Professional Documents
Culture Documents
Certified by:
Signature :_______________________
Date :_______________________
Confirmation of Cooperation
It is certified that this thesis research project was undertaken through cooperation
between ___________________ and ___________________
Endorsed by:
Signature : _______________________________ Date: ______________
Name : _______________________________
Post : _______________________________
(Official Seal)
Hamza Asmat
Waleed Murtaza
Taimoor Nasir
Ali Raza
Muzammil Ikram
COMSATS University
JUNE 2018
ii
DECLARATION
DEDICATION
“This is dedicated to our Parents, Respected Teachers and to our beloved friends who
helped us complete this Project.”
iv
ACKNOWLEDGEMENT
First, we are thankful to the grace of Allah (SWT), who has bestowed upon
us the dedication and determination required to complete this thesis and present a
good account of our learning experience throughout the duration of our final year
design project. We would extend our gratitude to Dr. Ume Salma Amjad, who gave
us the opportunity to work under her supervision and complete our final year design
project. Her dedication towards our project and her tireless efforts in assisting us
throughout the entirety of our project has helped us immensely and further enhanced
our concepts to a greater level.
Finally, we offer our regards and gratitude to all of those who supported us in
any respect during the completion of this thesis.
v
ABSTRACT
TABLE OF CONTENTS
LIST OF FIGURES
CHAPTER 1
Figure 1.1: Structure of Ethylene 2
CHAPTER 3
CHAPTER 7
Figure 7. 1: Fixed bed reactor 114
Figure 7. 2: Heat Exchanger 115
Figure 7. 3: Quench tower 116
Figure 7. 4: Absorber 117
Figure 7. 5: Adsorption column 118
Figure 7. 6: Distillation column 119
xii
LIST OF TABLES
CHAPTER 1
Table 1. 1: Properties of Ethylene 3
Table 1. 2: Comparison of different manufacturing processes 8
CHAPTER 4
Table 4. 1: Mole fractions of components 17
Table 4. 2: Overall and component material balance on Ethylene Column 17
Table 4. 3: Mole fraction of components 19
Table 4. 4: Overall component and material balance 19
Table 4. 5: Mole fractions of components 21
Table 4. 6: Overall and Component Balance of Components in the Streams 21
Table 4. 7: Mole Fractions of Components 23
Table 4. 8: Overall and Component Material Balance 24
Table 4. 9: Mole Fractions of Components 25
Table 4. 10: Overall and Component Material Balance 26
CHAPTER 5
Table 5. 1: Values of constants 28
CHAPTER 6
Table 6. 1: Feed to Reactor 42
Table 6. 2: concentration calculations 43
Table 6. 3: Calculation of Rates At Given Concentrations 44
Table 6. 4:Trapezoidal Formula Application 44
Table 6. 5: Reactor data 49
Table 6. 6: Specification Sheet 50
Table 6. 7: Mole fractions of components 76
Table 6. 8: Fractions of components 85
CHAPTER 8
Table 8. 1: HAZOP of Quench tower 123
Table 8. 2: HAZOP of Adsorption column 124
Table 8. 3: HAZOP of Heat exchanger 127
Table 8. 4: HAZOP of Reactor 128
Table 8. 5: HAZOP of Absorber 129
Table 8. 6: HAZOP of Distillation column 131
xiii
LIST OF SYMBOLS
d - Diameter
F - Force
g - Gravity = 9.81 m/s
l - Length
m - Mass
P - Pressure
Q - Volumetric flow-rate
r - Radius
Re - Reynolds number
V - Velocity
H - Height
θ - Angle
ρ - Density
μ - Viscosity
o
C - Degree Celsius
X - Conversion
D - Dilution Rate
H - Height of reactor
AR - Aspect Ratio
H′ - Working Depth
∝ - Relative Volatility
𝑚 - Minimum number of plates
𝑅𝑚 - Minimum reflux ratio
E - Efficiency
N - Theoretical number of plates
𝑎 - Actual number of plates
Δ𝑃 - Total pressure drop
𝐿𝑚 - Liquid flow rate
𝑚 - Vapor flow rate
xiv
𝐶 - Column diameter
A - Area
J - Joint efficiency
C - Corrosion allowance
F - Allowable stress
𝑃 - Heat capacity
𝜆 - Latent heat
U - Overall heat transfer coefficient
𝑟 - Prandtl number
𝑢 - Nestle number
xv
1
CHAPTER 1
LITERATURE REVIEW
1.1 Introduction
Ethylene was first obtained from ethanol in the 18th century, when ethanol
was passed over a heated catalyst[5]. The plastics industry gave rise to several ethanol
dehydration units which operated from the 1930s up until the 1960s. The advent of
naphtha (Liquefied Petroleum Gas) cracking rendered these dehydration units
2
ETHYLENE PROPERTIES
Formula C2H4
Ethylene is the most important organic chemical. It is the building block for a
vast range of chemicals from plastics to antifreeze solutions and solvents. The
principal uses of ethylene are to produce:
4
A. POLYMERS
• Polyethene.
• Chloroethene (vinyl chloride) and hence poly(Chloroethene), i.e. poly
(vinyl chloride), PVC.
• Ethylbenzene and hence Phenylethene and Poly(phenylethene),
i.e. Polystyrene
B. OTHER CHEMICALS
CHAPTER 2
• Pyrolysis of Hydrocarbons
• Ethanol Dehydration
• Ethylene from Coal
• Ethylene from Vacuum Gas oil
There are several possible routes from coal to ethylene by conventional and b
y novel technology. Synthesis gas produced from coal by commercially proven coal
gasification processes or second-generation processes hydrocarbons by Fischer-Trop
sch processes[6]. Fischer-Tropsch reactions have produced higher molecular weight s
aturated and olefinic hydrocarbons as well as oxygenated compounds. Ethylene may
be produced by cracking of hydrocarbons and by dehydration of recovered ethanol. S
7
Vacuum gas oil utilizes a solitary stage reactor as opposed to the two phases
in the Uncracking/FPP. What's more, vacuum gas oil works at a lower weight and a
higher temperature. Despite the fact that these distinctions result in various item
yields, the properties of the hydrocracked VG0 for ethylene generation from as far as
feedstock cost vacuum gas oil is the touchiest feedstock for ethylene creation
principally in light of the huge commitment of encourage stock cost and of item
credits which stay unaltered and turn out to be relatively less on the ethylene
generation cost. The lighter the feedstock the littler turned into the commitment to
the encourage cost[13].
In contrasting the ethylene esteems from a few fluid feedstocks, it creates the
impression that hydrocracked VGO has a monetary preferred standpoint over full
range naphtha, however it isn't as conservative a feedstock as hydro desulfurized
VGO (light H2 assimilation). In fact, be that as it may, hydrocracked VGO has
numerous alluring properties as an ethylene feedstock which hydro desulfurized
VGO needs.[11]
Merits
Demerits
2.4 HAZARDS
Ethanol and ethylene are both exceptionally combustible, and all things
considered watchful consideration must be paid to their transportation to and from
and capacity at the office. Ethanol unexpectedly combusts at around 790°F. Since the
reactors work close as far as possible (750°F), it is vital to put resources into precise
and cautious controllers to guarantee that the temperatures in the heaters and
compressor outlet stream never achieve this level. The plant is at no danger of
ethylene accidently autoigniting as ethylene's start temperature is 914°F and it spends
the greater part of the procedure under cryogenic conditions.[3]
12
CHAPTER 3
• Pyrolysis of Hydrocarbons.
• Ethanol Dehydration.
• Ethylene from Coal.
• Ethylene from Vacuum Gas oil.
