GROUP NO 12

FINAL YEAR DESIGN PROJECT

DESIGNER RAIS
UTILIZATION OF CARBON DIOXIDE

ID 19461

DETAILED DESIGN OF MAJOR EQUIPMENT DISTILLATION COLUMN (T-101) AND

DESIGN OF MINOR EQUIPMENT : HEAT EXCHANGER (E-114) AND COOLER (E-115)

DOC PREPARED REVIEWED

DESCRIPTION DATE
NO BY BY

1 GENERAL DESCRIPTION RAIS

2 PROCESS DESIGN RAIS

3 MECHANICAL DESIGN RAIS

SPECIFICATION SHEET AND

4 RAIS
DRAWING(S)

OPERATING MANUAL (START

5 RAIS
UP/SHUTDOWN)

6 COSTING RAIS

7 MINOR EQUIPMENT DESIGN RAIS

8 MINOR EQUIPMENT DESIGN RAIS

INFORMATION CONTAINED IS OUR PROPERTY AND MUST NOT BE USED BY OR

CONVEYED TO ANY PERSON WITHOUT AUTHORITY
LIST OF FIGURES iv
LIST OF TABLES iv
CHAPTER 1: INTRODUCTION 1
1.1 Process Description 1
CHAPTER 2: PROCESS DESIGN 2
2.1 Minimum Reflux Ratio 4
2.2 Reflux Ration and Actual Number of Stages 5
2.3 Feed Tray Location 6
2.4 Gas Loading Calculation 6
2.5 Column Diameter Calculation 7
2.6 Downcomer Liquid Velocity 9
2.7 Froth Height 9
2.8 Plate Pressure Drop Check 9
2.9 Pressure Drop of Clear Liquid Height on Tray 10
2.10 Downcomer Capacity Check 10
2.11 Column Height Estimation 10
CHAPTER 3: MECHANICAL DESIGN 11
3.1 Selection of Material Construction 11
3.2 Design of Cylindrical Shell 12
3.2.1 Design Pressure 12
3.2.2 Design Temperature 12
3.2.3 Cylindrical Shell Thickness 13
3.3 Design of Head Closure 13
3.3.1 Division of Column to Courses 13
3.3.2 Dead Weight of Plate 14
3.3.3 Weight of Insulation 14
3.3.4 Total Weight 14
3.4 Design of Nozzle 14
3.4.1 Feed Nozzle Sizing 14
3.4.2 Vapour Nozzle Sizing 15
3.4.3 Liquid Nozzle Sizing 15

CHAPTER 4: SPECIFICATIONS AND TECHNICAL DRAWING 16

ii
CHAPTER 5: OPERATING PROCEDURES 18
CHAPTER 6: COSTING OF DISTILLATION COLUMN 22
CHAPTER 7: MINOR EQUIOMENT (E-114) 21
CHAPTER 8: MINOR EQUIOMENT (E-115) 29

iii
 List of Figures
Figure 1 Distillation Column T-101.......................................................................................................... 1
Figure 2: Erbar-Maddox Corellation ....................................................................................................... 5
Figure 3: Heat exchanger E-114 ............................................................................................................ 21
Figure 4: constant to calculate bundle diameter .................................................................................. 25
Figure 5: Shell Bundle Clearance........................................................................................................... 26
Figure 6: Cooler E-115 ........................................................................................................................... 29

List of Tables
Table 1: Feed Component and Parameters ............................................................................................ 2
Table 2: Feed Flow and Component composition .................................................................................. 2
Table 3: Antoinne Constant for feed component ................................................................................... 3
Table 4: Relative Volatility ...................................................................................................................... 4
Table 5: Comparison of type of materials ............................................................................................. 11
Table 6: Properties of Material ............................................................................................................. 11
Table 7: Column Condition.................................................................................................................... 12
Table 8: Data for Distillation Costing .................................................................................................... 20
Table 9: Data of Hot Stream for E-114 .................................................................................................. 22
Table 10: Data of Cold Stream E-114 .................................................................................................... 22
Table 11: Properties of Tubes ............................................................................................................... 24
Table 12: Parameter and value for bundle diameter ........................................................................... 25
Table 13: Data of Hot Stream E-115 ..................................................................................................... 30
Table 14: Data of Cold Stream E-115 .................................................................................................... 30
Table 15: Properties of tube for Cooler E-115 ...................................................................................... 32

iv
 CHAPTER 1: INTRODUCTION

1.1 General Description

Process description

T-101 is a cryogenic distillation column for separation of Carbon Dioxide (CO2) from
hydrocarbon gases that are methane, ethane and propane, which majority of the CO2 will be
the bottom product while the remaining will be as distillate product. The operating conditions
for this process are following HYSYS simulation, as shown in Figure 1. As for the design of
this equipment, the aspects that will be covered are as follow:

1. The specification of the product

2. Finding the degree of separation
3. Calculate the number of stage and reflux
4. Size of column calculation
5. Internal of the column design Distillate (Stream 3)
6. Mechanical design Pressure: 3000 kPa

Temperature: -91.39oC

Feed Flow: 67150 kg/h

FEED (Stream 2)

Pressure: 4000 kPa

Temperature: -50oC Bottom (Stream 4)

Feed Flow: 259700 kg/h Pressure: 5000 kPa

Temperature: 11.59oC

Feed Flow: 192500kg/h

Figure 1 Distillation Column T-101

The difference between cryogenic distillation column and normal distillation

column is cryogenic works under very low temperature, to separate CO2. CO2 gas turns into
solid under very low temperature, hence can be separated. For this design, refrigerant type
R290 (Propane) is used since the temperature needed is very low, about -91oC. The refrigerant
will be kept recycle through evaporator, compressor, condenser and pump, and the cycle goes
on and on.

