 2540.738 0 2537.773 2537.773 0 2537.773 2537.773
water 0 0 23.54938 23.54938 0 23.54938 0 23.54938 1408.207 1408.207 3287.373 2328.886 2366.732 2366.732 23.68317 2344.676 2344.676 1965.676 4310.352 4310.352
hydrogen 0 0 0 0 0 0 0 0 17.09453 17.09453 0 17.09453 0 0 0 0 0 0 0 0
nitrogen 4051.522 0 0 0 4051.522 0 4051.522 4051.522 4051.522 4051.522 0 4051.522 0 0 0 0 0 0 0 0
summation kg/hr 5282.3285 2740.783 3157.091 3157.091 5282.328 3157.091 5282.328 8439.419 8438.052 8438.052 3287.373 6423.166 5302.297 5302.297 417.7417 4883.639 4883.639 1965.676 6849.315 6849.315
31
6- Mass balance (after Scaling) of wt. compositions (kg/kg):
stream number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
methanol 0.0000 1.0000 0.9868 0.9868 0.0000 0.9868 0.0000 0.3465 0.0374 0.0374 0.0000 0.0000 0.0539 0.0539 0.9034 0.0002 0.0002 0.0000 0.0001 0.0001
oxygen 0.2100 0.0000 0.0000 0.0000 0.2100 0.0000 0.2100 0.1363 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
formaldehyde 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.2596 0.2596 0.0000 0.0030 0.3704 0.3704 0.0000 0.3934 0.3934 0.0000 0.2608 0.2608
water 0.0000 0.0000 0.0132 0.0132 0.0000 0.0132 0.0000 0.0046 0.2376 0.2376 1.0000 0.4565 0.5756 0.5756 0.0966 0.6064 0.6064 1.0000 0.7390 0.7390
hydrogen 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0258 0.0258 0.0000 0.0299 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
nitrogen 0.7900 0.0000 0.0000 0.0000 0.7900 0.0000 0.7900 0.5126 0.4395 0.4395 0.0000 0.5106 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
summation kmol/year 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
7- Whole plant process stream conditions (after scaling and used in energy balance calculations):
stream number 1 2 3 4 5
Temperature (oC) 25 25 31.13 31.13 37.3
Press (atm) 1 1 1 3 3
Total kg/h 5282.328 2740.783 3157.091 3157.091 5282.328
Total kmol/h 183.1599 85.5372 99.1031 99.1031 183.1599
Component kmol/h
methanol 0.0000 85.5372 97.7948 97.7948 0.0000
oxygen 38.4627 0.0000 0.0000 0.0000 38.4627
formaldehyde 0.0000 0.0000 0.0000 0.0000 0.0000
water 0.0000 0.0000 1.3083 1.3083 0.0000
hydrogen 0.0000 0.0000 0.0000 0.0000 0.0000
nitrogen 144.6972 0.0000 0.0000 0.0000 144.6972
32
stream number 6 7 8 9 10
Temperature (oC) 150 150 150 200 165
Press (atm) 3 3 3
Total kg/h 3157.091 5282.328 8439.419 8438.052 8438.052
Total kmol/h 99.1031 183.1599 282.2630 329.2052 329.2052
Component kmol/h
methanol 97.7948 0.0000 97.7948 12.3221 12.3221
oxygen 0.0000 38.4627 38.4627 0.0000 0.0000
formaldehyde 0.0000 0.0000 0.0000 85.4727 85.4727
water 1.3083 0.0000 1.3083 78.2337 78.2337
hydrogen 0.0000 0.0000 0.0000 8.4794 8.4794
nitrogen 0.0000 144.6972 144.6972 144.6972 144.6972
stream number 11 12 13 14 15
Temperature (oC) 20 89.31 89.31 102 68.3
Press (atm) 1 1 1.2 1.2 1.2
Total kg/h 3287.373 6423.166 5302.297 5302.297 417.742
Total kmol/h 182.6318 283.4139 228.4252 228.4252 13.6139
Component kmol/h
methanol 0.0000 0.0000 12.3221 12.3221 12.2982
oxygen 0.0000 0.0000 0.0000 0.0000 0.0000
formaldehyde 0.0000 0.8547 84.6179 84.6179 0.0000
water 182.6318 129.3825 131.4851 131.4851 1.3157
hydrogen 0.0000 8.4794 0.0000 0.0000 0.0000
nitrogen 0.0000 144.6972 0.0000 0.0000 0.0000
33
stream number 16 17 18 19 20
Temperature (oC) 110 110 30 48 30
Press (atm) 1 3 3 3 3
Total kg/h 4883.639 4883.639 1965.676 6849.315 6849.315
Total kmol/h 214.8161 214.8161 109.2042 324.0203 324.0203
Component kmol/h
methanol 0.0372 0.0372 0.0000 0.0372 0.0372
oxygen 0.0000 0.0000 0.0000 0.0000 0.0000
formaldehyde 84.5192 84.5192 0.0000 84.5192 84.5192
water 130.2598 130.2598 109.2042 239.4640 239.4640
hydrogen 0.0000 0.0000 0.0000 0.0000 0.0000
nitrogen 0.0000 0.0000 0.0000 0.0000 0.0000
34
2. ENERGY BALANCE
Component Phase C1 C2 C3 C4
Methanol Liquid 75.86e-3 16..83e-5 0 0
Gas 42.93e-3 8.301e-5 -1.87e-8 -8.03e-12
water Liquid 75.4e-3 0 0 0
Gas 33.46e-3 0.688e-5 0.7604e-8 -3.593e-12
Formaldehyde Gas 34.28e-3 4.268e-5 0 -8.694e-12
N2 Gas 29e-3 0.2199e-5 0.5723e-8 -2.871e-12
O2 Gas 29.1e-3 1.158e-5 -0.6076e- 1.311e-12
8
H2 Gas 28.84e-3 0.00765e- 0.3288e-8 -0.8698e-12
5
P= 1.2 atm
T 15 =68.3 0C
n 15,w =1.32
n 15, m =12.3
P= 1 atm
T =??
T = 25 0C
n 3,w = 1.31 , x 3, w =0.0132
n2 = 85.54
n 3,m = 97.79 , x 3, m =0.9868
35
METHANOL IS
LIQUID AT THIS
POINT
Ein = Eout
∫ ∫ ∫
∫ ∫
T = 31.13 0 C
36
2.1.2. Pump P-101
At 30 0C
37
2.1.3. Heat Exchanger E-101
= w
[∫ ∫ ]
[∫ ∫ ]
[∫
= 4155051.3+6231729=4217368.59
38
2.1.4. Compressor C-101
For Air
Cp=29.1 , Cv =20.78
Where
Assumption:
1. N=0.75
2. Adiabatic.
3. Constant heat capacities.
4. Ideal gas.
39
2.1.5. Heat Exchanger E-102
[∫
2.1.7. Reactor
Species nin(mole) Ĥin nout(mole) Ĥout
CH3OH 97790 H1 12320 H5
O2 38460 H2 0 H6
N2 144700 H3 144700 H7
HCHO - - 85470 H8
H2 - - 8480 H9
H2o 1.31 H4 78230 H10
40
Where,
41
2.1.8. Heat exchanger inside the reactor
In this problem statement, heat exchange is joined with the reactor and
so, the endpoint reaction is at 343 oC and then products will cool down
to 200 oC. Energy balance has done over this heat exchange.
Heat Exchanger inside the Reactor: these are the enthalpies at the end of
the reactor and before interring the cooling section.
Ĥ ∫
Ĥ ∫
Ĥ ∫
Ĥ ∫
Ĥ ∫
Ĥ ∫
Also, these are the enthalpies at the end of the reactor and cooling
section.
Ĥ ∫
Ĥ ∫
Ĥ ∫
42
Ĥ ∫
Ĥ ∫
Ĥ ∫
, ,
So, this is the heat required to be removed from the system using cold
water.
2.1.9. Throttle
Throttle is used to reduce the temperature; its calculation depends on
the difference in pressure (ΔP) of the inlet and outlet of the reactor. This
leads to the need for the reactor’s dimensions. In order to fully evaluate
the energy balance around the throttle, it will be done in design section
of the project. The temperature after the throttle was decided to be
chosen 165 oC(from literature reference) in orderto continue the energy
balance around the absorber.
43
2.1.10. Absorber
Since there is a throttle, the temperature of the stream coming from the
reactor will be reduced further to less than 200 oC. Since calculating the
temperature after the throttle needs additional design specifications
such as the reactor length and diameter, this will be done afterwards in
the design section. The temperature is chosen through an educated
decision based upon stream load and literature reference of the same
plant to be less than 200 oC because the throttle is serving the
temperature decrease service. The chosen temperature is 165 oC.
We have four streams, the temperature of the two inlets streams are 20
and 164 oC for reaction product and water stream respectively. The
outlet temperature has calculated as follow:
– –
∑ ̇̂ ∑ ̇̂
∑ ̇̂ ∑ ̇̂ ∑ ̇̂
∑ ̇̂
Reference temperature is 25 oC
Heat in at stream n10 : ΔT=(165-25) oC
Qn10=(nCpΔT)n10m + (nCpΔT)n10w + (nCpΔT)n10f + (nCpΔT)n10H2 +
(nCpΔT)n10N2 = 4080729.58 kJ/hr.
44
So, Qin= Qn10 +Qn11=∫ ∑ ∫ ∑
∫ ∑ ∫ ∑
Ĥ ∫
Ĥ ∫
Ĥ ∫
Also,
Ĥ ∫
Ĥ ∫
45
Ĥ ∫
Thus,
∫ ∫
Tref =250 C
∫ ∫
46
[∫ ∫ ]
[∫ ∫ ]
∫ ∫ ∫
∫ ∫ ∫
Assumption :
∫ ∫ ∫
∫ ∫ ∫
47
2.1.13. Pump P-102
At 68.3 0C
48
2.1.14. Pump P-103
49
At 110 0C
∫ ∫ ∫
∫ ∫
50
∫
[∫
51
PROCESS SIMULATION
This chapter represents a process simulation of the term’s project on
the production of formaldehyde from methanol. The simulation mainly
covers the three major units of the plant; the reactor, the absorber and
the distillation column. The purpose of this simulation is to evaluate the
plant’s processes under given conditions (temperature, pressure and
composition). Also to compare results obtained from said simulation to
previously determined parameters through manual mass & energy
balances. The effect of varying the Flowrate of the utility water supplied
to the absorber is also to be studied. All process parameters that are
imperative to the reaction system are implemented including
conversion, selectivity, stoichiometric coefficients and reaction kinetics.