20
D-100 E-102
C-100
13 24
Cooling Water 25 26
15
10 ETHYLENE PRODUCT
E-45
4 6 8 11
Q-100 AB-100
1 E-101 14 17
2
AD-100
P-100
18 19
Steam Steam Waste to Purification Section Waste to Purification Section E-55 21
H-100 22 23
E-103
P-100 (CENTRIFUGAL R-100 R-101 R-102 R-103 E-101 (HEAT C-100 AD-100
AB-100 (ABSORBER/ D-100 (ETHYLENE E-103 (REBOILER)
PUMP) (REACTOR) (REACTOR) (REACTOR) (REACTOR) EXCHANGER) (COMPRESSOR) (ADSORBER
CAUSTIC WASH COLUMN / CRYOGENIC
WITH HEAT
COLUMN) DISTILLATION COLUMN)
EXCHANGER)
DEHYDRATION REACTORS
CHAPTER 4
MATERIAL BALANCE
So, in moles,
7083.33
Ethylene in product (S26) =
28
= 252.98 kmol/hr.
Thus,
252.98
S26 = = 253.36 kmol/hr
0.9985
We assume that 95% of ethylene in S19 is recovered in the S26. This means that we
have ethylene in S19, which will be
252.98
C2 H4 in S19 = = 266.29 kmol/hr.
0.95
So, we have overall material balance equation as:
S19 = S23 + S26
Component Balance of C2H4
Streams
Components S19 (mole fraction) S26 (mole fraction) S23 (mole fraction)
Streams
Components S19 (kmol/hr) S26 (kmol/hr) S23 (kmol/hr)
ETHYLENE 266.29 252.98 13.31
DIETHYL ETHER 15.64 0.00 15.64
METHANE 0.13 0.13 0.00
ACETALDEHYDE 3.99 0.00 3.99
ETHANE 0.33 0.00 0.33
HYDROGEN 0.25 0.25 0.00
Total 286.64 253.36 33.29
18
266.29
C2H4 in feed = = 268.98 kmol/hr.
0.99
As, we have assumed the flow rates of product components equal to that of feed
except for ethylene and water. We know the mole percentage of water in feed that is
0.1%. Now we calculate the flowrate of S16.
The mole percent of water in feed is 0.1% which means that the sum of moles of
other components is 99.9% of the feed. So,
268.98+15.64+0.13+3.99+0.33+0.25
S16 =
0.999
19
Stream W is not a continuous stream that’s why it is shown with dotted line. Stream
W contains adsorbed water and ethylene.
C2H4 in W = (268.98 – 266.29)
= 2.69 kmol/hr.
H2O in W = 0.290 kmol/hr.
Streams
Components S16 (mole fraction) S18 (mole fraction) W
Streams
Components S16 (kmol/hr) S18 (kmol/hr) W (kmol/hr)
WATER 0.28962 0.00 0.290
ETHYLENE 266.2805 266.29073 2.69
DIETHYL ETHER 15.64458 15.64458
METHANE 0.12668 0.12668
ACETALDEHYDE 3.99436 3.99436
ETHANE 0.33286 0.33286
HYDROGEN 0.25336 0.25336
Total 286.622 286.64 2.98
20
It is assumed that only CO2 is removed with absorbent (NaOH(aq).) and traces
of CO2 goes to product which are negligible. Thus, moles of feed component will be
same as that of product except that there is no CO2. For now, we apply balance only
on main streams.
We know the composition of CO2 in feed that is 0.173%. Now we calculate the
flowrate of S15
For S15
268.98+0.28962+15.64458+0.12668+3.99436+0.33286+0.25336
S15 =
(1-0.00173)
Streams
Components S16 (mole fraction) S15 (mole fraction)
Streams
Components S16 (kmol/hr) S15 (kmol/hr)
WATER 0.28962 0.28962
ETHYLENE 268.98 268.98
DIETHYL ETHER 15.644 15.644
METHANE 0.12668 0.12668
ACETALDEHYDE 3.99436 3.99436
ETHANE 0.33286 0.33286
HYDROGEN 0.25336 0.25336
CARBON DIOXIDE 0.000 0.50191
Total 289.622 290.12
22
Streams
Components S12 (mole S13 (mole S14 (mole
fraction) fraction) fraction)
ETHYLENE 0.43 0.92712 0.000
ETHANOL 0.009 0.00000 0.0167
WATER 0.5275 0.00100 0.9829
DIETHYLE 0.0250 0.05392 0.000
ETHER
METHANE 0.0002 0.00044 0.0000
ACTELDEHYDE 0.0064 0.01377 0.000
ETHANE 0.0005 0.00115 0.0000
HYDROGEN 0.0004 0.00087 0.0000
CARBONDIOXIDE 0.0010 0.00173 0.0000
TOTAL 1.00 1.00 1.00
24
Streams
Figure 4. 5: Reactor
25
= 311.869 kmol/hr.
311.869
S1 = = 354.40 kmol/hr.
0.88
H2O in S1 = (354.40) (12%)
= 42.528 kmol/hr.
Streams
Components S1 (mole fraction) S10 (mole fraction)
ETHANOL 0.88 0.009
WATER 0.12 0.5275
ETHYLENE 0.0 0.4300
DIETHYL ETHER 0.0 0.0250
METHANE 0.0 0.0002
ACETALDEHYDE 0.0 0.0064
ETHANE 0.0 0.0005
HYDROGEN 0.0 0.0004
CARBON DIOXIDE 0.0 0.0010
TOTAL 1.00 1.00
26
STREAMS
Components S3 (kmol/hr) S10 (kmol/hr)
ETHANOL 311.869 5.61
WATER 42.528 329.96
ETHYLENE 0.0 268.98
DIETHYL ETHER 0.0 15.64
METHANE 0.0 0.13
ACETALDEHYDE 0.0 3.99
ETHANE 0.0 0.33
HYDROGEN 0.0 0.25
CARBON DIOXIDE 0.0 0.63
TOTAL 354.40 625.54
27
CHAPTER 5
ENERGY BALANCE
Temperatures (K)
S19 S26 S23
245.15 247.45 257.15
Cp CONSTANTS [7][9]
COMPONENTS A B C
ETHYLENE 3.806 0.15659 -0.0000835
ETHANOL 9.014 0.21407 -0.0000839
WATER 32.243 0.0019238 0.000010555
DIETHYL ETHER 21.424 0.33587 -0.0001035
METHANE 19.251 0.052126 0.000011974
ACETALDEHYDE 7.716 0.18225 -0.0001007
ETHANE 5.409 0.17811 -0.00006938
HYDROGEN 27.143 0.0092738 -0.00001381
CARBONDIOXIDE 19.795 0.073436 -0.00005602
2 3
𝑏(𝑇 2 −𝑇𝑟𝑒𝑓 ) 𝑐(𝑇 3 −𝑇𝑟𝑒𝑓 )
∆𝐻 = 𝑚 (𝑎(𝑇 − 𝑇𝑟𝑒𝑓 ) + + ) [7]
2 3
Temperatures (K)
S18 S19
288.15 250.15
Temperatures (K)
S16 S18 W
301.15 299.15 299.15
Figure 5. 4: Absorber
Temperatures (K)
S15 S16
298.15 301.15
Qin = 318704.7026KJ/hr
For S16 (Product)
Qout = ΔHC2H4 + ΔHH2O + ΔH (C2H5)2O + ΔHCH4 + ΔHC2H4O + ΔHC2H6 + ΔHH2
Qout = 315432.4758 + 273.0150193 + 47891.02766 + 124.8790632 + 5786.629731 +
473.7260382 + 203.3584506
Qout = 370185.1118KJ/hr
Heat Duty
Qduty= Qin – Qout [7]
Qduty = -51480.40915 KJ/hr
Temperatures (K)
S12 S13 S14
323.15 314.75 314.75
Temperatures (K)
S10 S11
643.15 363.15
Temperatures (K)
S11 S12
363.15 323.15
Figure 5. 8: Reactor
Temperatures (K)
S1 S10
698.15 650.25
For S1 (Feed)
CHAPTER 6
EQUIPMENT DESIGN
Selection of the reactor type for a given process is subjected to many considerations:
• Temperature and pressure of the reaction.
• Need for removal or addition of the reactants and products.
• Required pattern of the product delivery.
• Catalyst use consideration such as requirement for solid catalyst particle and
contact with fluid reactants and products.