1
 CHAPTER 2: PROCESS DESIGN

In Figure 1, it shows the operating conditions such as temperature, pressure and mass
flow rate for both three streams, which are feed, distillate and bottom. The values and data was
produced by HYSYS simulation. Tables below will show the components and their
composition for each stream.

Feed Chemical Molecular Feed Flow

Boiling Point (oC)
component Formula Weight (g/mol) (kgmole/h)
Methane (LK) CH4 16.04 -161.5 118423.20
Carbon CO2 44.01 -78.5 125902.56
Dioxide (HK)
Ethane C2H6 30.07 -89 14465.29
Propane C3H8 44.1 -42 908.95
Table 1: Feed Component and Parameters

Stream 2 Stream 3 Stream 4

Feed Distillate Distillate Bottom Bottom
Feed flow
Component Fraction Flow fraction, Flow Fraction,
(kg/hr)
, xf (kg/hr) xd (kg/hr) xB
118423.2
Methane 0.456 65209.37 0.9711 19.25 0.0001
0
125902.5
CO2 0.4848 1638.46 0.0244 171767.75 0.8923
6
Ethane 14465.29 0.0557 302.18 0.0045 19461.75 0.1011
Propane 908.95 0.0035 0.00 0 1251.25 0.0065
Table 2: Feed Flow and Component composition

2
 To estimate the dew point and boiling point of the mixture, the concept of light key
(LK) and Heavy Key need to be applied. The components are arranged according to their
boiling point and the component that would like to be separated need to be determined. For this
process, Carbon Dioxide is the targeted component to be removed out, therefore a line is drawn
between methane and CO2. From that, the LK is determined as methane and the HK is CO2.
However, this is only applicable as the assumption of ideal thermodynamic was made.

Next, the bubble point and dew point can be determine by following formula:

Bubble point: ∑ 𝑦𝑖 = ∑ 𝐾𝑖 𝑥𝑖 = 1

𝐾
Dew point: ∑ 𝑥𝑖 = ∑ 𝑥 𝑖 = 1
𝑖

Where K is the vapour-liquid equilibrium constant. It can be calculated by the formula:

𝑃𝑖
𝐾𝑖 =
𝑃

Where Pi is the partial pressure that can be obtained from Antoine Equation, and P is the
operating pressure. The Antoine equation and the component coefficients are as below:

𝐵
log 𝑃𝑠𝑎𝑡 (𝑏𝑎𝑟) = 𝐴 −
(𝐶 + 𝑇(℃)

Name A B C T1 , K T2 , K
Methane 3.7687 395.744 266.681 90.7 120.6
Carbon
6.93556 1347.786 273 153.2 203.3
Dioxide
Ethane 3.95405 663.72 256.681 130.4 198.2
Propane 3.92828 803.997 247.04 164.7 247.8
Table 3: Antoinne Constant for feed component

Through trial and error method, the boiling point and dew point are determined as follow:

 Bubble point – feed = -54°C

 Dew point – Distillate = -93°C
 Bubble point – Bottom = -13.9°C

3
 Component Vapour pressure (kPa) K α
Methane 6261.73 2.087244971 23.56015571
Carbon Dioxide 265.78 0.088592155 1
Ethane 297.35 0.099115474 1.118783866
Propane 30.71 0.010236885 0.115550688
Table 4: Relative Volatility

From the information above, the minimum number of stage for the cryogenic distillation
column can be calculated by using the formula:

𝑥 𝑥
𝑙𝑜𝑔 [𝑥 𝐿𝐾 ] [ 𝑥𝐻𝐾 ]
𝐻𝐾 𝑑 𝐿𝐾 𝑏
𝑁𝑚𝑖𝑛 =
𝑙𝑜𝑔𝛼𝐿𝐾

Through the calculation, the minimum number of stages is obtained, which is 7 stages.

2.1 Minimum Reflux Ratio

Underwood equation can be used in determining the minimum reflux ratio. First, the value of
Θ need to be found out by trial and error based on this equation, where q=1.