The process simulator HYSYS was used to simulate the plant’s processes
utilizing a modified version of the thermodynamic package ‘NRTL’ as
the basis of simulation and SI as the unit system. An alternative process
design is to be introduced at the end of this chapter where the
distillation column is replaced by a heat exchanger, and results are
compared to the original design. The following is the original process
flow diagram (PFD) of the formaldehyde plant is the reference for unit
designation and stream numbering.
52
A. PROCESS VALIDATION
| |
Errors of calculated values that were found to be 100% are in fact zero
and relatively close to the simulated values, for example:
| |
Another example was calculating the overall mass balance across the
reactor for both the calculated and simulated which were 8439 kg/h
and 8177 kg/h respectively with error percent of 3.2%.
53
1. Flowrate Spreadsheets
stream number 1 2 3
calculated simulated %Error calculated simulated %Error calculated simulated %Error
methanol 0.0000 0 0.0000 85.5372 85.5372 0.0000 97.7948 90.0964 8.5446
oxygen 38.4627 38.4636 0.0000 0.0000 0 0.0000 0.0000 0.0009 0.0000
formaldehyde 0.0000 0 0.0000 0.0000 0 0.0000 0.0000 0.1415 100.0000
water 0.0000 0 0.0000 0.0000 0 0.0000 1.3083 0.0464 2719.6101
hydrogen 0.0000 0 0.0000 0.0000 0 0.0000 0.0000 0.0007 0.0000
nitrogen 144.6972 144.6963 0.0000 0.0000 0 0.0000 0.0000 0.0325 100.0000
summation kmol/hr 183.1599 183.1599 0.0000 85.5372 85.5372 0.0000 99.1031 90.3184 9.7264
stream number 4 5 6
calculated simulated %Error calculated simulated %Error calculated simulated %Error
methanol 97.7948 90.0964 8.5446 0.0000 0 0.0000 97.7948 90.0964 8.5446
oxygen 0.0000 0.0009 100.0000 38.4627 38.4636 0.0023 0.0000 0.0009 100.0000
formaldehyde 0.0000 0.1415 100.0000 0.0000 0 0.0000 0.0000 0.1415 100.0000
water 1.3083 0.0464 2719.6101 0.0000 0 0.0000 1.3083 0.0464 2719.6101
hydrogen 0.0000 0.0007 100.0000 0.0000 0 0.0000 0.0000 0.0007 100.0000
nitrogen 0.0000 0.0325 100.0000 144.6972 144.6963 0.0006 0.0000 0.0325 100.0000
summation kmol/hr 99.1031 90.3184 9.7264 183.1599 183.1599 0.0000 99.1031 90.3184 9.7264
54
stream number 7 8 9
calculated simulated %Error calculated simulated %Error calculated simulated %Error
methanol 0.0000 0 0.0000 97.7948 90.0964 8.5446 12.3221 5.241 135.1106
oxygen 38.4627 38.4636 0.0000 38.4627 38.4645 0.0047 0.0000 3.1232 100.0000
formaldehyde 0.0000 0 0.0000 0.0000 0.1415 100.0000 85.4727 84.9969 0.5598
water 0.0000 0 0.0000 1.3083 0.0464 2719.6101 78.2337 70.7289 10.6107
hydrogen 0.0000 0 0.0000 0.0000 0.0007 100.0000 8.4794 14.1737 40.1749
nitrogen 144.6972 144.6963 0.0000 144.6972 144.7288 0.0218 144.6972 144.7288 0.0218
summation kmol/hr 183.1599 183.1599 0.0000 282.2630 273.4783 3.2122 329.2052 322.9925 1.9235
stream number 10 11 12
calculated simulated %Error calculated simulated %Error calculated simulated %Error
methanol 12.3221 5.241 135.1106 0.0000 0 0.0000 0.0000 0.0086 100.0000
oxygen 0.0000 3.1232 100.0000 0.0000 0 0.0000 0.0000 3.1223 0.0000
formaldehyde 85.4727 84.9969 0.5598 0.0000 0 0.0000 0.8547 0.0105 0.0000
water 78.2337 70.7289 10.6107 182.6318 182.63 0.0010 129.3825 121.1805 6.7685
hydrogen 8.4794 14.1737 40.1749 0.0000 0 0.0000 8.4794 14.1729 40.1715
nitrogen 144.6972 144.7288 0.0218 0.0000 0 0.0000 144.6972 144.6963 0.0006
summation kmol/hr 329.2052 322.9925 1.9235 182.6318 182.63 0.0010 283.4139 283.1911 0.0787
55
stream number 13 14 15
calculated simulated %Error calculated simulated %Error calculated simulated %Error
methanol 12.3221 5.2325 135.4925 12.3221 5.2325 135.4925 12.2982 4.5792 168.5663
oxygen 0.0000 0.0009 0.0000 0.0000 0.0009 100.0000 0.0000 0.0009 100.0000
formaldehyde 84.6179 84.9864 0.4335 84.6179 84.9864 0.4335 0.0000 0.1421 100.0000
water 131.4851 132.1784 0.5245 131.4851 132.1784 0.5245 1.3157 0.0466 2723.4582
hydrogen 0.0000 0.0007 100.0000 0.0000 0.0007 100.0000 0.0000 0.0007 100.0000
nitrogen 0.0000 0.0325 100.0000 0.0000 0.0325 100.0000 0.0000 0.0325 100.0000
summation kmol/hr 228.4252 222.4314 2.6947 228.4252 222.4314 2.6947 13.6139 4.802 183.5052
stream number 16 17 18
calculated simulated %Error calculated simulated %Error calculated simulated %Error
methanol 0.0372 0.6533 94.3116 0.0372 0.6533 94.3116 0.0000 0 0.0000
oxygen 0.0000 0 0.0000 0.0000 0 0.0000 0.0000 0 0.0000
formaldehyde 84.5192 84.8443 0.3832 84.5192 84.8443 0.3832 0.0000 0 0.0000
water 130.2598 132.1318 1.4168 130.2598 132.1318 1.4168 109.2042 107 2.0600
hydrogen 0.0000 0 0.0000 0.0000 0 0.0000 0.0000 0 0.0000
nitrogen 0.0000 0 0.0000 0.0000 0 0.0000 0.0000 0 0.0000
summation kmol/hr 214.8161 217.6294 1.2927 214.8161 217.6294 1.2927 109.2042 107 2.0600
56
stream number 19 20
calculated simulated %Error calculated simulated %Error
methanol 0.0372 0.6533 94.3116 0.0372 0.6533 94.3116
oxygen 0.0000 0 0.0000 0.0000 0 0.0000
formaldehyde 84.5192 84.8443 0.3832 84.5192 84.8443 0.3832
water 239.4640 239.1318 0.1389 239.4640 239.1318 0.1389
hydrogen 0.0000 0 0.0000 0.0000 0 0.0000
nitrogen 0.0000 0 0.0000 0.0000 0 0.0000
summation kmol/hr 324.0203 324.6294 0.1876 324.0203 324.6294 0.1876
2. Energy Spreadsheet:
Results Hand Calculations Simulation Error %
E-101 4217368.59 3801000 10.95418548
E-102 607730 -103900 684.9181906
E-103 105975.16 387400 72.64451213
E-104 -509157.15 -10850000 95.30730737
E-105 571017.54 19900000 97.13056513
E-106 -392.35 905400 100.0433344
C-101 1215098.58 780444 55.69324385
P-101 1033.025 1020 1.276960784
P-103 1856.6 1785 4.011204482
57
3. Discussion of Mass Balance:
In this section of the validation, justifications are to be reported in the
case of high errors.
Stream 9, 10, 13 and 14: Since the product was produced from one
desired and one undesired reactions, which were hand-calculated using
the conversion given by the problem statement. These conversions
were 78.66 and 8.74 for the desired and undesired reactions
respectively. However, the simulated version of the process has
conversions of 78.45 and 15.73 for the desired and undesired reactions
respectively. As a result, larger amount of methanol was consumed
from the undesired reaction. And the amount of methanol remaining
became lesser in simulation. This makes high error in the methanol
amount.
58
4. Discussion of Energy Balance:
E-103: A relatively high error was observed in this unit's load due to:
59
of the heat exchanger in the simulation software (HYSYS) is 82.22
oC and the outlet temperature is 48 oC. So, the load found by hand
E-104 & E-105: high percentages of error were found in these heat
exchangers because:
In the hand calculation, the effect of pressure on the energy balance was
not taken into account.
B. SIMULATION
60
61
62
WATER FEED VARIATION TO THE ABSORBER
63
VARIATION OF INLET TEMPERATURE TO THE
ABSORBER
64
65
Discussion of results:
C. ALTERNATIVE PROCESS
66
67
68
1. Reactor’s Cooler E-100:
The cooling duty is observed to be varied between the original design
(87.4% conversion) and the alternative design (98% conversion). The
duty on the original design was 2.366 *106 kj/hr. while to be much
higher in the alternative with 6.105*106 kj/hr. The large duty in the
alternative design is a disadvantage because it leads to a higher capital
cost which must be tolerated in order to accomplish the 98%
conversion.
3. Reactor’s Volume:
One of the downsides of the alternative design is that, when simulated,
it requires a much higher net volume for the reactor in order to achieve
the specified conversion (98%). While the aternative reactor is 70000
m3 in volume, the original process’s reactor has a net volume of just
4000 m3. More details and evaluations are to be presented when
performing the design of the plant later.