• Relative cost of the reactor.
Since our reaction is the gaseous phase and exothermic reaction so the choice is the
tubular reactor
.
6.1.2 Selection of the Bed
Use of the catalyst requires modifications to basic reactor design to fixed bed
reactors, moving bed reactors or fluidized bed reactors.
These are used in the heterogeneous catalyst reactions and pressure drop across the
bed is small. The design of the fixed bed reactor is very easy as compared to the
moving bed and fluidized bed reactors. Their size is also compact as compared to
other fluidized bed and moving bed reactors. The energy requirement is also small
because no amount of energy is needed as in fluidized bed and moving bed required
to fluidize or move the bed.
These are the reactors with a gas phase working fluid that requires gas flow around
and across the fine particles at a rate sufficient to fluidize the particles suspended
within the reactor. Since the catalyst bed has to be fluidized so the energy
requirement in these reactors is large. Pressure drop is also large as compared to the
fixed bed reactors because the pressure is dissipated to fluidize the bed. The volume
of the reactor required is also large as compared to fixed bed reactor, because the
void spaces between the fluidized beds occupy the more volume.
These units are fluid reactors used where the fluid contain solid particles that can be
separated from the suspension fluid. Mostly suitable for liquid phase reactions or
where the slurry travels through the reactor. Moving bed reactors are not preferred
40
for the gas phase reactions. In these reactors, the pressure drop is the greater among
all.
From above points we see that the suitable reactor for our process is fixed bed
tubular reactor, with the reaction occurring in the tubes and the heat exchanging
material flowing outside the tubes.
The reaction occurring in Adiabatic Fixed Bed reactor is heterogeneous reaction, the
reactants are in gaseous phase and the catalyst is in solid phase. The process is
continuous. Since the Adiabatic Fixed Bed reaction is endothermic reaction so heat
will be not be generated.
Catalyst Selection:
T=698.15 K
Po=410 kPa
P=378 kPa
Parameter Evaluation
-rA=kCA
k=Aexp−Ea/RT
A=3x108exp(-E/RT)
Ea=-26.6 kcal/mol
R=0.001985 kcal/K.mol
T=698.15K
k=3x10^exp(-26.6/0.001985x698.15)
k=1.40s-1 (REF) J. Chem. Soc. B, 1968,0, 905-908 REF
43
Reaction
C2H50HC2H4+H2O
Calculation of Concentrations
Cao (yAo x Po) /RTo 0.062205367 kmol/m3
CA1 (At 0% Conversion) 0.061526196 kmol/m3
CA2 (At 3.1889% Conversion) 0.05797304 kmol/m3
CA3 (At 6.377% Conversion) 0.054541909 kmol/m3
CA4 (At 9.566% Conversion) 0.051320407 kmol/m3
CA5 (At 12.755% Conversion) 0.048261469 kmol/m3
CA6 (At 15.944% Conversion) 0.045353094 kmol/m3
CA7 (At 19.133% Conversion) 0.042584431 kmol/m3
CA8 (At 22.322% Conversion) 0.03994565 kmol/m3
CA9 (At 25.511% Conversion) 0.037427822 kmol/m3
CA10(At 28.700% Conversion) 0.035022815 kmol/m3
DATA (PROPERTIES)
REFERENCED BY US PATENT
Density of ɤ-Al2O3 Catalyst (kg/m3)
650
Pore Volume of ɤ-Al2O3 Catalyst
0.60 cc/g or 0.00060 m3/kg
US4301033A (REFRENCE US PATENT)
GIVEN DATA
Weight of catalyst is
XA dX A
W = FAo *
o -rA
where (H.SCOTT FOGLER) REF
XA dX A
o -rA
= Area under the curve
9791)+2(1.28601217)+2(1.368480776)+2(1.457453702)+2(1.553732033)+2(1.6582
54041)+ 1.7721259)
W=2450.43 Kg
Weight Of Catalyst= Volume x Density Of Catalyst
Volume of Reactor
Height Of Reactor
Height of the reactor is equal to the height of the tubes plus 20% allowance
H=(4.14+(2x0.2(4.14)) = 5.8m
𝐏𝐢 𝐃𝐢
е= + C.A
𝟐𝐟−𝐏𝐢
(COUSLON VOL 6 REF)
e= Thickness (m)
Pi= Internal Pressure (kPa)=1.1 x 410.325= 451.3575kPa
Di= Internal Diameter (m)=1.38m
48
𝐏𝐢 𝐃𝐢
е= + C.A
𝟐𝐉𝐟−𝟎.𝟐𝐏𝐢
𝒅𝑷 𝑮 (𝟏 − 𝝋) 𝟏𝟓𝟎(𝟏 − 𝝋)
= 𝒙 [ 𝝁 + 𝟏. 𝟕𝟓𝑮]
𝒅𝒛 𝝆𝑫𝒑 𝝋𝟑 𝑫𝒑
Calculated Data
DATA (PROPERTIES)
Water (Viscosity Calculation)
A=-36.826
B=4.2900 X 10-1
C=-1.62 X 10-5
CONSTANTS
Ethanol (Viscosity Calculation)
A=1.499
B=3.0741 X 10-1
C=-4.4479 X 10-5
(REF)
Parameter evaluation
AREA= 𝝅/𝟒 𝒙 𝑫𝟐 = 1.49m2
ɸ (POROSITY) 0.4
(Dp) DIAMETER OF
CATALYST PARTICLE 0.005 m
Mw x P / RT
DENSITY OF ETHANOL 3.249 kg / m3
AVERAGE VISCOSITY OF
FEED 0.0000201679 kg / m.s
FEED
Mw (AVERAGE
MOLECULAR WEIGHT) 42.62 kg / kmol
MASS VELOCITY
Mass Flow Rate
(G)= Area 2.471734464 kg / m2s
VELOCITY OF FEED
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒
V= 0.003132743 m/s
𝐴𝑟𝑒𝑎
Re 645.2109233 LAMINAR
The pressure drop is in appropriate range and within 10% of the Operational
pressure
Reactor
ID number: R-100
Design data
Type Fixed Bed
Position Vertical
Material of construction Stainless steel
Weight of catalyst (kg) 2450.43
Diameter of Reactor (m) 1.38
Height of Reactor (m) 5.8
Volume of Reactor (m3) 6.18
Pressure Drop(psi) 3.12
51
9328.17 kg/h \
15111.06 kg/h
T =hot fluid
t = cold fluid
T1= 363.15 k
t1=298.15 k
T2= 313.15 k
t2= 355.15 k
Q = mCp∆T
= 15111.06 * .75* (53.5)
= 606331.28 Kj/ hr
Qhot = Qcold
606331.28 = m * (1) * (65)
m = 9328.17 kg/h
∆Tln= { ( T1 – t2) - ( T2 – t1) } / ln { ( T1 – t2) / ( T2 – t1) }
52
S=(t2-t1)/(T1-t1) =0.87
Ft = 0.8
[From D.Q kern fig. 18]
∆Tm= ∆Tln * Ft
∆Tm=10.152
Assume:
U=250 kj /hr.m2
[From Coulson vol. 6]
Q=UA∆Tm
A= Q / U∆Tm
A=238 m2
(Since Area is large enough , so we will select Shell and Tube Heat Exchanger)
V= 4.3 m/s
V= 14.07 ft/s
G= 129866.45kg/h.m2
54
𝜂
4∗(𝑃𝑡− ∗𝐼.𝐷2 )
4
de=
𝜂∗𝐼.𝐷
de = .01978 m
𝐷𝑒∗𝐺
Re = ( )
𝜇
viscosity=0.0562Kj
Re= 45727.16
Jh=110
K=0.504KJ/kg.m.k
Jh∗K 𝐶𝑝 𝜇 −1 𝜇
Hi = *( ) 3 *(𝜇 𝑤)-0.14
D 𝐾
𝑄
A=
𝑈𝑑∗ ∆Tlm
A= 238 m2
nt = actual area/(3.14*L*OD)
nt=853
6.2.3 Pressure Drop Calculation for shell side
𝑓∗𝐺𝑠 2 ∗𝑑𝑠 (𝑛+1)
∆P =
Sg∗De∗ɸs∗5.22∗1010
N + 1=L/B
N + 1=18/.616
N + 1= 29 ft
f = .002ft2/in2
(from D.Q KERN)
Sg = 0.75
55
Ds= 3.08. ft
De=.065 ft
∆P= .101 psi<10
6.2.4 Pressure Drop calculations for tube side
f= 0.003 From graph
D= 0.0485 ft
S.g=.268
G= 4384 lb/ ft2 h
∆Pt= 1.43 psi
4∗𝑛𝑝 𝑉2
∆Pr = *
𝑆𝑔 2𝑔
𝑃𝑀
Density of Gas mixture =
𝑅𝑇
𝑁𝑚
R = 8.314×103
𝑘𝑚𝑜𝑙 𝐾
M = 0.43×28+0.009×46.07+0.5275×18+0.0250×74.12+0.0002×16.04+0.0064×44.05
+ 0.0005×30.07+0.0004×2+0.0010×44.01
𝑘𝑔
M =24.147
𝑘𝑚𝑜𝑙
13600×24.147
So, ρg =
8.314×103 ×378.15
ρg = 1.045kg/m3
Where ρL, ρg are the densities and L,G are the liquid and gas flow rates of liquid and
gas respectively.