𝛼𝑖 𝑥𝑖,𝑓
∑ =𝑞−1
𝛼𝑖 − Θ

By trial and error method, the value of Θ is identified as Θ = 7.727. Next, the minimum reflux
ratio can be calculated from the formula;

𝛼𝑖 𝑥𝑖,𝑑
∑ = 𝑅𝑚𝑖𝑛 − 1
𝛼𝑖 − Θ

The value of Rmin is 2.038. Based on the result obtained, the minimum vapour flow can be
calculated by the formula

𝛼𝑖 𝑥𝑖,𝑑 𝑘𝑔
𝑉𝑚𝑖𝑛 = 𝐷 ∑ = 𝐷(𝑅𝑚𝑖𝑛 − 1) = (259700)(2.038) = 529268
𝛼𝑖 − Θ ℎ

4
2.2 Reflux ratio and actual number of stages

The reflux ratio for this equipment has been fixed to 1.75, Therefore,

𝑅
= 0.64
𝑅+1

𝑅𝑚𝑖𝑛
= 0.67
𝑅𝑚𝑖𝑛 + 1

The ratios above can be used to find out the actual number of stages from diagram below

Figure 2: Erbar-Maddox Corellation

𝑁𝑚𝑖𝑛
= 0.4
𝑁

Therefore N = 18 stages

5
2.3 Feed Tray Location

2
𝑁𝑟 𝐵 𝑥𝑓,𝐻𝐾 𝑥𝑏,𝐿𝐾
𝑙𝑜𝑔 ( ) = 0.206𝑙𝑜𝑔 [( ) ( )( ) ]
𝑁𝑠 𝐷 𝑥𝑓,𝐿𝐾 𝑥𝑑,𝐿𝐾

Nr= Number of stages above feed including condenser

Ns= Number of stages below feed including reboiler

𝑁𝑟
( ) = 0.7873
𝑁𝑠

Nr+Ns = 18

Nr = 18 - NS

Ns = 10 stages below feed

Nr = 18 – 10 =8 stages above feed

Hence the feed tray is the 8th feed from top of distillation column.

2.4 Gas Loading Calculation

The liquid droplets are blown off the tray as the maximum gas load in the tray. When
the liquid droplets are formed, the proper column operation ends as there are no longer counter
current of liquid flow to the gas. The relative free area, Φ is assumed to be 0.1 m and the
maximum gas load, Fmax can be calculated by the formula:

1
2
𝐹𝑚𝑎𝑥 = 2. 5[(Φ 𝜎(𝜌𝐿 − 𝜌𝑔 )𝑔]4

1
𝐹𝑚𝑎𝑥 = 1.911 𝑃𝑎2

6
The minimum gas flow can be calculated using formula:

2𝜎
𝐹𝑚𝑖𝑛 = Φ√
𝐷𝐻

Where DH is assumed to be equal to 0.005 m

1
Therefore Fmin = 0.1378 𝑃𝑎2

Minimum gas flow means the gas can be no longer flows through all tray opening uniformly
or the liquid can flows or leaks through the trays. By adding the new condition, the liquid can
be prevented from leaking through sieve tray, as below:

0.37𝐷𝐻 𝑔(𝜌𝐿 − 𝜌𝐺 )1.25 1

𝐹𝑚𝑖𝑛 = Φ√ 0.25
= 0.506 𝑃𝑎2
𝜌𝐺

The design value of gas load, F can then be determined with the assumption of

1
𝐹𝐷𝑒𝑠𝑖𝑔𝑛 = 0.6 𝐹𝑀𝑎𝑥 = 1.1466 𝑃𝑎2

2.5 Column Diameter Calculation

Based on the gas load values, the column diameter can be calculated as the formula below:

𝐹
𝑆𝑢𝑝𝑒𝑟𝑓𝑖𝑐𝑖𝑎𝑙 𝐺𝑎𝑠 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝜇𝑔 = = 0.1572𝑚/𝑠
√𝜌𝐺

𝐺𝑀𝐺
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐺𝑎𝑠 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑉𝑔 = = 0.3504𝑚3 /𝑠
𝜌𝐺

𝑉𝐺
𝐴𝑐𝑡𝑖𝑣𝑒 𝐴𝑟𝑒𝑎, 𝐴𝑎𝑐 = = 2.23 𝑚2
𝜇𝐺

For the next part, the assumptions that have been made are (Sinnot, 1996):

 Relative weir length, Iw/Dc =0.65

 Ratio of Ad/Ac = 0.4

7
Thus,

𝐴𝑎𝑐
𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝐴𝑟𝑒𝑎, 𝐴𝑐 = = 11.15 𝑚2
𝐴𝑑
1 − 2 (𝐴 )
𝑐

4𝐴𝑐
𝐶𝑜𝑙𝑢𝑚𝑛 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝐷𝑐 = √ = 3.768 𝑚
𝜋

𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 𝑎𝑟𝑒𝑎, 𝐴𝑑 = 0.4𝐴𝑐 = 4.46 𝑚2

𝑁𝑒𝑡 𝑎𝑟𝑒𝑎, 𝐴𝑛 = 𝐴𝑐 − 𝐴𝑑 = 6.69 𝑚2

𝐻𝑜𝑙𝑒 𝑎𝑟𝑒𝑎, 𝐴ℎ = 0.1𝐴𝑐 = 0.223 𝑚2

𝜋𝐷𝐻 2
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒, 𝐴ℎ1 = = 0.0000196 𝑚2
4

𝐴ℎ
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 = = 11357 ℎ𝑜𝑙𝑒𝑠
𝐴ℎ1

Liquid flows downwards the column through the down comer due to the force of gravity. The
following rules of thumb are taken into consideration in order to determine the maximum liquid
flowrate:

1. Liquid weir load (Vl/lW) should be between 2m3/mh and 60m3/mh.

2. Liquid velocity in the down comer should not exceed 0.1 m/s.

3. Froth height should be less than half of tray spacing.

The height of clear liquid in the down comer should be less than half of the tray spacing.