69
EQUIPMENT SIZING
This chapter covers the equipment design and sizing of the
formaldehyde production plant. The main units to be designed are the
reactor, absorber, distillation column, heat exchangers, pumps and the
compressor. The reactor design covered mainly the volume of the
reactor, the weight of the silver catalyst with its distribution along the
packed bed reactor, the temperature inlet and outlet of the reactor, the
pressure drop across the reactor. The absorber design is concerned
with determining the height of the packed tower, the diameter and the
type of packing. The design of the distillation tray column covered the
minimum reflux ratio, the minimum and actual number of stages, the
diameter and height of the column, the efficiency of the trays, and the
detailed layout of the sieve tray dimensions for the rectifying and
stripping sections. The heat exchangers design covered the
determination of the shell side and tube side diameter and the length of
the tubes. A detailed pinch analysis was done on all heat exchangers to
optimize the heating cooling Q to a minimum and ultimately lower the
fixed capital cost. The compressor and the pumps were designed by
determining the work of the shaft according to the pressure drop across
the unit. The design pipes were done by taking into account the
mechanical limits of the flowing fluids and the pressure drop across the
pipe.
70
EQUIPMENT & LINING LIST (referring to the PFD on page )
Below is a listing of the units and pipe lines to be presented in the
design.
71
REACTOR DESIGN
In this section, designing a plug flow reactor for multi reaction and non-
isothermal condition has been done. this reactor is supported with a
heat exchange to remove the heat generated from the exothermic
reaction. in this designing section, mole balances were considered to be
in the form of the final mole which is the remaining at the end of the
reaction period. Since the reaction is parallel, taking in mind the
reaction rates is too important by combining all these rates for each
material. Then evaluating the rest of these rate using the stoichiometric
coefficients. Evaluating the concentration of each material were done in
which all the pressure and temperature effect was considered. Here one
assumption was used which is the ideality of the gas introduced to the
reactor. By the end of this step, combination all previous steps can be
done to reduce the number of equations. Using Ergun equation,
pressure drop across the reactor was evaluated. In energy balance, to
increase the accuracy of the results, we use the integrated heat capacity
instead of assuming it constant. This is also has been done for
calculation of viscosity.
A C+ E (Undesired Reaction)
72
Where:
A is methanol
B is Oxygen.
C is formaldehyde.
D is Water.
E is hydrogen
I is Nitrogen inert gas
2- MOLE BALANCE
Methanol(A):
Oxygen (B):
Formaldehyde (C):
Water (D):
Hydrogen (E):
Where:
73
3- NET RATE LAWS
4- RATE LAWS
The reaction rate expressions are:
74
( )
( )
( )
( )
where:
Where:
75
Based on the stoichiometric coefficients, the relative rates can be found
using these relationship:
5- STOICHIOMETRY
In this design problem, the calculation will be done in case there is a
variation in both temperature and pressure. So for gas phase, the
concentration can be found as follow:
( ) ( ) ( )
Therefore,
( ) ( )
( ) ( )
( ) ( )
( ) ( )
( ) ( )
( ) ( )
in our design we decided to make the inlet pressure “ Po” to be 5.7 atm.
where the following parameters mean:
76
CTo= Po/(R*To)= 820.732.5kPa*/(8.314 kPa.m3/(kmol.K)*500K) =
0.1974338 (kmol/m3)
FT (kmol/h)= FA+FB+FC+FD+FE+ FI
yAo=FAo/FTo=97.7948/282.26=0.34647
CAo=yAo*CTo=0.34647* 0.1974338 = 0.0684 (kmol/m3)
( )
( )
( )
( )
Methanol(A):
Oxygen (B):
Formaldehyde (C):
Water (D):
Hydrogen (E):
6- COMBINATION
Mole balances, rate equation and stoichiometric relations are combined
together to form the main design equation. Note, the temperature
Methanol(A):
( ) ( )
(1)
( ) ( )
77
Oxygen (B):
( )
(2)
( )
Formaldehyde (C):
( ) ( )
(3)
( ) ( )
Water (D):
( )
(4)
( )
Hydrogen (E):
( )
(5)
( )
Conversion equation:
(6)
7- PRESSURE DROP
Pressure drop can be calculated using the differential equation of Ergun
equation:
(7)
Where:
78
- Po1=820.732.5kPa
- To =500 (K)
- FTo =282.26 (kmol/hr)
- FT = FA+FB+FC+FD +FE +FF +FI (kmol/hr)
- FI= FBo*(0.79/0.21)
-
⁄
-
-
- ⁄
⁄
(8)
⁄
(9)
⁄
79
8- ENERGY BALANCES
Using the energy balance design equation of a PBR with heat exchange:
∑( )
Reactor: ∑
for to reaction :
( ) ( )
∑
(10)
For variable coolant temperature, Ta, the energy balance equation is:
Coolant:
1) ∫ ∑ ∫ ∑
2) ∫ ∑ ∫ ∑
by simplification:
1) ∫ ∑ (11)
2) ∫ ∑ (12)
80
FOR THE SECOND REACTION:
81
Hydrogen (E): HoE=0
Nitrogen (I): HoI=0
COOLANT FLOWRATE:
82
to be 18 atm with its saturated temperature equal to 480K. Water inter
the reactor is 480K and leave at same temperature but in steam phase.
So the heat of vaporization is needed. Heat of vaporization is equal to
1910 kJ/kg of water
To evaluate the flow rate of this water in the shell side of the reactor,
energy balance is needed. by applying the following equation:
(13)
TC1=480 K TC2=480 K
Th1=500 K Th2=616 K
( )
(14)
( )
Therefore,
So
83
The procedure used to solve this cooling system is same as normal heat
exchanger. First of all, the length of the tube and the diameter of the
inside tubes were chosen. It is assumed that stainless steel is the
material of construction. Since our aim for cooling is just converting the
water of cooling to steam at same temperature. So correction factor is 1.
overall heat transfer was assumed at the first time to be 700 kJ/hr.m2.K.
Using this guessed overall heat transfer, the provisional area was
determined:
(15)
Where Q is gotten from our last calculation in mass and energy balance.
Based on the assumption of the length and the diameter of the tubes,
number of tubes needed is calculated:
(16)
pitch: (17)
( ) (18)
Where K1 and n1 are constant and they were chosen from the following
table to be 0.215 and 2.207 respectively.
84
The type of floating head of the exchanger to be outside packed head
and the bundle diameter clearance, BDC is gotten from the following
graph to be 0.038 m.
from information derived above, the shell diameter , baffle space, cross
sectional area, shell side mass velocity and the equivalent diameter
were calculated:
(19)
(20)
85
( )
(21)
(22)
(23)
To find the heat transfer coefficient of the shell side , Reynolds, Prandtle
and Nauseate number are needed.
(24)
(25)
( ) (26)
86
(27)
Pressure drop in the shell can be calculated from the following relation:
( )( )( )( ) (28)
for tube side calculation, tube-side mass velocity, tube side velocity,
Reynolds, Nauseate and Prandtle numbers were calculated:
(29)
(30)
(31)
87
(32)
Since the Reynolds number is in the range of the turbulent flow, heat
transfer coefficient was calculated from the following relation:
( ) (
) (33)
(34)
( )
( ) ( ) ( )
By the end of this step we will get the calculated result of the overall
heat transfer coefficient. Since this value is neither equal nor close to
the guessed one. So this value was looped several time until the prober
overall transfer coefficient was obtained.
Sp
Sn
88
11- EVALUATING OTHER PARAMETERS
Number of tubes and height were calculated using the correlations from heat
exchanger and equation 16 mentioned above. Then, the ratio of the total
length to the total diameter was manipulated until it became between the
range of 2-3
The size of the reactor needed is calculated from the weight of catalyst
needed to achieve our reaction conversion:
(35)
The height of the reactor is assumed to be once and a halve of the tube
height.
(36)
The shell size of the reactor was calculated. assuming the cover of the shell
size is 10 cm.