0.867 1.045 0.5
X= ×[ ]
4.195 1000
X = 0.0067
Now we will be able to calculate flood point as:
lnYFlood = - [3.5021+1.028(ln0.0067)+0.11093(ln0.0067)2]
YFlood = 0.32
Now, we will calculate capacity Factor, Cs,flood at flooding :
𝑌𝑓𝑙𝑜𝑜𝑑 0.5
Cs,flood = [ ]
𝐹𝑝 ×𝜇 0.1
Select metal pall ring packing, for this type of packing Fp = 27 ft2/ft3
0.32
Cs,flood = [ ]0.5
27×(0.001)^0.1
Cs,flood = 0.154
0.154
VG, F = 1.045
( )0.5
1000−1.045
Suppose there is no or very less liquid flow rate, we can calculate dry gas pressure
drop:
∆𝑃𝑜 ψ×a×ρg×v2g
=
∆𝑍 𝜀^2×2×𝑘𝑤
Now for this equation we must know, kw, ψ, and 𝜀.
KW = wall factor, it can be found as:
1 2 1 𝑑𝑝
=1+ ( )
𝑘𝑤 3 1−𝜀 𝐷
1−𝜀
For effective particle diameter, dp = 6×( )
𝑎
59
For metal Pall ring, 𝜺= radial void fraction = 0.951 and a = 112.6 m2/m3
1−0.951
dp = 6×( )
112.6
dp = 0.002611 m
Now, for wall factor,
1 2 1 0.002611
=1+ ×( )×
𝑘𝑤 3 1−0.951 1.23
Kw = 0.972
For dry packing resistance co-efficient, ψ, we will first calculate Reynold’s number,
ReG.
𝑣𝐺 ×𝑑𝑝 ×𝜌𝑔 ×𝑘𝑤
ReG = [ ]
(1−𝜀)𝜇𝑔
µg = 0.00002145 Pa.s
3.33×0.002661×1.045×0.972
ReG =
(1−0.951)×0.00002145
ReG = 8411
Now, calculate ψ.
64 1.8
Ψ = Cp × [ ]+[ ]
𝑅𝑒𝐺 (𝑅𝑒𝐺)^0.08
Ψ = 0.6723
Finally, we can calculate dry gas pressure drop:
∆𝑃𝑜 ψ×a×ρg ×v2g
=
∆𝑍 𝜀 2 ×2×𝑘𝑤
∆𝑃𝑜 0.6723×112.6×1.045×3.332
=
∆𝑍 0.9512 ×2×0.9721
∆𝑃𝑜
= 499.67 Pa/m
∆𝑍
For determining the pressure drop when the bed is irrigated, we will find liquid
hold-up for this:
Liquid Hold-up
60
𝐿
And mass velocity, Gx, = 𝐴
0.867
GX =
1.204
GX = 0.719 kg/m2s
0.719
ReL =
112.6×0.001
ReL = 6.38
𝐺𝑥2 × 𝑎
Now FrL =
𝜌𝐿2 × 𝑔
For metal pall ring packing, specific area, a =112.6 m2/m3 𝝆𝑳 = 1000 kg/m3
0.7192 ×112.6
FrL =
10002 ×9.8
FrL = 5.94183 × 10-6
For ReL > 5
The ratio of specific area is given as:
𝑎ℎ
= 0.85×Ch×ReL0.25 × FrL0.1
𝑎
Ch =0.784 (For metal Pall Ring)
𝑎ℎ
= 0.85×0.784×6.38970.25 × (5.94183 × 10-6)0.1
𝑎
𝑎ℎ
= 0.3095
𝑎
12𝐹𝑟𝐿 1/3 𝑎ℎ 2/3
hL = [ ] [ ]
𝑅𝑒𝐿 𝑎
∆𝑃 𝜀 𝑅𝑒𝐿
=[ ]1.5 × exp[ ]
∆𝑃𝑂 𝜀− ℎ𝐿 100
61
∆𝑃 0.951 6.389
= [0.951− 0.0102253]1.5 × exp[ ]
∆𝑃𝑂 200
So,
∆𝑃 ∆𝑃
× = 1.02×499.67
∆𝑃𝑂 ∆𝑧
∆𝑃
= 508 Pa/m
∆𝑍
Column height
y1/y2 = 527.5
𝑚𝐺𝑚
We can take = 0.6 - 0.8
𝐿𝑚
𝑚𝐺𝑚
Take, = 0.6
𝐿𝑚
Figure 6. 3: graph
𝒎𝑮𝒎
Now, for HOG = HG + ×HL
𝑳𝒎
𝐺𝑚
And, HG =
𝐾𝐺×𝑎ℎ ×𝑃
𝐿𝑚
Also, HL =
𝐾𝐿×𝑎ℎ ×𝐶𝑡
For this we will calculate effective area, ah, mass transfer co-efficient KL and KG
Lw* = liquid mass flow rate per unit area = 0.7194 kg/m2s
µL= 0.001 Pa.s
g = 9.8 m2/s
a = 112.6 m2/m3
𝑎ℎ
= 0.309533174
𝑎
ah= 112.6 × 0.309533174
ah = 34.853 m2/m3
DL (Diffusivity of Liquid) = 6.0116×10-10 m2/s (Chapter 8, Coulson and
Richardson)
Now, we will determine liquid film mass transfer coefficient, KL
𝜌𝐿 1 𝐿∗𝑤 2
𝜇𝐿 −0.5
KL ( )3 = 0.0051×( )3 × ( ) ×(𝑎×𝑑𝑝 )0.4
𝜇𝐿 𝑔 𝑎ℎ×𝜇𝐿 𝜌𝐿 𝐷𝐿
1
1000
KL (0.001×9.8)3
63
0.719
2
0.001 −0.5
= 0.0051×( )3 × ( ) ×(112.6 ×
34.853×0.001 1000×6.0116×10−10
0.002661)0.4
KL = 1.23405 ×10-5m/s
𝟏
𝒌𝑮 ×𝑹×𝑻 𝑽∗𝒘 𝟎.𝟕 𝝁𝒗 𝟑
𝒂×𝑫𝒗
= 𝑲𝟓 ×(
𝒂×𝝁𝑽
) ×(
𝝆𝒗 𝑫𝒗
) ×(𝒂×𝒅𝒑 )−𝟐.𝟎
V*w = 3.4830
µv = 0.00001055 Pa s
𝑘𝐺 ×0.08314×378.15
112.6×2.22459×10−5
1
3.4830 0.7 0.00002145 3
= 5.32×(112.6×0.00002145) × ( ) ×(112.6×
1.045×2.22459×10−5
−2.0
0.002661)
P = 1.36 bar
625.4
Molar gas flow, Gm = = 0.14424 kmol/m2 hr
1.2046×3600
0.14424
HG =
0.7766×34.853×1.36
HG = 0.00391 m
𝑳𝒎
HL =
𝑲𝑳×𝒂𝒘×𝑪𝒕
𝜌𝐿
ct =
𝑀.𝑊
1000
ct = = 55.5 kmol/hr
18
64
Lm = 0.7194/18
Lm = 0.039971 kmol/ m2 s
0.039971
HL =
1.23405×10−5 ×34.85×55.5
HL = 1.673 m
Then, Height of gas transfer unit, HOG will be:
𝐦×𝐆𝐦
HOG = HG + HL
𝐋𝐦
𝒎×𝑮𝒎
= 0.6 - 0.8 is an optimum value. Select 0.6.