Based on previous assumption,

Weir length, lw= 0.65Dc

𝐼𝑊 = 0.65(3.768𝑚) = 2.4492 𝑚

𝐿𝑀𝐿
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐿𝑖𝑞𝑢𝑖𝑑 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑉𝐿 = = 0.0678𝑚3 /𝑠
𝜌𝐿

𝑉𝐿
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑝𝑒𝑟 𝑤𝑒𝑖𝑟 𝑙𝑒𝑛𝑔𝑡ℎ, = 0.0277𝑚3 /𝑚. 𝑠
𝐼𝑊

8
2.6 Downcomer Liquid Velocity

𝑉𝐿
𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 𝐿𝑖𝑞𝑢𝑖𝑑 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = 0.0152 𝑚/𝑠
𝐴𝑑

The velocity is accepted as it is less than acceptable limit, 0.1 m/s

2.7 Froth Height

0.28
𝐹
𝑅𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑙𝑖𝑞𝑢𝑖𝑑 𝑐𝑜𝑛𝑡𝑒𝑛𝑡, 𝜀𝐿 = 1 − ( ) = 0.1333
𝐹𝑚𝑎𝑥

Assuming : weir height, hw = 0.05 m

: Tray spacing, H = 0.55 m

Therefore,

𝑉𝐿 2/3 2
1.45 𝐿𝑊 125 𝐹 − 0.2√𝜌𝐺
𝐹𝑟𝑜𝑡ℎ ℎ𝑒𝑖𝑔ℎ𝑡 = ℎ𝑊 + 1/3 ( ) + [( )] = 0.251𝑚
𝑔 𝜀𝐿 (𝜌𝑙 − 𝜌𝐺)𝑔 1 − 𝜀𝐿
[ ]

Froth height is accepted as it does not exceed half of the tray spacing. This is because, if the
froth height exceed to the next tray, it may blocking opening of the tray and cause flooding. It
will cause sharp drop in plate efficiency and increase the pressure drop in the column.

2.8 Plate Pressure Drop Check

Pressure Drop of tray

𝜉 𝐹 2
∆𝑃𝑑 = ( )
2 𝛷

Assuming plate thickness, s = 0.003 m

s/Dh= 0.6

Therefore the value of 𝜉= 3.25 as s/Dh > 0. So ∆𝑃𝑑 = 213.64 N/m2

9
2.9 Pressure Drop of Clear Liquid Height on Tray

∆𝑃𝐿 = ℎ𝑓 𝜀𝐿 𝜌𝐿 𝑔 = 258.17 𝑁/𝑚2

Therefore, Total Pressure Drop, PT = ∆PL + ∆Pd = 471.81 N/m2

Clear liquid height = 0.047181 m

2.10 Downcomer Capacity Check

Non-foaming system is assumed, thus εLd = 0.4. The pressure different between inlet and outlet
of down comer can be expressed by formula below:

∆P
ℎ𝑝 = = 0.0612 𝑚
𝜌𝐿 𝑔

The maximum liquid flow per weir length,

VL/LW = 51.9538 m2/m.h

2.11 Column Height Estimation

Actual trays required = 18 trays

Estimated column height = H (Nactual-1) + S (Nactual) = 15.354m

Estimated column head closure height (top and bottom) = 5m

Total column height = 20.354 m

10
 CHAPTER 3: MECHANICAL DESIGN

3.1 Selection of Material Construction

The material construction is important for the distillation column especially cryogenic
distillation column as it has very high pressure and very low temperature. According to
(Schmidt, Winegardner, Dennehy, & Castle-Smith, 2001), the best material for cryogenic
distillation column is stainless steel as it can stand under very low temperature and has the
highest relative strength, as in table below. Therefore stainless steel is chosen and the
parameters and value are tabulated in table. (Coulson and Richardson, 2005)

Table 5: Comparison of type of materials

Table 6: Properties of Material

11
3.2 Design OF Cylindrical Shell

3.2.1 Design Pressure

Operating Parameter Value Operating Parameter Value

Pressure 4000kPa Safety factor 5%

Noise Band 0.5% Pnoise band 0.6 kPa

Dead zone of relief 1% Pdead zone 1.2 kPa

valve
Table 7: Column Condition

The operating pressure is 4000 kPa as taken from HYSYS. The column need to be
withstand the pressure, therefore hydrostatic pressure need to be consider higher than operating
pressure.

Assume liquid level = 5% of total height of column = 1.0177m

The hydrostatic pressure = hρg = 530.93 kPa

The fraction of hydrostatic pressure to operating pressure is 13.27% which more than 5%, thus
the hydrostatic pressure need to be considered in the design.

Working pressure, Pw = Poperating – Pdead zone = 3998.8 kPa

Maximum working pressure, MWP = 3998.8 kPa

Design pressure, PD=1.05 x MWP = 4198.74 kPa

3.2.2 Design Temperature

Same as design pressure, the design temperature also need to be considered as the
temperature may increases or decreases. It can be calculated by multiplying the operating
temperature with safety limit for column operation, which is 1.05.