So, The width of the reactor can be found using this equation:
(37)
89
12- RESULTS
12.1. POLYMATH REASULTS:
12.1.1. Differential equations
1 d(FA)/d(W) = rA1+rA2
kmoleA/(kg cat. hr)
2 d(FB)/d(W) = 0.5*rA1
kmoleA/(kg cat. hr)
3 d(FC)/d(W) = -rA1-rA2
kmoleA/(kg cat. hr)
4 d(FD)/d(W) = -rA1
kmoleA/(kg cat. hr)
5 d(FE)/d(W) = -rA2
kmoleA/(kg cat. hr)
d(T)/d(W) = ((306.495*4/1500/0.0092456)*(480-
6
T)+(rA1*DHrxn1)+(rA2*DHrxn2))/(sumFiCPi)
7 d(y)/d(W) = (-alpha)*(FT/FTo)*(T/To)/2/y
8 d(V)/d(W) = 1/1500
2 FI = 144.693
kmol/hr
3
k1 = exp(12.5-(8774/T))
4
k2 = exp(-17.29+(7439/T))
5
k3 = exp(16.9-(12500/T))
6 k4 = exp(25-(15724/T))
7 CTo = 8.2/(0.082*To)
kmole/m3
8 FT = FA+FB+FC+FD+FE+FI
90
kmole/hr
9 CA = CTo*(FA/FT)*(To/T)*y
kmole/m3
10 Pa = 0.082*CA*T
atm
11
rA1 = -((Pa*k1)/(1+Pa*k2))
12
rA2 = -((Pa^0.5*k3)/(1+Pa^0.5*k4))
13 CB = CTo*(FB/FT)*(To/T) *y
kmole/m3
14 CC = CTo*(FC/FT)*(To/T) *y
kmole/m3
15
CD = CTo*(FD/FT)*(To/T) *y
kmole/m3
16 CE = CTo*(FE/FT)*(To/T) *y
kmole/m3
17 FTo = 282.26
kmol/hr
18
CI = CTo*(FI/FT)*(To/T) *y
kmole/m3
19 CAo = 0.3465*CTo
kmole/m3
20 Conversion = (97.79-FA)/97.79
21 Si = rA1/rA2
alpha = 2*(((8439.419/(3600*(3.14*(1/2)^2)))*(1-0.5)/(1.858*1*0.001*0.5^3)*((150*(1-
22 0.5)*4.894e-
5/0.001)+(1.75*(8439.419/(3600*(3.14*(1/2)^2)))))))/((3.14*(1/2)^2)*3000*(1-
0.5)*101.325*8.2)/1000
DHrxn1 = 1000*(((-115.9+(34.28E-3*((T-273.15)-(To-273.15))+2.134e-5*((T-273.15)^2-
23 (To-273.15)^2)-2.1735e-12*((T-273.15)^4-(To-273.15)^4)))+(-241.83+(33.46E-3*((T-
273.15)-(To-273.15))+3.44e-6*((T-273.15)^2-(To-273.15)^2)+2.535e-9*((T-273.15)^3-
(To-273.15)^3)-8.9825e-13*((T-273.15)^4-(To-273.15)^4)))-(-201.2+(42.93E-3*((T-
91
273.15)-(To-273.15))+4.1505e-5*((T-273.15)^2-(To-273.15)^2)-6.233e-9*((T-273.15)^3-
(To-273.15)^3)-2.0075e-12*((T-273.15)^4-(To-273.15)^4)))-(0+0.5*((29.1E-3*((T-
273.15)-(To-273.15))+5.79e-6*((T-273.15)^2-(To-273.15)^2)-2.0253e-9*((T-273.15)^3-
(To-273.15)^3)+3.2775e-13*((T-273.15)^4-(To-273.15)^4))))))
kJ/kmol
DHrxn2 = 1000*(((-115.9+(34.28E-3*((T-273.15)-(To-273.15))+2.134e-5*((T-273.15)^2-
(To-273.15)^2)-2.1735e-12*((T-273.15)^4-(To-273.15)^4)))+(0+(28.84E-3*((T-273.15)-
24 (To-273.15))+3.825e-8*((T-273.15)^2-(To-273.15)^2)+1.096e-9*((T-273.15)^3-(To-
273.15)^3)-2.1745e-13*((T-273.15)^4-(To-273.15)^4)))-(-201.2+(42.93E-3*((T-273.15)-
(To-273.15))+4.1505e-5*((T-273.15)^2-(To-273.15)^2)-6.233e-9*((T-273.15)^3-(To-
273.15)^3)-2.0075e-12*((T-273.15)^4-(To-273.15)^4)))))
kJ/kmol
25 CPIg = 29e-3+0.2199e-5*(T-273.15)+0.5723e-8*(T-273.15)^2-8.69e-12*(T-273.15)^3
26 CPAg = 42.93e-3+8.301e-5*(T-273.15)-1.87e-8*(T-273.15)^2-8.03e-12*(T-273.15)^3
27 CPBg = 29.1e-3+1.158e-5*(T-273.15)-0.6076e-8*(T-273.15)^2+1.311e-12*(T-273.15)^3
28 CPCg = 34.28e-3+4.268e-5*(T-273.15)-8.69e-12*(T-273.15)^3
29 CPDg = 33.46e-3+0.688e-5*(T-273.15)+0.7604e-8*(T-273.15)^2-3.593e-12*(T-273.15)^3
30 CPEg = 28.84e-3+0.00765e-5*(T-273.15)+0.3288e-8*(T-273.15)^2-0.8698e-12*(T-
273.15)^3
31
sumFiCPi = (FA*CPAg+FB*CPBg+FC*CPCg+FD*CPDg+FE*CPEg+FI*CPIg)*1000
kJ/h
32 Q = 58.8527*305.2868*60.514
kJ/hr
33 mc = Q/(1910)
kg/hr
34
XA = FA/FT
35
XB = FB/FT
36
XC = FC/FT
37
XD = FD/FT
38
XE = FE/FT
92
39 XI = FI/FT
12.1.3. The result of solving these differential and explicit equations were:
93
33 Q 1.087E+06 1.087E+06 1.087E+06 1.087E+06
34 rA1 -0.0143181 -0.1176075 -0.0143181 -0.0411258
35 rA2 -0.0005053 -0.0217943 -0.0005053 -0.0126897
36 Si 28.3337 3.240879 28.3337 3.240879
37 sumFiCPi 1.166E+04 1.166E+04 1.274E+04 1.264E+04
38 T 500. 500. 635.7779 616.0361
39 To 500. 500. 500. 500.
40 V 0 0 1.198667 1.198667
41 W 0 0 1798. 1798.
42 XA 0.3397928 0.0330373 0.3397928 0.0330373
43 XB 0.1528877 0.0142585 0.1528877 0.0142585
44 XC 0 0 0.2586236 0.2586236
45 XD 0.0045519 0.0045519 0.2378521 0.2378521
46 XE 0 0 0.0246786 0.0246786
47 XI 0.5027676 0.43155 0.5027676 0.43155
48 y 1. 0.8683294 1. 0.8683294
As it is clear in the result of the polymath, we need 1798 kg of catalyst with diameter of 0.001 m
and porosity of 0.5 to achieve this reaction. this amount lead to 88.67% conversion of methanol
to formaldehyde.
12.1.4. Graphs:
94
95
12.2. HEAT EXCHANGER RESULTS:
Heat exchanger was calculated as the procedure mentioned above. the results are shown below:
Q (kJ/hr) 1087245.768
K1 0.215
n1 2.207
A m2 58.8527
n 910.5372
Bundle diameter m 0.6034
BDC 0.0380
DS 0.6414
BS 0.2565
pt 0.0171
As m2 0.0329
GS (kg/hr/m2) 16354.9775
equivalent dia. m 0.0135
Re s 562.5432
pr 0.0057
Nu shell 0.4652
ho 82.2360
dPs (kPa) 0.0000
GM kg/hr/m2 138032.6281
Velocity m/s 74259.9563
Ret 7243.2726
Prt 0.0009
hi 732.6217
96
UTILITY PROPERTIES
kf (kJ/(hr.m.K)) 2.394
Viscosity kg /(m.hr) 0.393754633
Density kg/m3 936.76
Cpc kJ/kg K 1.833333333
mc(kg/hr) 538.1871933
REACTION PROPERTIES
Viscosity kg /(m.hr) 0.176190312
Density kg/m3 1.858776048
Cph kJ/kg K mix 0.667622394
mh (kg/hr) 8438
TUBES PROPERTIES
k (kJ/(hr.mK)) 126
di (m) 0.0092456
do (m) 0.013716
Ai (m) 6.71367E-05
Ao (m) 0.000147756
guess L (m) 1.5
L/D 2.228554938
97
14- RESULTS COMPARISON
Flow rates produced from our design is compared with the one gotten from mass balance:
98
ABSORBER DESIGN
One of the most common unit operations in the industry is the
absorption process. Absorption is the mechanism of transporting
molecules or components of gases into liquid phase. The component
that is absorbed is called the solute and the liquid that absorbs the
solute is called the solvent. Actually, the absorption can be either
physical where the gas is removed due to its high solubility in the
solvent, or chemical where the removed gas reacts with the solvent and
remains in solution.
1- Packed-Bed Absorber
The packed-bed absorbers are the most common absorbers used for gas
removal. The absorbing liquid is dispersed over the packing material,
which provides a large surface area for gas-liquid contact. Packed beds
are classified according to the relative direction of gas-to-liquid flow
into two types. The first one is co-current while the second one the
counter current packed bed absorber. The most common packed-bed
absorber is the countercurrent-flow tower. The gas stream enters the
bottom of the tower and flows upward through the packing material
and exits from the top after passing through a mist eliminator. Liquid is
introduced at the top of the packed bed by sprays or weirs and flows
downward over the packing. In this manner, the most dilute gas
contacts the least saturated absorbing liquid and the concentration
difference between the liquid and gas phases, which is necessary or
mass transfer, is reasonably constant through the column length. The
maximum (L/G) in countercurrent flow is limited by flooding, which
occurs when the upward force exerted by the gas is sufficient to prevent
the liquid from flowing downward. The minimum (L/G) is fixed to
ensure that a thin liquid film covered all the packing materials.
99
Packing material
The main purpose of the packing material is to give a large surface area
for mass transfer. However, the specific packing selected depends on
the corrosiveness of the contaminants and scrubbing liquid, the size of
the absorber, the static pressure drop, and the cost. There are three
common types of packing material: Mesh, Ring, and Saddles. In our
project Ceramic Berl Saddles packed was selected since it is good liquid
distribution ratio, good corrosion resistance, most common with
aqueous corrosive fluids and Saddles are beast for redistributing liquids
low cost. Also we use 2 inches diameter packing.
100
PACKED TOWER DIAMETER:
101
= 1.620 = 995.65
= 150 m-1 ψ=
-3
μ = 0.797 P
√ √
G’ flooding = √
Where: G' = mass flow rate of gas per unit cross-sectional area of column, g/s•m2
= density of the gas stream (
= density of the absorbing liquid ( )
102
√ 54
PACKING HEIGHT:
0.128131 0.020408
0.256075 0.041667
0.383319 0.06383
0.509738 0.086957
0.63521 0.111111
0.759703 0.136364
0.883187 0.162791
1.005826 0.190476
1.128138 0.219512
1.250327 0.25
103
0.7 Y vs X
y = 5.8413x
0.6
0.5
y = 7.481x + 0.0073
0.4
Y
0.3
0.2
0.1
0
0 0.02 0.04 X 0.06 0.08 0.1 0.12
Calculating and Z :
Z= HOG
= number of transfer units based on an overall gas-film coefficient.