𝑳𝒎
1 1 1
= +
𝑈𝑎 2006.797 1299.785
1. Packed column
2. Plate column
1. Selection of column.
2. Selection of packing and material
3. Calculating the size of packing
4. Calculating the diameter of column
5. Determining the no. of transfer units (NOG)
6. Determining the height of packing
7. Determining the height of the column
8. Calculating the operating velocity
9. Calculating the flooding velocity
10. Determining the pressure drop.
11. Select and design the column internal features: packing support, liquid
distributer and redistributer.
67
Y1/Y2 = 11.5
Colburn has suggested that the economic range for mGm/Lm lies from 0.7 to 0.8. For
our process,
mGm/Lm = 0.70
Now,
L g
G L = 0.00042
k 4 *ρg * ρ L -ρ g
0.5
As,
G
Area = A = = 10.71 m2
G*
4*A
Diameter of column = D =
π
D = 2.085 m
aw
0.75
Lw
0.1
Lw 2 a
0.05
Lw 2
0.2
1 exp 1.45 c
2g a
a
l a L L L L
Where
Lw = 0.003452 kg/m2s
µL= 0.133 cp
ρL = 1436 Kg /m3
aw = 36.79012 m2/m3
1 2 1
3 Lw 3 L
ad
2
K L L 0.0051 0.4
L
g aw L L DL
p
dp = packing size = 51 mm
KL = 6.57*10^-7 m/s
1
0 .7
V g 3
ad p 2
K G RT g
K5 w
aD g a D
g g g
Where
KG = Gas film coefficient, kmol/m2s.bar
KG = 2.96*10^-5 kmol/m2s.atm
Now,
G
H m
G K a P
G w
Where,
Gm = 5.24*10^-3 Kmol/m2.s
Then,
HG = 4.54 m
L
H m
L K a C
L w t
72
And ,
HL= Liquid-film transfer unit height
HL = 3.366 m
HG = 4.54 m
HL = 3.366 m
So,
HOG = 6.89 m
Z = 2.7*6.89 = 18.62 m
Zt = 20.62 m
Gx y
Gy x y = 0.00041
And,
G2 × Fp × μ0.1
l
= 0.000352
ρg (ρl - ρg) gc
6.5.1 Adsorption
Adsorption process can be delegated either mass detachment or purging relying upon
the centralization of the adsorbate in the fluid or gas stream being dealt with. The
warmth freed in the two procedures might be altogether unique, the more prominent
being in mass partition. For decontamination, this discharge isn't as imperative.
Even though adsorption has been utilized as a physical/synthetic process for a long
time, it is just finished the most recent four decades that the procedure has created to
a phase where is currently a noteworthy modern strategy. Adsorption is generally
done in settled beds, as this is observed to be generally practical.
Recommended adsorbent for commercial drying is molecular sieve type 3A. It has
the advantage that is adsorbs water only leaving ethylene pure in contrast to other
adsorbents which adsorb ethylene as well. Molecular sieve is the effective option for
eliminating water from gases and liquids. Usually products like silica gel have been
75
used for such purposes but molecular sieve desiccants can give cleaner outcomes.
The sieves have tiny and uniform pores, which makes them ideal adsorbents.
Keller et al. has developed a simple matrix that can rapidly serve as a guide for
making this choice with essentially no calculations. The table is shown below: (plant
design and economics for engineers by peter timmerhaus)
From the table, the temperature swing adsorption seems the most appropriate.
Molecular sieves require elevated temperature (300oC) for regeneration at high
pressure (far above 30 bar). But life time of 3A molecular sieve would be shortened
extremely using such a temperature. The reduction in pressure helps decreasing the
o
regeneration temperature. A temperature of 200-230 C is recommended for
regeneration.
76
Figure 6. 6: adsorber
= 267.21 kmol/hr.
287.730 ×0.1
Molar flowrate of water = Fwater =
100
= 0.29 kmol/hr.
It is assumed that all the water present in the feed is removed through adsorption,
only a small amount of water is present in the product which is negligible.
Adsorbent 3A zeolite is selected for the following adsorption. It has the advantage
that is adsorbs water only leaving ethylene almost pure in contrast to other
adsorbents that adsorb ethylene as well. The properties of adsorbent 3A zeolite are
taken from the research article on 3A zeolite molecular sieve regeneration.
Now, the next step to calculate the partial pressure of water in feed to determine the
maximum adsorbent loading from given isotherm data for the adsorption of water on
zeolite 3A.
27 ×0.1
Partial pressure of water in feed at 27 bars = = 0.027 bar or 2.7 kPa.
100
From the above graph, it is observed that the maximum adsorbent loading at 27 bars
is 20 wt.%. The above isotherm is taken from the research article on water adsorption
on molecular sieve 3A.
20 kg of water
So, maximum adsorbent loading = m1 =
100 kg of adsorbent
0.2 kg of water
=
kg of adsorbent
79
Now, for the minimum adsorbent loading after regeneration if the fresh or
completely regenerated adsorbent is used then the minimum adsorbent loading
becomes zero (m2 = 0); but complete regeneration is often too costly. So, for our
calculations we take it to be the 20 percent of the maximum adsorbent loading.
Reference is Unit Operation by McCabe and Smith
0.2 × 20
So, minimum adsorbent loading = m2 =
100
0.04 kg of water
=
kg of adsorbent
Now the next step is to calculate the mass of adsorbent used in the adsorption
column. For calculating the mass of adsorbent, we use the mass balance equation of
the bed that is taken from the book Chemical Engineering Design vol. 6. Ed. 5.
The mass balance on the bed gives
The total cycle time is equal to the time spent in adsorption multiplied by the number
of beds in sequence. The selected fL is 0.7 and cycle time is 60 minutes. For two
beds, the fL is taken 0.7 when lead lag arrangement is used and cycle time is taken as
60 minutes because less time results in less mass of adsorbent used which results in
smaller length of bed and less pressure drop so, the adsorption time is (from
Chemical Engineering Design vol. 6. Ed. 5.)
80
60
Time the bed is in adsorption stage of the cycle = ta =
2
= 30 minutes or 1800 sec.
Substituting values into mass balance equation
1000
{(287.730 × 0.001)-(286.64 ×0.0001)} × × 1800 × 18 = (0.2-0.04) × Ma × 0.7
3600
0.259 ×9000
Ma =
0.112
Hence, mass of adsorbent = Ma = 20817 kg
20800
Volume of adsorbent bed = V = = 24.55 m3
848
πD2 L 3πD3
Assume L/D = 3:1 cylinder, volume = =
4 4
3 4V
So, diameter of the vessel = DT = √
3π
3 4×30.65
=√ = 2.35m
3π
Since, we have selected two vessels so, the total quantity of adsorbent =
2 × 20817 = 41635 kg
The next step is to calculate the pressure drop across the adsorbent bed.
Ergun equation is used to calculate the pressure drop across the adsorbent bed. The
equation is as follows (from Unit Operation by McCabe and smith, research article
on fixed bed adsorber pressure drop).
∆P (1-ϵ)2 μ (1-ϵ) ρ 2
= 150 u + 1.75 u
L ϵ2 d2p ϵ dp
The properties of pure components are taken from the table 2-141 from Perry’s vol. 1
From these properties, the critical temperature, pressure and molecular weight of a
mixture are calculated.