TD = Toperating x 1.05 = -52.5

12
 3.2.3 Cylindrical Shell Thickness

The minimum wall thickness is important for the safety of the column as it need to
withstand its own weight and any accident. The formula for minimum shell thickness is as
below:

𝑃𝐷 𝐷1
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑆ℎ𝑒𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠, 𝑡= +𝑐
2𝐹𝐽 − 𝑃𝐷

Where f = design stress = 165 N/mm2

J = welding efficiency = 0.85

C = corrosion allowance = 2mm

Therefore, t = 2.057 mm =0.002057m

Column outside diameter = DO = DI+2t = 3.772 m

Since t/Di < 0.1, the vessel is considered as thin walled.

3.3 Design of Head and Closure

3.3.1 Division of Column to Courses

Total column height = 20.354 m

Diameter, Di = 3.768 m

Circumference = 11.838 m

3.3.2 Dead weight of plate

𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡

Cv is factor to account for the weight of nozzles = 1.15

Dm is mean diameter = (Di +t x 10-3) = 3.77 m

Hv = Height between tangent length (column height) = 20.354m

Therefore, Wv = 50023.4 N

13
 3.3.3 Weight of Plate

𝜋𝐷 2
Plate area = = 11.16 𝑚2
4

Weight of plate = 1.2 x 11.16 x 18 = 241.056 kN

3.3.3. Weight of Insulation

The mineral wool is assumed to be used for insulation with 75mm thick. The density
of mineral wool is 130kg/m3.

Volume of insulation = 20.354 x 3.768 x 0.075 = 5.752 m3

Insulation weight = 5.752 x 130 x 9.81 = 7335.5 N

The weight is double for fitting purpose = 14671 N

3.3.4 Total Weight

The total weight of distillation column = 14.671kN + 241.056kN + 50023.4kN =

50281.127 kN.

3.4. Design of Nozzle

3.4.1. Feed Nozzle Sizing

Mass flow rate, G = 72.14 kg/s

Density = 194 kg/m3

Dopt = 303.7 mm

Nozzle thickness, t = 6.615 mm

14
 3.4.2. Vapour Nozzle Sizing

Mass flow rate, G = 18.65 kg/s

Density = 786.4 kg/m3

Dopt = 94.62 mm

Nozzle thickness, t = 3.438 mm

3.4.3. Liquid Nozzle Sizing

Mass flow rate, G = 53.47 kg/s

Density = 53.18 kg/m3

Dopt = 411.29 mm

Nozzle thickness, t = 8.25 mm

15
 CHAPTER 4: MECHANICAL DESIGN

Tag. Num T-101

Sheet Nu, 1 of 1
Distillation Column Specification Data Sheet To separate
Function Carbon Dioxide
from natural gas
OPERATING DATA
NUMBER OF
COLUMN INSIDE DIAMETER 3.768m 18 STAGES
STAGES
COLUMN OUTSIDE STAGE AT FEED
3.772m 8th STAGE
DIAMETER ENTERS
TRAY SPACING 0.55m
INTERNAL CONDITIONS AT TRAY NUMBER
o
TEMPERATURE ( C) -50.00 -91.39 11.59
PRESSURE (kPa) 4000.00 3000.00 5000.00
MOLAR FLOW (kgmole/hr) 8519.00 4518.99 4000.01
MASS FLOW (kg/hr) 30217.63 17961.19 12256.44
DENSITY (kg/m3) 194.00 786.40 53.18
STD IDEAL VOL LIQ FLOW
471.10 256.22 214.88
(m3/h)
HEAT FLOW (kJ/h) -2.049E+09 -1.679E+09 -3.53E+08
TECHNICAL/MECHANICAL DATA
CYLINDRICAL SHELL CORROSION
0.002057m 0.002m
THICKNESS ALLOWANCE
VESSELS
THICKNESS CLOSURE 0.042m Stainless Steel
MATERIALS
FEED NOZZLE THICKNESS 0.006615m TRAY MATERIALS Stainless Steel
SIEVE TRAY HOLE
FEED NOZZLE DIAMETER 0.002460m 0.005m
DIAMETER
LIQUID NOZZLE
VAPOR NOZZLE THICKNESS 0.003438m 0.008250m
THICKNESS
LIQUID NOZZLE
VAPOR NOZZLE DIAMETER 0.094620m 0.411290m
DIAMETER

DATA OF ENQUIRY DATA OF ORDER

ORDER NO. DRG NO.
NOTES

PREPARED BY
CHECKED BY
APPROVED BY
DATE ENG PROCESS REV APPRR. DATE
SERVICE
COMPANY
EQUIPMENT NO.
PROJECT NO.

16
17
 CHAPTER 5: OPERATING PROCEDURE

Pre-Startup Procedure

No Procedure Checklist
Verify tower readiness for start-up ensuring that all maintenance works
1 have already been completed, manhole closed and all blinds are removed
and proper gaskets are installed.
Check and make sure that all pumps have proper lubrication and the switch
2
gears are energized.
3 Commission cooling water.
Purge if the column were opened for maintenance. Purge for 30 minutes or
4
until the level of oxygen gas is below 5%.
After purging has already been completed, close the required bleeds and
5
install plugs or caps.
Check the following transmitters are at zero: Steam to reboiler and vapour
6
to condenser.

Start-Up Procedure
No Procedure Checklist
1 Isolate the column by closing the isolation valve.
2 Fill up to about 50% level by opening the valve.
Verify the level transmitter in column by checking the level in the sight
3
glass.