HOG = height of a transfer unit based on an overall gas-film coefficient, m
= mole fraction of solute in entering gas
= mole fraction of solute in exiting gas
[ ]
[ ]
HOG was obtained from table 15-4 in “Separation Process Engineering”. For
ceramic packing with size 2 in, HOG = 3 ft = 0.9 m
Z = HOG
104
3- Control Loop System
For the control ability of the absorber three different loops will be added to
the process. The first one will be added to the inlet of the liquid and gas to
control the flow rate. The second one will be added to the gas outlet to
control the pressure of the absorber. The third one will be added to the
liquid outlet to control the level as in Figure.
105
4- Design Summary
106
DISTILLATION COLUMN DESIGN
This section represents an equipment design and sizing for the
distillation unit of the term’s project on the production of formaldehyde
from methanol. The basis for this equipment sizing is the previously
obtained process data for the simulation of the project, which proved to
be reliable and accurate (available in APPENDIX). Preliminary
calculations are to be presented first to serve as a baseline of all the
calculations that follows. These calculations include a mass balance of
the distillation unit, average physical properties of the components and
relative volatilities. The minimum reflux ratio of the column is obtained
through underwood’s equations. The diameter of the column is sized in
the rectifying section and the stripping section. The minimum tray
number is obtained through Fenske’s relation along with their
correlated efficiencies (top & bot). The layout of the sieve trays and
their hydrodynamic effects are then obtained in a detailed fashion for
the top and bottom sections. The process simulator HYSYS was used to
simulate the distillation unit utilizing a modified version of the
thermodynamic package ‘NRTL’.
A. PRELIMINARY CALCULATIONS
This first section of the design is set to present the initial calculations
needed in the design and sizing of the distillation column. These
calculations include material balance, physical properties of the system
and the relative volatilities of the participating components.
1. Material Balance
This initial mass balance around the distillation column gives an
indication of the accuracy of the simulated parameters that are to be
used in the upcoming calculations on a kmol/hr. basis.
107
Assumptions:
9- Light Key : methanol
10- Heavy key: H20
11- Non-heavy key: formaldehyde
12- Constant Molal Overflow (CMO)
n14 = D + B ……………………………………………. (1)
Mol Mass
Molecular
Component fraction nj = yi * ntot mi = ni * M fraction xi
weight
(yi) = mi/Mtot
Methanol 0.00173 0.0038 32.042 0.12176 0.006244
Formaldehyde 0.39345 8.6425 30.026 259.5 0.51965
Water 0.60637 13.3194 18 239.73 0.4801
108
2. Physical Properties
The physical parameters to be included are the molecular weight and
average density on the basis of mole fractions of the components in
both the rectifying and stripping section.
Molecular Weight
= 31.57g/mol
= 22.63 g/mol
Average Density
Rectifying Section:
̅̅̅̅̅̅
Stripping Section:
̅̅̅̅̅̅
109
3. Relative Volatilities
The volatility of each component is to be calculated for the rectifying
and stripping sections and their average relative to an reference
component with is methanol in our case.
Rectifying Section
⁄ ⁄
⁄ ⁄
⁄ ⁄
⁄ ⁄
⁄ ⁄
⁄ ⁄
Stripping Section
⁄ ⁄
⁄ ⁄
⁄ ⁄
⁄ ⁄
⁄ ⁄
78547
⁄ ⁄
√ √
√ √
√ √
110
B. MINIMUM REFLUX
111
Using underwood first equation to find minimum vapor:
= 32.063
Minimum refluxes
External Reflux:
Internal Reflux:
External Reflux:
Internal Reflux:
112
C. COLUMN DIAMETER
Sieve tray column is decided to be used in the design. This decision is
based upon the compatibility of this tray type with our methanol-
formaldehyde-water separation process. Also depends on the many
features that serve the upcoming economical evaluation of the column.
These features include high capacity, relatively high efficiency, low cost,
low fouling tendency and low maintenance requirements. We are to use
Fair’s (1963) approach to calculating the diameter of the column
starting with determining the vapor flooding velocity, then the
operating velocity and finally sizing the actual diameter of the column.
This approach is to be applied to the rectifying section and extended to
the stripping section of the column.
̅̅̅̅̅̅̅
√ ̅̅̅̅̅̅̅ √
113
Then, the operation velocity is calculated as follows:
√ √
114
Diameter sizing of the top section:
̅ ̅
̅
̅
̅
(̅) 1.145 * 7.9039
̅̅̅̅̅̅̅
( ) √
̅̅̅̅̅̅̅
115
Diameter sizing of the bottom section:
̅̅̅̅̅
( ) ( ) ( ) ( ) ( ) ( ) ( )
̅̅̅̅̅
( ) ( ) ( ) ( ) ( )
D. TRAY SPECIFICATIONS
This section is aimed to investigate the design specifications of the
column in relation to the tray instillation. These specifications include
the minimum number of stages, the theoretical number of stages, the
optimum feed stage, the tray efficiency and the actual construction
stages.
[( ) ( ) ] [( ) ( ) ]
=
116
2. Total Number of Stages (theoretical)
The calculation of the theoretical number of stages of the distillation
column is presented here through two distinct approaches: Gilliland
correlation (1940) and Molokanov correlation (1972) as follows:
( ) → ( )
( ) ( )
Abscissa = → Ordinate = 0.62
( )
117
Second Approach: MOLOKANOV CORRELATION
[( )( )]
[( )( )]
⌈( ) ( ) ⌉ ⌈( ) ( ) ⌉
⌈( ) ( ) ⌉ ⌈( ) ( ) ⌉
118
4. Tray Efficiencies & Column Height
Since the Diameters of the rectifying section and the stripping section
are different, a slight change in the tray efficiency is to be considered in
the column design. The efficiency of the trays is to be determined using
O’Connell Correlation which is estimated the efficiency as a function of
the product of the feed liquid viscosity and the volatility of the key
components in the following manner:
= 0.8573 → 85.7%
119
BOTTOM SIDE EFFICIENCY
= 0.841 → 84.1%
COLUMN HEIGHT
The column height is heavily dependent upon the spacing between the
sieve trays. In our design, 18 inches were chosen for spacing to provide
a reasonable space to ease the accessibility for manual workers to crawl
between the plates for maintenance. According to Turton’s Distillation
Column Design Heuristics (1955), a safety factor of 10% is to be added to
the final design height. The column height is determined as follows:
120
E. TRAY LAYOUT AND HYDROULICS (TOP)
This section is a detailed representation of the design layout
calculations for the sieve plates in the top section. The decided type of
tray is a single pass sieve plate counter-flow tray with a straight
segmental vertical downcomer and a weir. The use of single pass tray is
due to the relatively small diameter of the column and its liquid load.
Also to avoid the propagation of mal-distribution of the liquid, this could
lead to a major decrease in the efficiency of the tray and the capacity of
the column if a multiple-pass tray was used. The decision to use a
segmental straight downcomer is due to its simple geometry, low cost.
Also because it utilizes most of the column area for the large downflow
in our system and the ease at which it’s operated and maintained. The
sequence of the tray layout design is applied as follows:
1. Tray Dimensions
Diatop = 8.115 ft.
121
( )
ENTRAINED LIQUID:
(e) =
L+e=
( )
Atot =
DOWNCOMER AREA:
Ad = Atot =
WEIR LENGTH:
122
Since a non-fouling operation is aimed, the tray holes are punched from
the bottom down to provide safer maintenance of personnel.
ORIFICE COEFFICIENT:
( ) ( )
( )
( )
The chosen weir height is h weir = 2 inch. This optimum height is enough
to retain the down flowing liquid and provide the downcomer with
enough head to remain sealed. It also provides a reasonable residence
time of the liquid in the sieve tray.
123
WEIR CORRECTION FACTOR
̅̅̅̅̅ ( )
The abscissa =
( ) ( )
124
LIQUID FRACTIONAL LOSS
With a gap between the downcomer apron and the lower tray is chosen
to be 1 inch as a standard. The fractional loss of the liquid head is
encountered during down flow through the downcomer and the lower
tray and is estimated by the empirical equation by Ludwig (1997):
( ) ( )
̅̅̅̅̅
The total pressure head on the downcomer is the summation of all the
hydrodynamic effects determined previously as follows:
Since the aerated liquid head is much less than the tray
spacing which is 18 inch, there would be no operational problem and
the liquid flooding is regulated.
125
WEEPING CHECK
Correlation parameter:
X=
Correlation term:
Condition:
≥ 0.10392+0.25199X-0.021675X2
→ ≥ 0.66241
126
3. Design Schematics
127
F. TRAY LAYOUT AND HYDROULICS (BOT)
Since the diameters of the top section and the bottom section are
different, a different layout parameters and to be determined. A similar
procedure to the top side is used in the bottom side and the following
parameters were obtained:
1. Tray Dimensions
Dia bot = 9.244 ft.
Atot =
Ad =
= 6.7111 ft.
0.83118
0.365
128
2. Flooding & Weeping Check
FLOODING CHECK
The total pressure head on the downcomer is the summation of all the
hydrodynamic effects determined previously as follows:
Since the aerated liquid head is much less than the tray
spacing which is 18 inch, there would be no operational problem and
the liquid flooding is regulated.
WEEPING CHECK
X=
Condition:
≥ 0.10392+0.25199X-0.021675X2
→ ≥ 0.303
129
G. DESIGN FLOWSHEET
This following is a detailed design flow sheet of the distillation column
based upon the previously determined parameters. Due to the corrosive
nature of concentrated formaldehyde at relatively elevated
temperatures, a stainless steel Material of Construction (MOC) is
decided to be chosen for the column interior walls and sieve trays.