The calculated properties for mixture are:
Tpc = 294.9565 K, Ppc = 4.9755 MPa, Mm = 30.668
ωm = 0.09934, Vpc = 0.140213 m3/kmole
301.45
Now, reduced temperature = Tr = 294.9565 = 1.022
2.7
Reduced pressure = Pr = 4.9755 = 0.5427
kmol
ρ = 1.35
m3
kg
ρ = 1.35 × 30.668 = 41.4018
m3
So, the density of gaseous mixture = 41.4018 kg/m3 or 2.58 lb./ft3
ρr = ρVpc
ρr = (1.35) (0.140213)
ρr = 0.18928
1 2
-8 30.6682 4.97553 1.858 )
μ - μo = 5×10 × 1 [e(1.439(0.18928)) - e(-1.11(0.18928) ]
294.95656
μ - μo = 1.132×10-7
= 28.6 bar
N
Pi = 2.86 mm2
Vapor liquid mass transfer operation may be carried out either in plate column or
packed column. These two types of operations are quite different. A selection
scheme considering the factors under four headings .
• Factors that depend upon the system i.e. scale, foaming, fouling factors,
corrosive systems, heat evolution, pressure drop, liquid holdup.
• Factors that depend upon the fluid flow moment.
• Factors that depends upon the physical characteristics of the column and
its internals i.e. maintenance, weight, side stream, size and cost.
• Factors that depend upon mode of operation i.e. batch distillation,
continuous distillation, turndown.
There are three main plate types, the bubble cap, sieve plates, and ballast or valve
plates. Sieve plate is selected because:
• They are lighter in weight and less expensive. It is easier and cheaper to
install.
• Pressure drop is low as compared to bubble cap trays.
• Efficiency is generally high.
• Maintenance cost is reduced due to the ease of cleaning.
• High turnover
Process Design
Temp. of feed = -28oC
Temp. of top = -25.7oC
Temp. of bottom = -16oC
𝟐.𝟓𝟐
Ethylene=𝟎.𝟖𝟗 = 2.83
𝟎.𝟗𝟖
Acetaldehyde=𝟎.𝟖𝟗 = 1.15
𝟎.𝟖𝟗
Ethane=𝟎.𝟖𝟗= 1.0
𝟏.𝟖
Hydrogen=𝟎.𝟖𝟗 = 1.8
𝟎.𝟗𝟗
Diethyle ether=𝟎.𝟖𝟗 = 1.12
𝟐.𝟏
Methane = = 2.35
𝟎.𝟖𝟗
Underwood’s Equation:
θ = 1.17
Rm for Distillate:
𝛼𝑥𝑑𝑎 𝛼𝑥𝑑𝑏 𝛼𝑥𝑑𝑐 𝛼𝑥𝑑𝑑
+ + + += Rm + 1
𝛼𝑎 − 𝜃 𝛼𝑏 − 𝜃 𝛼𝑐 − 𝜃 𝛼𝑑 − 𝜃
(1.7202262048)+(9.95×10-4)+(-5.88×10-4)+(8.20×10-3)=Rmin+1
Rmin+1=1.71
Rmin=0.71
87
We know, the optimum reflux ratio lies 1.2-1.5 times of minimum reflux ratio
(Coulson V6);
R=1.31Rmin
R=1.31(0.71)
R=0.9301
q line Calculation
we know,
λ + hfs − hf
q=
λ
So,λ at feed pressure and feed boiling temperature is
kJ
λ = 2.9550 ∗ 10^4
kgmol
So,
hf = CP,f (Tf )
kJ
hf = 80322.23.
kgmol
kJ
hfs = 67992.235
kgmol
Now,
λ + hfs − hf
q=
λ
29550 + 80322.23 − 67992.235
q=
29950
q = 1.41168
So equation root value satisfied.
So,
88
Ln=(R)(D)
Ln=(0.9301)(253.56)
kgmol
Ln=235.65 hr
Vn=Ln+D
Vn=235.65+253.36
kgmol
Vn=489.01 hr
As the
Lm=Ln+F
kgmol
Lm=522.29 hr
kgmol
Vm=489.65 hr
The equation for the bottom operating lines may then be written as;
Lm W
ym = ( ) (xm+1 ) − ( ) (xb )
Vm Vm
Ethylene:
522.29 33.29
ym,ethylene = ( ) (xm+1 ) − ( ) (0.3950)
489.65 489.65
ym,ethylene = (1.06)(xm+1 ) − 0.02689
Diethyl ether;
89
522.29 33.29
ym,diethyl ether = ( ) (xm+1 ) − ( ) (0.4676)
489.65 489.65
ym,diethyl ether = (1.06)(xm+1 ) − 0.03183
Acetaldehyde;
522.29 33.29
ym,aceteldehyde = ( ) (xm+1 ) − ( ) (0.1288)
489.65 489.65
ym,acetaldehyde = (1.06)(xm+1 ) − 0.0087684
Ethane;
522.29 33.29
ym,ethane = ( ) (xm+1 ) − ( ) (0.086)
489.65 489.65
ym,ethane = (1.06)(xm+1 ) − 0.005854
Since starting from bottom to top
Table 6.6.2
Stage no.1:
Table 6.6.3
Stage no.2:
Table 6.6.4
Stage no.3:
Table 6.6.5
Stage no.4
Table 6.6.6
The equation for the top operating lines may then be written as;
Ln D
yn = ( ) (xn+1 ) + ( ) (xd )
Vn Vn
Ethylene;
yn,ethylene = (0.4818)(xn+1 ) + 0.5166
Methane;
yn,methane = (0.4818)(xn+1 ) + 0.0003
Ethane;
yn,methane = (0.4818)(xn+1 ) + 0.00005
Hydrogen;
yn,methane = (0.4818)(xn+1 ) + 0.0011
92
Table 6.6.7
Stage no.5
Table 6.6.8
Stage no.6
Table 6.6.9
(mol fraction)
Stage no.7
Table 6.6.10
Stage no.8
Table 6.6.11
N=8
Column Efficiency:
10−3 − 2.9
I = Souder’s’ index(Table 8.1Coulson V6)
µm = viscosity of mixture
ρm= density of mixture
x1& x2 & x3 = mol fraction of components
M1& M2& M3 = molecular masses of components.