4 Warm up the column by throttling the steam flow to the reboiler.

5 Control the bottom level 50%.

When the column bottom temperature reaches half of the targeted
temperature, increase the steam to reboiler at about 1% every 5minutes until
6
the bottom temperature reaches the desired value (or until the steam flow
rate reaches the desired value).
Start the reflux flow to column when the tray temperature indicator reaches
7
-50°C. Maintain the reflux flow of steam on reboiler.

18
8 Adjust the reflux to bring the temperature to approximately -70°C.

Note: when reflux is commissioned to the column, the whole column

temperature profile will start to drop. Immediately increase the steam
reboiler to compensate vapour load lost due to the cooling effect from the
9 reflux. Try to increase the steam to reboiler to maintain a good column
temperature profile (use the tower temperature as guide). Use the steam
flow increment followed by reflux increment until the column is at its
desired operation.
10 Bring the column up to its desired conditions (turndown conditions).
Sample the tower bottoms as the tower stabilizes. Adjust the reboiler flow
11
as necessary to keep the bottom product (ethanol) about 99.99% mole
using lab samples.
12 Monitor the top analysers and compare them with the lab analysis. Make
slight adjustments on the steam flow or reflux as necessary to control the
tower at its desired conditions.

Shut-down Procedure
No Procedure Checklist
1 Turn off the distillation column steam valve.
2 Slowly close the main steam inlet valve to the column.
3 Drain the liquid from sieve trays inside the column.
Drain the feed tank, the feed valve to column should be closed and the
4
drain valve should be opened and turn on the pump.
Drain the solution in the reboiler to the feed tank and note its
5 concentration. The drain valve should be closed and the feed valve should
be opened.

Drain the still pot and the feed tank and note its concentration. The drain
6
valve should be opened and the pump should be on.

Turn off all water and power sources. Unplug the pump. (Note: the
7 condenser cooling water needs to run for at least 15 minutes after the
distillation column steam valve has been turned off).

19
 CHAPTER 6: COSTING FOR DISTILLATION COLUMN

Diameter, Dc 3.768 m

Height, Hc 20.354 m

Operating Pressure 40 bar

Type of vessel Sieve Tray

Construction material Stainless Steel 316

Number of tray, N 18

M&S Cost index 1581

Table 8: Data for Distillation Costing

Purchase cost
The pressure vessel cost can be calculated by the formula

Where,
Fc = FMFP
Fm = material factor
FP = 1 + 0.0074 (P-3.48) + 0.00023(P – 3.48)2 = 1.277
Fm = 3.67
FC = 4.685
Therefore, Purchase cost = $1233191.81
Installed Cost

Therefore, installed cost = $1807014.25

Cost of Trays

Therefore, tray installed cost = $409045.25

Total cost would be
Total cost = $1233191.81 + $1807014.25 + $409045.25 = $3449251.31

20
 CHAPTER 7: MINOR EQUIPMENT DESIGN
HEAT EXCHANGER (E-114)

Heat exchanger is an equipment that function to transfer the heat between two fluids. It is an
important equipment especially in chemical industry as it can control the temperature for the fluid
flow according to the heat exchanger’s design. The mechanism for heat exchanger is basically the
exchanging the heat from higher temperature’s fluid to lower temperature’s fluid and vice versa.

For E-114, four streams are involve which are, stream 13 and 50 which in the hot stream (tube)
and Stream 49 and 51 which are in cold stream (shell).

Figure 3: Heat exchanger E-114

21
Operating Parameter

The parameters were obtained from HYSYS and tabulated in tables below

Parameters Symbol Unit Inlet Stream Outlet Stream

Temperature T1,T2 °C 850.0 211.2
Flowrate M Kg/hr 339403.5586 339403.5586
Heat Capacity Cp kJ/kg.°C 1.927 1.680
Thermal Kg W/m.°C 0.1633 0.0862
Conductivity
Viscosity υg Cp 0.0417 0.0203
Density ρg Kg/m3 1.01 2.33
Table 9: Data of Hot Stream for E-114

Parameters Symbol Unit Inlet Stream Outlet Stream

Temperature t1,t2 °C 128.98 831.76
Flowrate M Kg/hr 339398.9206 339398.9206
Heat Capacity Cp kJ/kg.°C 1.282 1.940
Thermal Kg W/m.°C 0.0338 0.1115
Conductivity

Viscosity υg Cp 0.0183 0.0400

3
Density ρg Kg/m 9.96 3.57
Table 10: Data of Cold Stream E-114

Heat Duty Calculation

The heat transferred, Q can be calculated by formula;

Q  mC p T  = 116054.1 kW

Where
Mass flowrate (kg/hr) = m = 339403.56
Total heat capacity (kJ/kg.oC) = Cp = 1.927
Change of T = 638.8oC.

22
Log Mean Temperature

The log mean temperature is needed for the next method, which is calculating the
heat transfer area. There are two types of current flow, which are co current flow and counter
current flow. For HE-114, the counter current flow is decided as the temperature difference
is quite high. The formula for counter current log mean temperature is as below.