130
H. DESIGN SIMULATION
As a measure of accuracy and consistency, this final part of the design is
set to present a simulated version of the design as a reference and a
comparison to the actual design parameters obtained through rigorous
calculations previously. A snapshot of the simulated column is the
following:
131
HEAT EXCHANGER DESIGN
This section presents the design of six heat exchangers involved in the
project, including the condenser and the reboiler. The type of all these
heat exchangers is shell and tube heat exchanger, and the utilities are
either medium pressure steam in the heaters or cooling water in the
cooler. All parameters and specifications are to be determined and
tabulated for each heat exchanger. For example, tube length, inner and
outer tube diameters, shell diameter, total surface area of tubes, number
of tubes, tube and shell heat transfer coefficients , heat duty and other
design specification. In the case of designing the condenser and the
reboiler, the local heat transfer coefficients should be used. In each heat
exchanger, we are trying to follow the heuristic that say ' the ratio of the
shell length to its diameter should be close to 3 '. Many trials may need
to be performed, depends on the first guess of the overall heat transfer
coefficient. For simplicity, Microsoft Excel could be used to implement
the trials faster. Pinch analysis for each equipment was performed to set
an energy target for the project.
132
4. Assuming Tshell, in = = 180 oC and Tshell, out = = 155 oC.
∑
= w
[∫ ∫ ]
[∫ ∫ ]
[∫ ∫
133
5. LMTD for Counter-Current Flow:
( ) ( )
( )
( )
134
LMTD = 66.197 oC
9. Provisional Area =
⁄
Bundle diameter = ( )
135
For square pitch and two tubes passes, k1 and n1 can be found by:
⁄ ⁄
So, Bundle diameter = ( ) ( )
= 0.489 m
12. For fixed and U-tube heat exchanger with bundle diameter ≈ 0.50 m
136
( )
16. Shell-side mass velocity =
⁄ ⁄
( )
137
So, jh =2.7E-3
⁄ ⁄
( )
( )( ) ( ) ,
Where, and
Thus, jf = 2.8E-2
( )( )
138
22. Number of tubes per pass (Ntpp) =
= 25.38 kg/m2.oc
ρm =
25.
139
So,
Also,
26. Because
( ) ( ) , assuming that
( )
( [ ( ) ]) , assuming that
( [ ])
28. Overall heat transfer factors based on inside and outside tube flow:
( ⁄ )
=
( ⁄ )
=
Because the assumed overall heat transfer coefficient (U=1000 W/m2.oC) is not in
the range (between Ui and Uo), use the calculated value in step 8 and do loop using
Excel sheet until the difference between the calculated U in the two consecutive
iterations is small.
140
Design of E-101
141
Design of E-102
142
Design of E-103
143
Design of E-106
144
DESIGN OF CONDENSER AND REBOILER
All steps followed for design heat exchangers are the same in the case of
condenser and reboiler, except using of the local heat transfer coefficient where
changing of phase is taking place.
In the case of condenser, when the tubes are arranged horizontally, the
tube-side heat transfer coefficient can be calculated as follow:
⁄
[ ]
( )
Because ;
g = 9.8 m/s
Tg : Vapor temperature at the edge of the film (saturation temperature).
Tw : Wall temperature.
hfg : Latent heat of vaporization.
For tube-side:
hfg = ; ;
In the case of film-boiling inside the reboiler and all the tubes are arranged
horizontally, the tube-side heat transfer coefficient can be calculated by the
following equation:
⁄
[ ]
Because ;
145
Design of Condenser (E-104)
146
Design of Reboiler (E-105)
147
Pinch Analysis for E-101
1. Select Input Method from the Dropdown list: Mass Flowrate & Specific Heat Capacity
3. Select appropriate units for the input data from the drop down lists below (E15/F15). Requires Input -
Optional Input -
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams). Calculation cell -
148
Pinch Analysis for E-102
1. Select Input Method from the Dropdown list: Mass Flowrate & Specific Heat Capacity
3. Select appropriate units for the input data from the drop down lists below (E15/F15). Requires Input -
Optional Input -
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams). Calculation cell -
149
Pinch Analysis for E-103
1. Select Input Method from the Dropdown list: Mass Flowrate & Specific Heat Capacity
3. Select appropriate units for the input data from the drop down lists below (E15/F15). Requires Input -
Optional Input -
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams). Calculation cell -
150
Pinch Analysis for E-106
1. Select Input Method from the Dropdown list: Mass Flowrate & Specific Heat Capacity
3. Select appropriate units for the input data from the drop down lists below (E15/F15). Requires Input -
Optional Input -
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams). Calculation cell -
151
Pinch Analysis for Condenser
1. Select Input Method from the Dropdown list: Mass Flowrate & Specific Heat Capacity
3. Select appropriate units for the input data from the drop down lists below (E15/F15). Requires Input -
Optional Input -
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams). Calculation cell -
152
Pinch Analysis for Reboiler
1. Select Input Method from the Dropdown list: Mass Flowrate & Specific Heat Capacity
3. Select appropriate units for the input data from the drop down lists below (E15/F15). Requires Input -
Optional Input -
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams). Calculation cell -
153
PUMPS, COMPERSSOR & PIPING DESIGN
Here is a comprehensive design of the fluid flow related equipment
including the pumps, compressor and pipes across the entire plant.
Schematic sketches for the pipes dimensions are presented at the end of
this section.
PUMP P-101
At 30 0C
154
PUMP P-102
At 68.3 0C
155
PUMP P-103
At 110 0C
156
COMPRESSOR C-101
For Air
Cp=29.1 , Cv =20.78
Where
Assumption:
5. N=0.75
6. Adiabatic.
7. Constant heat capacities.
8. Ideal gas.
157
VISCOSITY ESTIMATION
stream number 1 2 3 4 5
material
g l l l g
condition
temperature C 20 89.31 89.31 102 68.3
temperature K 293.15 362.46 362.46 375.15 341.45
Pressure (atm) 1 1 1.2 1.2 1.2
composition viscosity composition viscosity composition viscosity composition viscosity composition viscosity
methanol 0.000 5.75E-04 0.000 2.78E-04 0.054 2.78E-04 0.054 2.53E-04 0.903 3.33E-04
oxygen 0.000 2.29E-05 0.000 1.67E-05 0.000 1.67E-05 0.000 1.59E-05 0.000 1.82E-05
formaldehyde 0.000 1.48E-04 0.003 9.04E-05 0.370 9.04E-05 0.370 8.42E-05 0.000 1.03E-04
water 1.000 1.02E-03 0.457 3.16E-04 0.576 3.16E-04 0.576 2.73E-04 0.097 4.18E-04
hydrogen 0.000 0.00E+00 0.030 0.00E+00 0.000 0.00E+00 0.000 0.00E+00 0.000 0.00E+00
nitrogen 0.000 9.19E-07 0.511 3.46E-07 0.000 3.46E-07 0.000 2.95E-07 0.000 4.57E-07
Summation 1 1.02E-03 1.000 1.45E-04 1.000 2.30E-04 1.000 2.02E-04 1.000 3.41E-04
158
stream number 6 7 8 9 10
material
g g g g g
condition
temperature C 110 110 30 48 30
temperature K 383.15 383.15 303.15 321.15 303.15
Pressure (atm) 1 3 3 3 3
composition viscosity composition viscosity composition viscosity composition viscosity composition viscosity
methanol 0.000 2.39E-04 0.000 2.39E-04 0.000 5.04E-04 0.000 4.08E-04 0.000 5.04E-04
oxygen 0.000 1.54E-05 0.000 1.54E-05 0.000 2.18E-05 0.000 2.00E-05 0.000 2.18E-05
formaldehyde 0.393 8.07E-05 0.393 8.07E-05 0.000 1.36E-04 0.261 1.18E-04 0.261 1.36E-04
water 0.606 2.52E-04 0.606 2.52E-04 1.000 8.20E-04 0.739 5.79E-04 0.739 8.20E-04
hydrogen 0.000 0.00E+00 0.000 0.00E+00 0.000 0.00E+00 0.000 0.00E+00 0.000 0.00E+00
nitrogen 0.000 2.67E-07 0.000 2.67E-07 0.000 7.89E-07 0.000 6.06E-07 0.000 7.89E-07
Summation 1.000 1.84E-04 1.000 1.84E-04 1.000 8.20E-04 1.000 4.59E-04 1.000 6.41E-04
stream number 11 12 13 14 15
material
l g l l l
condition
temperature C 25 25 31.13 31.13 37.3
temperature K 298.15 298.15 304.28 304.28 310.45
Pressure (atm) 1 1 1 3 3
methanol 0.0000 5.38E-04 1.0000 5.38E-04 0.9868 4.97E-04 0.9868 4.97E-04 0.0000 4.61E-04
oxygen 0.2100 2.23E-05 0.0000 2.23E-05 0.0000 2.17E-05 0.0000 2.17E-05 0.2100 2.10E-05
formaldehyde 0.0000 1.42E-04 0.0000 1.42E-04 0.0000 1.35E-04 0.0000 1.35E-04 0.0000 1.28E-04
water 0.0000 9.13E-04 0.0000 9.13E-04 0.0132 8.01E-04 0.0132 8.01E-04 0.0000 7.07E-04
hydrogen 0.0000 0.00E+00 0.0000 0.00E+00 0.0000 0.00E+00 0.0000 0.00E+00 0.0000 0.00E+00
nitrogen 0.7900 8.51E-07 0.0000 8.51E-07 0.0000 7.76E-07 0.0000 7.76E-07 0.7900 7.08E-07