Iethylene = 95.7
Iact = 153
Ihydrogen = 5.4
Methane = 116.6
Mmethane = 61
MDe = 278
95
PV=ZnRT
Z from chart for this we require Tr and Pr so for that Tc and Pc taken from plant
design book and the from T/Tc and P/Pc we get Pr and Tr(Appendix C Coulson V6)
ρm = 17.33
log(𝑙𝑜𝑔 10 μ𝑚 ) = 17.33×
0.9290×95.7+0.0139×150.9+0.0009×5.4 0.0012×116.6+0.0004×61+0.0546×278
[ 0.9290×28+0.0139×44.05+0.0009×2.0 ] ×10−3 − 2.9
0.0012×30+0.0004×16+0.0546×74.12
log(𝑙𝑜𝑔 10 μ𝑚 )
= 17.33[3.41785 + 3.4256 + 2.7 + 3.8867 + 3.8125 + 3.75]×10
− 3 − 2.9
μ𝑚 = 1.19
αa Isthe average relative volatility of Lk,
αa = 2.83
So,
Eo = 51 − 32.5 log(1.19999×2.83)
Eo = 33.86
We know,
N
Nactual =
Eo
8
Nactual =
0.3386
Nactual = 24
Where Nr = number of stages above the feed, including any partial condenser
Ns = number of stages below the feed, including the reboiler
B = molar flow bottom product
D = molar flow top product
Xf,HK = concentration of the heavy key in the feed
Xf,LK = concentration of the light key in the feed
Xd, HK = concentration of the heavy key in the top product
XB, LK =concentration of the light key if in the bottom product
Say,
Ns = 7
And
Nr =17
Mechanical Design
Physical properties
For top at operating pressure:
Vapor density at top=14kg/m3
97
Column Diameter
Lw ρv
FLV = √
Vw ρL
Lm ρv
FLV,bottom = √
Vm ρL
16
FLV,bottom = 1.068√
990
98
FLV,bottom = 0.13577
Ln ρv
FLV,top = √
Vn ρL
14
FLV,top = 0.4818√
1020
FLV,top = 0.05644
Taking as First trial,
Plate spacing=0.6m
From Figure (Coulson V6);
base K1 = 0.074
top K1 = 0.13
We know, if liquid surface tension will other than 0.02 N/m, then surface tensions
would multiply the value of K1 by [σ/0.02]0.2
So,
Surface tension at top=0.01072N/m
Say,
Surface tension at top=0.01072N/m
1.073 0.2
top K1 = (0.13) ( )
20
top K1 = 0.07241
For base:
Surface tension at bottom=0.01213 N/m
1.2141 0.2
base K1 = (0.074) ( )
20
base K1 = 0.0422
The flooding velocity can be estimated;
ρL − ρv
uf = K1 √
ρv
K1=constant
Flooding Vapor Velocity for bottom;
ρL − ρv
base uf = K1 √
ρv
990 − 16
base uf = 0.0422√
16
m
base uf = 0.3296
s
Flooding Vapor Velocity for top;
ρL − ρv
top upf = K1 √
ρv
1020 − 14
top uf = 0.07241√
14
m
top uf = 0.613
s
Design for 80 percent flooding at maximum flow rate;
base uv = 0.8uf
base uv = (0.8)(0.3296)
m
base uv = 0.2636
s
top uv = 0.8uf
top uv = (0.8)(0.613)
m
top uv = 0.4904
s
So,
Vm Mw
base =
3600ρv
(490)(48.7576)
base =
(3600)(16)
m3
base = 0.413
s
Vn Mw
top =
3600ρv
(489.01)(27.937)
top =
(3600)(14)
m3
top = 0.27106
s
Net area required:
0.413
bottom =
0.2636
bottom = 1.56m2
0.27106
top =
0.4904
top = 0.552 m2
So, taking down comer as 12 percent of total;
Column cross sectional area;
1.56
base =
0.88
base = 1.77m2
0.552
top =
0.88
top = 0.6272 m2
Column diameter
(1.77)(4)
base = √
π
base = 1.50 m
(0.6272)(4)
top = √
π
top = 0.89 m
101
(552.29)(48.7576)
Maximum Volumetric liquid rate =
(3600)(990)
m3
Maximum Volumetric liquid rate = 0.07147
s
So, column area is from the Figure (coul.V6).we can use single pass plate.
Provisional plate design
Column diameter;
Dc = 1.50 m
Column Area;
Ac = 1.77 m2
Down comer area taking as 12 percent of total;
Ad = 0.12(1.77)
Ad = 0.2124 m2
Net area;
An = Ac − Ad
An = 1.77 − 0.2124
An = 1.5576m2
Active area;
Aa = Ac − 2Ad
Aa = 1.77 − 2(0.2124)
Aa = 1.3452 m2
Taking hole area as 10 percent of active area;
Ah = .10(Aa )
Ah = .10(1.3452)
Ah = 0.13452 m2
Weir length (coul.V6);
lw = 0.77(Dc )
102
lw = 0.77(1.50 )
lw = 1.155 m
Weir height;
Weir height will normally 40 to 50 mm is recommended.
So, taking weir height=50 mm
Hole size;
Taking hole diameter=5mm
By using carbon steel;
Plate thickness=5mm
Check weeping
Lm Mw
Maximum liquid rate =
3600
Kgmole
Lm = 522.29
hr
(522.29)(48.7576)
Maximum liquid rate =
(3600)
kg
Maximum liquid rate = 7.07
s
Minimum liquid rate, at 70 percent turn-down;
Minimum liquid rate = .70(7.07)
kg
Minimum liquid rate = 4.95
s
Weir liquid crest;
Lw 2⁄3
how = 750 [ ]
ρL lw
Where lw = weir length, m
how = weir crest, mm liquid
Lw = liquid flow-rate, kg/s.
Lw 2⁄3
maximum how = 750 [ ]
ρL lw
2⁄3
7.07
maximum how = 750 [ ]
(990)(1.155 )
Lw 2⁄3
minimum how = 750 [ ]
ρL lw
2⁄3
4.96
minimum how = 750 [ ]
(990)(1.155 )
minimum how = 18.94 mm liquid
At minimum rate;
plate thickness 5
= =1
hole diameter 5
Ah Ah 0.1537
≃ = = 0.1
Ap Aa 1.537
Total drop:
ht = hd + (hw + how ) + hr
ht = 11.0 + (44.203 ) + 12.62
ht = 67.823 mm liquid
hap = 40 mm
Area under apron;
𝐴𝑎𝑝 = 𝑙𝑤 ℎ𝑎𝑝
Aap = 1.155(0.04)
Aap = 0.0462 m2
Lwd 2
hdc = 166 [ ]
ρL Am
Where Lwd = liquid flow rate in down comer, kg/s,
Am = either the down comer area Ad or the clearance area under the down comer Aap;
whichever is the smaller, m2
We know,
Ad = 0.2124
So, Aap is less than Ad. We will use Aap in above equation.
2
Lwd
hdc = 166 [ ]
ρL Aap
2
7.07
hdc = 166 [ ]
990(0.0462)
hdc = 3.96636 mm
Back-up in down comer;
hb = (hw + how ) + ht + hdc
Where hb = down comer back-up, measured from plate surface, mm
hdc = head loss in the down comer, mm.
hb = (67.823 ) + 44.203 + 3.96636
hb = 115.99 mm
hb = 0.1159
1
0.1159 < (plate spacing + weir height)
2
1
0.1159 < (0.6 + 0.05)
2
0.1159 < 0.325
It’s satisfied b/c it’s less than 0.32
Check residence time;
The down comer residence time is given by:
106
Ad hbc ρL
tr =
Lwd
wheretr = residence time, sec.
hbc = clear liquid back-up, m.
(0.2124)(0.1159)(990)
tr =
7.07
t r = 3.44
>3 s, satisfactory.
Check entrainment
Maximum volumetric flow rate of vapors
uv =
An
0.413
uv =
1.5576
m
uv = 0.2651
s
The percentage flooding is given by;
uv
percentage flooding =
uf
0.2651
percentage flooding =
0.3296
percentage flooding = 80.430
We know,
FLV,bottom = 0.13577
Perforated Area
lw 1.155
= = 0.77
Dc 1.50
From Figure11.32(Coulson V6), we obtain;
θc = 105∘
angle subtended by the edge of the plate = 180 − 105
angle subtended by the edge of the plate = 75∘
Mean length, unperforated edge strips=Mlues:
Width of unperforated strip =wus;
π ∗ angle subtended
Mlues = (Dc − wus) ( )
180
π ∗ 75
Mlues = (1.50 − 0.05) ( )
180
Mlues = 1.898045562 m
Area of unperforated edge strips = wus ∗ Mlues
Area of unperforated edge strips = 0.05 ∗ 1.898045562
Area of unperforated edge strips = 0.094945 m2
Mean length of calming zone, approx.=Mlcz:
Mlcz = weir length + wus
Mlcz = 1.155 + 0.05
Mlcz = 1.205 m
Ah 0.13452
=
Ap 1.12955
Ah
= 0.1190
Ap
Hole pitch:
lp
From (Coulson V6),Figure 11.33d =1.898045562=2.56
h
The hole pitch (distance between the hole centers) lp should not be less than 2.0-hole
diameters, and the normal range will be 2.5 to 4.0 diameters.