Tlm 
T1  t 2   T2  t1 
T  t 
ln 1 2
T2  t1 

Where

T1 = Hot fluid temperature inlet

T2 = Hot fluid temperature outlet

t1 = Cold fluid temperature inlet

t2 = Cold fluid temperature outlet

Tlm 
850.0  831.76  (211.2  128.98)  42.49o C
ln
850  83.176
(211.2  128.98)

The true temperature difference can be calculated by using the formula

∆𝑇𝑙𝑚 = 𝐹∆𝑇𝑙𝑚

Where F is the temperature correction factor and can be calculated from

 1  S  
R 2

 1 ln 
1  RS 
Ft 

2  S R 1
R  1 ln 
R 2

1 
 2  S R  1  

R 2
 1 

23
Where

R
T1  T2   1.162
t 2  t1

S
t 2  t1   0.114
T1  t1

The value of Ft = 1. The true log mean temperature can be calculated.

Tlm  42.49o C 1  42.49o C

After getting the log mean temperature, the heat transfer area can be calculated.

Q 116054.1 103W
A   64.23m 2
UTlm  2 o o
42527W m . C 42.49 C  

Number of tubes

For this equipment design, the one shell two tube passes is chosen and material
from steel is selected which has properties as table below.

Material Steel
Length of tube, Lt (m) 6
Outside Diameter (mm) 20
Wall Thickness(mm) 2
Table 11: Properties of Tubes

The outer area of tube can be find by using the formula;

At  Ld 2  6m    0.002m  0.377m 2

2

Therefore, the number of tube required is

A 64.23m 2
Nt    170tubes
At 0.377m 2

24
 The diameter of tube bundle can be calculated by assuming the shell side fluid is clean
and the triangular pitch is used. From the table below, at no passes is 2, the K1 and n1 constant
can be obtained (as tabulated) and will be used into the formula

1
 N n
Db  d o  t  =385.15 mm
 K1 

Figure 4: constant to calculate bundle diameter

Parameter/Constant Value
Tube pitch, Pt (m) 0.025
K1 0.249
n 2.207
Table 12: Parameter and value for bundle diameter

Diameter of Shell

The diameter of the shell can be obtained from the equation below, as the shell bundance can
be refer to Shell Bundle Clearance.

𝐷𝑠 = 𝐷𝑏 + 𝑠ℎ𝑒𝑙𝑙 𝑏𝑢𝑛𝑑𝑙𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒

𝐷𝑠 = 385.15 + 13 = 398.15 𝑚𝑚 = 0.3982 𝑚

25
Figure 5: Shell Bundle Clearance

26
Cost estimation
According to Gutrie correlation, the purchased cost and installed cost can be calculated by the
formula:

Purchased cos t 
M &S
280

101.3 A 0.65 Fc 

Installed cos t 
M &S
280

101.3 A 0.65 2.29  Fc  

Fc= (FD+FP) x Fm
Where Fd = 1, Fm = 1, Fp = 0.45 and Fc = 1.45

The purchased cost is = $56430.16

The installed cost = $14550.90
Total cost = $201981.10

27
 Equipment
E-114
No.
Heat Exchanger
Specification Sheet To reduce the temperature of gases before enter the FT-
Function
Reactor

Sheet No 1 of 1
OPERATING DATA
TYPE U-Tube (Bundle) Heat Exchanger
SHELLS IN SERIES 1 Horizontal
SHELLS IN PARALLEL 1 EXCHANGE ORIENTATION
TUBES PASSES PER
SHELL 2
PERFORMANCE OF ONE UNIT

Shell Side Tube Side

Fluid Circulating
Tin Tout Tin Tout
T (oC) 128.98 831.76 850 211.2
339398.920 339403.558 339403.558
339398.9206
Mass Flow 6 6 6
Heat Capacity
1.282 1.94 1.927 1.68
(kJ/kg.oC)
Viscosity (cP) 0.0183 0.04 0.0417 0.0203
Mass Density (kg/m3) 9.96 3.57 1.01 2.33
MECHANICAL CONSTRUCTION
Shell Side Tube Side
Material Steel Steel
Bundle Clearance Length of Tube (m)
(mm) 13 6

Shell Diameter (mm) 398.15 Outside Diameter (mm) 20

Wall Thickness (mm) 2

Number of Tubes 170
Tube Pitch 0.025

28
 CHAPTER 8: MINOR EQUIPMENT DESIGN
COOLER (E-115)

Cooler E-115 is one of the minor equipment that responsible to cool down the fluid that
pass through it. It is located before the cryogenic distillation unit, therefore it needs to cooldown
the fluid from 70oC to -50oC. One of the advantage in using cooler instead of normal heat
exchanger is it can gives larger heat transfer area.

The Cooler E-115 will be designed with advantages such as:

 Number of baffles are provided at shell side to increase the velocity and efficiency
 Unlimited pressure range and pressure drop
 Reasonable cost in term of thermal stresses
 Thermal capacities has variety and large range
 Easy to be clean and repair

For shell, the fluid that will be used is refrigerant R-290 or propane as it has very low boiling
point.