Summation 1 5.36E-06 1 5.38E-04 1 5.01E-04 1 5.01E-04 1 4.97E-06
159
stream number 16 17 18 19 20
material
l l l l l
condition
temperature C 150 150 150 343 165
temperature K 423.15 423.15 423.15 616.15 438.15
Pressure (atm) 3 3 3 3 3
methanol 0.9868 1.89E-04 0.0000 1.89E-04 0.3465 1.89E-04 0.0374 1.09E-04 0.0374 1.75E-04
oxygen 0.0000 1.33E-05 0.2100 1.33E-05 0.1363 1.33E-05 0.0000 7.90E-06 0.0000 1.27E-05
formaldehyde 0.0000 6.69E-05 0.0000 6.69E-05 0.0000 6.69E-05 0.2596 3.80E-05 0.2596 6.29E-05
water 0.0132 1.79E-04 0.0000 1.79E-04 0.0046 1.79E-04 0.2376 6.67E-05 0.2376 1.62E-04
hydrogen 0.0000 0.00E+00 0.0000 0.00E+00 0.0000 0.00E+00 0.0258 0.00E+00 0.0258 0.00E+00
nitrogen 0.0000 1.68E-07 0.7900 1.68E-07 0.5126 1.68E-07 0.4395 2.76E-08 0.4395 1.42E-07
Summation 1 1.88E-04 1 2.93E-06 1 6.81E-05 1 2.98E-05 1 6.16E-05
DENSITY ESTIMATION
( ( ) )
160
stream number 1 2 3 4 5
material
g l l l g
condition
temperature C 25 25 31.13 31.13 37.3
temperature K 298.15 298.15 304.28 304.28 310.45
Pressure (atm) 1 1 1 3 3
methanol 0.000 788.577 1.000 788.577 0.987 782.664 0.987 782.664 0.000 3.769
oxygen 0.210 1.308 0.000 1015.182 0.000 1.282 0.000 3.845 0.210 3.769
formaldehyde 0.000 732.164 0.000 732.164 0.000 719.981 0.000 719.981 0.000 3.533
water 0.000 993.996 0.000 993.996 0.013 991.694 0.013 991.694 0.000 2.120
hydrogen 0.000 0.082 0.000 0.082 0.000 0.080 0.000 0.240 0.000 0.236
nitrogen 0.790 1.145 0.000 1.145 0.000 1.121 0.000 3.364 0.790 3.298
Summation 1.000 1.175 1.000 788.577 1.000 784.848 1.000 784.848 1.000 3.386
stream number 6 7 8 9 10
material g g g g g
condition
temperature C 150 150 150 343 165
temperature K 423.15 423.15 423.15 616.15 438.15
Pressure (atm) 3 3 3 3 3
methanol 0.987 2.765 0.000 2.765 0.346 2.765 0.037 1.899 0.037 2.670
oxygen 0.000 2.765 0.210 2.765 0.136 2.765 0.000 1.899 0.000 2.670
formaldehyde 0.000 2.592 0.000 2.592 0.000 2.592 0.260 1.780 0.260 2.503
water 0.013 1.555 0.000 1.555 0.005 1.555 0.238 1.068 0.238 1.502
hydrogen 0.000 0.173 0.000 0.173 0.000 0.173 0.026 0.119 0.026 0.167
nitrogen 0.000 2.419 0.790 2.419 0.513 2.419 0.440 1.661 0.440 2.336
Summation 1.000 2.737 1.000 2.485 1.000 2.568 1.000 1.150 1.000 1.617
161
stream number 11 12 13 14 15
material l g l l l
condition
temperature C 20 89.31 89.31 102 68.3
temperature K 293.15 362.46 362.46 375.15 341.45
Pressure (atm) 1 1 1.2 1.2 1.2
methanol 0.000 793.339 0.000 1.076 0.054 721.509 0.054 706.631 0.903 744.784
oxygen 0.000 1.330 0.000 1.076 0.000 1.291 0.000 1.247 0.000 1.371
formaldehyde 0.000 741.891 0.003 1.009 0.370 582.103 0.370 541.967 0.000 638.064
water 1.000 995.773 0.457 0.605 0.576 962.786 0.576 954.676 0.097 974.749
hydrogen 0.000 0.083 0.030 0.067 0.000 0.081 0.000 0.078 0.000 0.086
nitrogen 0.000 1.164 0.511 0.941 0.000 1.130 0.000 1.092 0.000 1.199
Summation 1.000 995.773 1.000 0.573 1.000 763.935 1.000 733.787 1.000 762.162
stream number 16 17 18 19 20
material l l l l l
condition
temperature C 110 110 30 48 30
temperature K 383.15 383.15 303.15 321.15 303.15
Pressure (atm) 1 3 3 3 3
methanol 0.000 696.882 0.000 696.882 0.000 783.761 0.000 765.931 0.000 783.761
oxygen 0.000 1.018 0.000 3.054 0.000 3.859 0.000 3.643 0.000 3.859
formaldehyde 0.393 512.462 0.393 512.462 0.000 722.250 0.261 684.755 0.261 722.250
water 0.606 949.208 0.606 949.208 1.000 992.129 0.739 984.651 0.739 992.129
hydrogen 0.000 0.064 0.000 0.191 0.000 0.241 0.000 0.228 0.000 0.241
nitrogen 0.000 0.891 0.000 2.672 0.000 3.377 0.000 3.188 0.000 3.377
Summation 1.000 710.815 1.000 710.815 1.000 992.129 1.000 883.671 1.000 903.990
162
PIPING SCHEMATICS
The plant piping layout is designed to accommodate all process units in the PFD inside a confined
rectangular space of 80 meters by 40 meters. The plant area is divided into three sections as follows:
The first section includes the feed areas of methanol and air, the reactor feed mixing, the reactor and the
absorber. The second section accommodates the the distillation tower and its reflux area. The third and final
section side of the plant is where the product is mixed with deionized water and pumped for storage
loading. The following are pipes sizing and dimensions tables for each section in the formaldehyde
production plant.
163
SECTION 1
164
STREAM weight density velocity 1
PIPE CODE flow rate m3/hr D1 A m2
# kg/hr kg/m3 m/s
10 in,
1 5282.328 1.175390216 4494.105811 0.24765 0.04816888 25.91637448
Sche.40
2 6 in, Sche.40 2740.783 788.5773877 3.475604351 0.154054 0.018639568 0.051795495
3 6 in, Sche.40 3158.5247 784.8484078 4.024375496 0.4 0.125663706 0.008895823
4 6 in, Sche.40 3158.5247 784.8484078 4.024375496 0.154054 0.018639568 0.059973605
10 in,
5 5282.328 1.175390216 4494.105811 0.24765 0.04816888 25.91637448
Sche.40
6 3158.5247 2.736824764 1154.083645 0.24765 0.04816888 6.65530924
10 in,
7 5282.328 1.175390216 4494.105811 0.24765 0.04816888 25.91637448
Sche.40
10 in,
8 8440.8527 2.56763335 3287.405773 0.254508 0.050873634 17.94973557
Sche.40
9 8440.8527 1.149918745 7340.39056 1.4 1.5393804 1.32455719
10 10 in, 8440.8527 1.149918745 7340.39056 0.254508 0.050873634 40.079649
Sche.40
11 6 in, Sche.40 3287.373 995.7732285 3.301326955 0.154054 0.018639568 0.049198311
12 6423.166 0.573238289 11205.05403 0.77 0.465662571 6.684056658
165
STREAM ԑ ԑ/D viscosity Re profile of f L
# flow
1 0.000254 0.001025641 5.36336E-06 1406558.519 Turbulent 0.00499 5
2 0.000254 0.001648773 0.000537992 11695.8874 Turbulent 0.0080587 8
3 0.000254 0.000635 0.000501236 5571.728029 Turbulent 0.0092525 2
4 0.000254 0.001648773 0.000501236 14466.94803 Turbulent 0.00772764 3
5 0.000254 0.001025641 4.97133E-06 1517476.457 Turbulent 0.0049897 6
6 0.000254 0.001025641 0.000188464 23934.52002 Turbulent 0.00677 8.5
7 0.000254 0.001025641 2.93309E-06 2571986.956 Turbulent 0.00497 6.3
8 0.000254 0.000998004 6.80734E-05 172311.7307 Turbulent 0.0053 10.125
9 0.000254 0.000181429 2.98101E-05 71532.41049 Turbulent 0.0050414 3
10 0.000254 0.000998004 2.98101E-05 393486.1564 Turbulent 0.0050928 2
11 0.000254 0.001648773 0.001021406 7388.99484 Turbulent 0.00871225 44.14
12 0.000254 0.00032987 0.000144745 20382.71052 Turbulent 0.0065198 3
STREAM LOSS
A1 D2 A2 velocity 2 LOSS PIPE m constant
# expand
1 0.04816888 0.254508 0.050873634 24.53850133 0.201494044 0 0
2 0.018639568 0.4 0.125663706 0.007682772 0.836974048 32.96793914 0
3 0.125663706 0.154054 0.018639568 0.059973605 0.092525 0 1.109
4 0.018639568 0.154054 0.018639568 0.059973605 0.300971348 0 0
5 0.04816888 0.254508 0.050873634 24.53850133 0.241778316 0 0
6 0.04816888 0.254508 0.050873634 6.301472251 0.464728447 0.003152989 0
7 0.04816888 0.254508 0.050873634 24.53850133 0.25286493 0.003152989 0
8 0.050873634 1 0.785398163 1.162681953 0.421695978 208.4620923 0.044
9 1.5393804 0.254508 0.050873634 40.079649 0.021606 0.934995931 0
10 0.050873634 0.254508 0.050873634 40.079649 0.080041492 0 0
11 0.018639568 0.77 0.465662571 0.001969313 4.992518403 575.1591911 0
12 0.465662571 0.15405 0.0186386 166.9929618 0.050803636 0 1.0105
166
STREAM LOSS loss 90 Gate valve 0.25
# of elbow lv (m2/s2) Po (Pa) Pf (Pa)
# contra elbow open
1 0 0 0 0 121.3272302 101325 101192.6074
2 0 4 3 0 0.00217241 101325 101323.5455
3 0.42915279 0 0 0 0.001876388 111457.5 111455.6822
4 0 0 0 0 0.001082544 303975 303974.1504
5 0 0 0 0 145.5839232 303975 303814.0963
6 0 1 0.75 0 48.36030898 303975 303844.2147
7 0 1 0.75 0 605.7616654 303975 303273.2079
8 841.9473529 3 2.25 0 1423.585967 303975 300422.7285
9 0 2 1.5 24 42499.31029 303302 254200.5981
10 0 3 2.25 0 3742.928007 254201 249896.9369
11 0 2 1.5 0 0.002255758 101325 101323.0546
12 0.882082046 0 0 0 26015.05587 120000 103092.1633
SECTION 2
167
STREAM PIPE CODE weight density flow rate m3/hr D1 A m2 velocity 1
# kg/hr kg/m3 m/s
13 5302.297 763.9345926 6.940773532 0.77 0.465662571 0.004140321
14 5 in, Sche.40 5302.297 733.7866677 7.225938046 0.1281938 0.012906959 0.155513397
15 5 in, Sche.40 417.7417 762.1619183 0.548100987 0.1281938 0.012906959 0.011795984
21 5 in, Sche.40 8139.398333 710.8153975 11.45079069 0.1281938 0.012906959 0.246438781
22 5 in, Sche.40 8139.398333 710.8153975 11.45079069 0.1281938 0.012906959 0.246438781
23 5 in, Sche.40 3255.759333 710.8153975 4.580316275 0.1281938 0.012906959 0.098575512