From Stream 1

Figure 6: Cooler E-115

29
Operating Parameter

Parameters Symbol Unit Inlet Stream Outlet Stream

Temperature T1,T2 °C 70.9273 -50
Flowrate M Kg/hr 259664.8394 259664.8394
Heat Capacity Cp kJ/kg.°C 1.490 2.485
Thermal Kg W/m.K 3.163e-002 -
Conductivity
Viscosity υg Cp 1.586e-002 -
Density ρg Kg/m3 46.80 194.0
Table 13: Data of Hot Stream E-115

Parameters Symbol Unit Inlet Stream Outlet Stream

Temperature t1,t2 °C -110 -10
Flowrate M Kg/hr - -
Heat Capacity Cp kJ/kg.°C 0.0736 -
Thermal Kg W/m.°C 0.1721 -
Conductivity
Viscosity υg Cp 0.5254 -
Density ρg Kg/m3 654.3 -
Table 14: Data of Cold Stream E-115

Heat Duty Calculation

The heat transferred, Q can be calculated by formula;

Q  mC p T  = 12996.64 kW

Where

Mass flowrate (kg/hr) = m = 259664.8394

Total heat capacity (kJ/kg.oC) = Cp = 1.490

Change of T = 120.93oC

30
Log Mean Temperature

The log mean temperature is calculated in the next procedure where the determination
of type of flow is needed to know first. There are two types of flows, which are co-current flow
and counter current flow. Since this equipment, E-115 has very high temperature difference,
the counter current flow is decided to be chose. The formula for counter current log mean
temperature is as below.

Tlm 
T1  t 2   T2  t1 
T  t 
ln 1 2
T2  t1 

Where

T1 = Hot fluid temperature inlet

T2 = Hot fluid temperature outlet

t1 = Cold fluid temperature inlet

t2 = Cold fluid temperature outlet

Tlm  15 .52 o C

The true temperature difference can be calculated by using the formula

∆𝑇𝑙𝑚 = 𝐹∆𝑇𝑙𝑚

Where F is the temperature correction factor and can be calculated from

 1  S  
R 2

 1 ln 
1  RS 
Ft 

2  S R 1
R  1 ln 
R 2

1 
 2  S R  1  

R 2
 1 

Where

T1  T2 
R  1.411
t 2  t1

t 2  t1 
S  0.368
T1  t1

31
The value of Ft = 0.98. The true log mean temperature can be calculated.

Tlm  15.52o C  0.98  15.21o C

After getting the log mean temperature, the heat transfer area can be calculated.

Q 12996.64 10 3 W
A   2848.27m 2
UTlm  2 o
42527W m . C 15.21 Co
 

Number of tubes

For this equipment design, the one shell two tube passes is chosen and material from steel is
selected which has properties as table below.

Material Steel
Length of tube, Lt (m) 6
Outside Diameter (mm) 20
Wall Thickness(mm) 2
Table 15: Properties of tube for Cooler E-115

The outer area of tube can be find by using the formula;

At  Ld 2  6m    0.002m  0.377m 2

2

Therefore, the number of tube required is

A 2848.27m 2
Nt    7555tubes
At 0.377m 2

32
 The shell side fluid is assumed to be clean and using the triangular pitch. The number
of passes is assumed to be two and K1 and n1 is constant, as tabulated below. Therefore, the
tube bundle diameter is calculated based on the formula below.

1
 N n
Db  d o  t  =2147.03 mm
 K1 

Parameter/Constant Value
Tube pitch, Pt (m) 0.025
K1 0.249
n 2.207

Diameter of Shell

The diameter of the shell can be obtained from the equation below, as the shell bundance can
be refer to Shell Bundle Clearance Graph.

𝐷𝑠 = 𝐷𝑏 + 𝑠ℎ𝑒𝑙𝑙 𝑏𝑢𝑛𝑑𝑙𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒

𝐷𝑠 = 2147.03 + 13 = 2160.03 𝑚𝑚 = 2.16 𝑚

33
Cost Estimation

According to Gutrie correlation, the purchased cost and installed cost can be calculated by the
formula:

Purchased cos t 
M &S
280

101.3 A 0.65 Fc 

Installed cos t 
M &S
280

101.3 A 0.65 2.29  Fc  

Fc= (FD+FP) x Fm

Where Fd = 1, Fm = 1, Fp = 0.45 and Fc = 1.45

The purchased cost is = $663681.06

The installed cost = $1711839.41

Total cost = $2375520.47

34
 Equipment
Heat Exchanger No. E-114
Specification
To reduce the temperature of gases before cryogenic
Sheet Function
Distillation Column

Sheet No 1 of 1
OPERATING DATA
TYPE U-Tube (Bundle) Heat Exchanger
SHELLS IN
SERIES 1 Horizontal
SHELLS IN EXCHANGE
PARALLEL 1 ORIENTATION
TUBES PASSES
PER SHELL 2
PERFORMANCE OF ONE UNIT

Shell Side Tube Side

Fluid Circulating
Tin Tout Tin Tout
T (oC) -110 -10 70.93 -50
259664.839 259664.83
- -
Mass Flow 4 9
Heat Capacity
0.0736 1.94 1.49 2.485
(kJ/kg.oC)
Viscosity (cP) 0.5254 0.04 1.59E-02 -
Mass Density
654.3 3.57 46.8 194
(kg/m3)
MECHANICAL CONSTRUCTION
Shell Side Tube Side
Material Steel Steel
Bundle Clearance
Length of Tube (m)
(mm) 13 6
Shell Diameter
(mm) 2160.03 Outside Diameter (mm) 20

Wall Thickness (mm) 2

Number of Tubes 7555
Tube Pitch 0.025

35