24 5 in, Sche.40 696.2361667 762.1619183 0.913501646 0.1281938 0.012906959 0.019659973
25 5 in, Sche.40 696.2361667 762.1619183 0.913501646 0.1281938 0.012906959 0.019659973
26 5 in, Sche.40 278.4944667 762.1619183 0.365400658 0.1281938 0.012906959 0.007863989
168
STREAM LOSS # of elbow loss 90 Gate valve 0.25 lv (m2/s2) Po (Pa) Pf (Pa)
# contra elbow open
13 0.882082046 2 1.5 0 0.032453174 101325 101299.1878
14 0 2 1.5 0 0.020892743 101299.1878 101286.0615
15 0 3 2.25 0 0.000119526 121590 121589.922
21 0 0 0 0 0.005874525 101303 101298.8243
22 0 2 1.5 0 0.214463137 101303 101150.5563
23 0 1 0.75 0 0.010307734 101303 101295.6731
24 0 2 1.5 0 0.000319753 121590 121589.7927
25 0 1 0.75 0 0.000314863 121590 121589.7965
26 0 0 0 0 4.99067E-05 121590 121589.9678
SECTION 3
169
STREAM PIPE CODE weight density flow rate m3/hr D1 A m2 velocity 1
# kg/hr kg/m3 m/s
16 5 in, Sche.40 4883.639 710.8153975 6.870474412 0.1281938 0.012906959 0.147863268
17 5 in, Sche.40 4883.639 710.8153975 6.870474412 0.1281938 0.012906959 0.147863268
18 5 in, Sche.40 1965.676 992.1287895 1.981271001 0.1281938 0.012906959 0.042640026
19 5 in, Sche.40 6849.315 883.6712054 7.750976786 0.1281938 0.012906959 0.166813046
20 5 in, Sche.40 8814.991 903.990441 9.751199349 0.1281938 0.012906959 0.209860938
STREAM LOSS # of elbow loss 90 Gate valve 0.25 lv (m2/s2) Po (Pa) Pf (Pa)
# contra elbow open
16 0 0 0 0 0.005138922 101286.0615 101282.4087
17 813.2432284 0 0 0 0.004802446 101282.4087 101280.9371
18 813.2432284 0 0 0 0.000403363 101325 101324.8252
19 0 0 0 0 0.00293474 101324.8252 101322.2319
20 0 0 0 0 0.004686089 101322.2319 101317.9957
170
Equations used in piping calculations:
( )
√ √
( ( ) )
( )
( )
( )
(( ) )
∑ ∑ ∑
171
HAZOP ANALYSIS
This chapter of the report is aimed to investigate some of the problems during normal production hours. A
troubleshooting sequence is to be presented through the HAZOP (Hazard & Operability) tables with a
contingency protocol to prevent reoccurrence of the problem in the future.
Unit: REACTOR
Parameter: FLOW
Install a micrometer in
Pump(P- 101) tripping Low quality Product
the reactor section
No No methanol inlet flow
Regular inspection of
Pipe Blockage Pressure Drop, Leakage
transferring lines
172
Unit: HEAT EXCHANGER (E-102)
Parameter: FLOW
Install a spare
Compressor(C- 101) No Oxygen inlet to
compressor for
tripping the Reactor
No No Air inlet flow Emergency
Regular inspection
Pipe Blockage Deficient Product
of transferring lines
173
Unit: PUMP (P-103)
Perform Regular
Pump Tripping Low quality Product Maintenance and
provide spare Pump
Very Low Pressure
Very Low No Inlet Flow due to
Drop
low liquid Inspect the
entrainment in Pump Damage Distillation Column
Distillation Column and its Effluent
Trays
174
Unit: ABSORBER (T-101)
Parameter: PRESSURE
Pressure increased
Relief valve failure Install back up relief
absorber tank
and open valve
leakage
High High pressure
Effluent (stream Temperature Regular inspection
13) Blocked increase of transferring lines
175
Unit: DISTILLATION COLUMN (T-102)
Parameter: FLOW
176
ECONOMICS AND COST ESTIMATION
This last part of the design project is done to determine a detailed yet
approximate analysis for the economic feasibility of the project in
relation to the Cost of Manufacturing (COM) for the formaldehyde
project. This analysis covers the three major costs for the plant; Direct
Manufacturing Cost (DMC), Fixed Manufacturing Costs (FMC) and
General Expenses (GE). The determination of these items requires the
analysis of several costs including the Fixed Capital Investment (FCI), the
cost of operating labor (COL), Cost of utilities (CUT), cost of waste
Treatment (CWT) and the cost of raw materials (CRM). The cash flow
diagram is to be utilized to present the cost in relation to the production
profitability. In this analysis we make use of the cost analysis Excel
implemented CAPCOST, where the total bare module cost (CBM), total
module cost (CTM) and fixed capital investment (FCI) are to obtained
from this software package.
Cost of Labor:
177
The number of operators per shift (NOL) is as follows:
178
CARBON STEEL MATERIAL OF CONSTRUCTION
1- EQUIPMENT SUMMARY
Power Purchased Bare Module
Compressors Compressor Type (kilowatts) # Spares MOC Equipment Cost Cost
C-101 Centrifugal 183 0 Carbon Steel $189,000.00 $517,000.00
179
2- CASH FLOW ANALYSIS
Discounted Cash Flow Rate of Return 52.23% Rate of Return on Investment 76.00%
Economic Options
Cost of Land $ 1,000,000
Taxation Rate 42%
Annual Interest Rate 10% Economic Information Calculated From Given Information
Salvage Value $ 1,556,000 Revenue From Sales $ 34,200,000
Working Capital $ 2,260,000 CRM (Raw Materials Costs) $ 6,722,144
FCIL $ 15,560,000 CUT (Cost of Utilities) $ 310,329
Total Module Factor 1.18 CWT (Waste Treatment Costs) $ -
Grass Roots Factor 0.50 COL (Cost of Operating Labor) $ 351,232
180
3- SIMULATION
181
4- CASH FLOW DIAGRAM
182
STAINLESS STEEL MATERIAL OF CONSTRUCTION
1- EQUIPMENT SUMMARY
Power Purchased Bare Module
Compressors Compressor Type (kilowatts) # Spares MOC Equipment Cost Cost
C-101 Centrifugal 183 0 Carbon Steel س.ر. 189,000 س.ر. 517,000
183
Discounted Profitibility Criterion Non-Discounted Profitibility Criteria
Net Present Value (millions) 51.34 Cumulative Cash Position (millions) 117.17
Discounted Cash Flow Rate of Return 50.44% Rate of Return on Investment 72.06%
Economic Options
Cost of Land $ 1,000,000
Taxation Rate 42%
Annual Interest Rate 10% Economic Information Calculated From Given Information
Salvage Value $ 1,626,000 Revenue From Sales $ 34,200,000
Working Capital $ 2,330,000 CRM (Raw Materials Costs) $ 6,722,144
FCIL $ 16,260,000 CUT (Cost of Utilities) $ 310,329
Total Module Factor 1.18 CWT (Waste Treatment Costs) $ -
Grass Roots Factor 0.50 COL (Cost of Operating Labor) $ 351,232
184
3- SIMULATION
Net Present Value Data
Low NPV -172.9 1000
185
4- CASH FLOW DIAGRAM
186
Cost Analysis (MOC - Carbon Steel)
Total Bare Module Cost (CBM) By CAPCOST $ 1617600
187
Cost Analysis (MOC - Stainless Steel)
Total Bare Module Cost (CBM) By CAPCOST $ 2229100
188
3- DECISION FOR CONSTRUCTION
Based upon the previously conducted study for the estimation of the capital
cost for the construction of the plant’s equipment using carbon steel &
stainless steel, a decision has been made to go for the SS scenario of MOC.
This decision is based upon the following items:
The CS project costs $ 1617600, while the SS model costs $ 2229100. This
advantage of the CS model is not large compared to the yearly revenue after
two years of construction.
The ROR for the CS model is 52.22 % and the discounted PBP is 1.4 years. The
ROR for the SS model is 50.44 % and the discounted PBP is 1.5 years. These
small differences can be economically tolerated over the assumed minimum
years of plant lifetime which favors the one with highest lifetime - stainless
steel.
Salvage Value:
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CONCLUSION
Our Chemical Engineering senior project design was aimed to bring forth an
integrated detailed design for the PRODUCTION OF FORMALDEHYDE FROM
METHANOL. This project covered several aspects of the plant’s design
including firstly a literature background on the production of formaldehyde
through different routes. Rigorous comprehensive mass and energy balances
were done throughout the plant including the reaction area. The third task
was set to simulate the process to obtain an optimized view of the plant’s
operations. The fourth task was the detailed design and sizing of the plant’s
equipment including the three major units in the plant; the reactor, the
absorber and the distillation column. The final task was to estimate the
economical feasibly of the formaldehyde manufacturing process. The
guidance and support from our mentor prof. Shawabkeh is much
appreciated, and the knowledge he passed on to us is something to
cherished, so for that we express our deep gratitude.
187
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188
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189
19- Turton, Richard. Analysis, Synthesis and Design of Chemical Processes:
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