Number of holes
π (dh )2
Area of one hole = ( )
4
We know;
dh = 0.005 m
π (0.005)2
Area of one hole = ( )
4
Area of one hole = 1.964×10−5 m2
We have calculated area of hole;
Ah = 0.13452 m2
So, Number of holes;
Ah
Number of holes
Area of one hole
0.13452
Number of holes =
1.964×10−5
Number of holes = 6851.04
Hc = (Nactual − 1)Hs + ∆H
Hc = Height of column
HS=Tray spacing=1.968 ft. (standard)
∆H=Top clearance +Bottom Clearance
Assume:
Top clearance = 12 in = 1 ft.
Bottom Clearance = 12 in = 1ft
Hc = (24 − 1)(1.968) + 2
Hc = 14 m
110
CHAPTER 7
7.1 Introduction:
The presence of a properly designed control system along with its supporting
instruments is essential for the efficient operation and performance of a process. The
purpose of installing control systems in a process is to ensure that proper conditions
for the process are maintained such as level, temperature, flow, pressure and
composition. The control systems responsible for maintaining these conditions are
level control, temperature control, flow control, pressure control and composition
control.
NOTE: A control system has to satisfy:
Flow Controllers: These are used to control flow rates. Orifice plates are by
far the most type of flow rate sensor. Normally, orifice plates are designed to give
pressure drops in the range of 20 to 200 inches of water. Venture tubes and turbine
meters are also used.
Level Controller: Liquid levels are detected in a variety of ways. The three
most common are:
• Following the position of a float, that is lighter them the fluid.
• Measuring the apparent weight of a heavy cylinder as it buoyed up more or
less by the liquid (these are called displacement meters).
• Measuring the difference in static pressure between two fixed elevations, one
in the vapour above the liquid and the other under the liquid surface. The
113
differential pressure between the two-level taps is directly related to the liquid
level in the vessel
Transmitter: The transmitter is the interface between the process and its control
system. The job of the transmitter is to convert the sensor signal (millivolts,
mechanical movement, pressure differential, etc.) into a control signal 3 to 15 psig
air-pressure signal, 1 to 5 or 10 to 50 milliampere electrical signal, etc.
Control Valves: The interface with the process at the other end of the control
loop is made by the final control element is an automatic control valve which
throttles the flow of a stem that open or closes an orifice opening as the stem is raised
or lowered. The stem is attached to a diaphragm that is driven by changing air-
pressure above the diaphragm. The force of the air pressure is opposed by a spring.
114
Here the reactor temperature is measured at three different positions and compute an
error by Auctioneering system, and an error signal is sent from this point to the
Temperature controller; Temperature controller then compares the output with set
point and sends the signal to Valve V1. Hence feed is manipulated before entering
the reactor. Flow transmitter transmits the signal to Flow Controller to control the
output of reactor from valve V2.
Pressure inside the reactor is measured with the help of PT and signals are send to
the PC. It compares it with set point and computes an output either increase or
decrease the flow rate of feed stream with the help of controller installed.
Coolant is not used as this reactor is adiabatic and endothermic reaction is occurring.
Temperature drops from inlet to outlet. Hence it is maintained at 425 C at inlet and
377 C at outlet.
115
Temperature transmitter is installed on the hot side of the exchanger in which the hot
water is flowing in and coming out of the heat exchanger from the tube.
Temperature sensor such as thermocouple is installed to sense the temperature and
temperature transmitter converts the value and send it back to the temperature
controller. Temperature controller is already given a set point from the control room.
Controller compares the value of the signals and the set point and then sends the
signal to the valve installed at the shell side inlet of the heat exchanger where hot
fluid such as methanol is flowing. If temperature of the output of the tube side is low
as compared to the set point given to the controller, controller will send the signal to
the open the valve more. Now it depends on the type of valve used, whether it is a
Fail open or Fail close valve.
Depending upon the type of the valve used, controller output is set according to the
type of the valve. If Fail close valve is installed, then to open the valve less signals
should be sent to the valve by controller.
116
There are mainly two main disturbances in the operation of quench tower - feed flow
rate and temperature. Feed flow rate is to be maintained because if there were a high
gas flow rate there would be a high gas pressure drop and it would give rise to a
condition called flooding. And we will install temperature controller so as to shower
the required amount of water needed for cooling.
117
Figure 7. 4: Absorber
Figure 7. 6: Distillation column
for this purpose feed backward control system is installed over the ref ilux drum
so that after occurrence of disturbance level is measure by level measuring
sensor and signal send to level controller where value is compared with set
point and flow rate of distillate will be controlled by opening or closing the
valve. Reflux flow rate is also controlled by valve that receives data of
concentration from distillate.
121
CHAPTER 8
HAZOP STUDY
8.1 Hazop
Characteristics:
More More gas flow Control valve Flooding in the Install high level
fully open column alarm
Install
Control valve Flow controller
failure
ATELY
OPENS
IT
less FLOW V-11 PRESSURE FLOW
BUILDUP, CONTRO
TIME LLER
CONSUMIN AND
G FLOW
SENSOR
Install low
More flow of hot Failure of flow Not enough temperature
water control valve contact between alarm at the
More the two fluids outlet of the
resulting in less exchanger
heat transfer
System:
Distillation
Column
High level
Level HGH LEVEL Level controller Level rises and alarm
Fault re-boiler
operation stops
More reflux
LOW than Composition can Control reflux
optimum be affected ratio
CHAPTER 9
COST ESTIMATION
Height = 20.6 m
Diamter = 2.08 m
Purchased cost = (bare cost from fig * Material factor* Pressure factor)
Bare cost = 100*1000 = $100000
Material Factor = 100000*2 =$200000
Pressure Factor = 200000*1= $200000
Purchase cost = $200000
Cost in year 2018 = Cost in year 2004*(cost index in year 2018/cost index in year
2004)
Cost in year 2018 = 200000*(548.9/411)
Cost in year 2018 = $267104.6
The costing of Heat exchanger is calculated from page 321 -323 & table 7.2 and by
using cost Escalation method page 335 for shell and tube heat exchanger
C=a+bSn
a = 2800
b = 54
134
A = 291.15
n = 1.2
by putting the values in above equation
C = 51702 US dollars
Now by cost Escalation method
CPEIC 2010=532.9
CPEIC 2018=567.5
Cost in year A =cost in year B*cost index in year A/cost index in year B
Hence cost in 2018 = 55058.89 US dollar
= $24981.36
Volume of inert packing (ceramic) = 6.138 m3
Cost of packing = 2000(6.138)
= $12276
Total cost of one adsorption column = 12276 + 24981.36 + 104549.34
= $141806.7 (2010)
Now we calculate cost on basis of cost index of 2017 which is 567.6
Cost index of 2010 = 532.9
141806.7 ×567.5
Cost adsorption = 532.9
= $151,014 or 17,464,653.45
Since we have two adsorption columns so cost is 34,929,306 PKR.
Vessel cost
= 20,500×2.0×1.0
= 50,000 £
Volume of packing
= π/4 (13.1)
= 10.28 m3
Packing cost
= 830 £ / m3
= 830 ×10.28
= 8532.4 £
= 50,000 + 8532.4
= 58532.4 £
567.5
Cost in year 2018 = 58532.4 × 411
Or
Reactor
ID number: R-100
Design data
Type Fixed Bed
Position Vertical
Material of construction Stainless steel SS-304
Weight of catalyst (kg) 2450.43
Diameter of Reactor (m) 1.38
Height of Reactor (m) 5.8
Volume of Reactor (m3) 6.18
Thickness of Wall (m) 0.0560
SS-304 Metal density (kg/m3) 7999.49
The cost estimation is done based on year 2010 data available in chemical
engineering design vol. 6
Table 7.2 from vol. 6 is used for calculations. The correlations in table 7.2 are of the
form
Ce=a+𝒃𝑺𝒏
Cost of Catalyst
Price range of activated Gamma Alumina catalyst = $1.5- $1.8 per kg (ref)
Weight of Catalyst= 2450.43 kg
$1.8
Cost of Catalyst= 2450.43 𝑘𝑔 𝑥 = $4411
𝑘𝑔
Height of vessel = 14 m
Diameter = 1.5 m
Cost in USD =?
Cost = 24 × 1000
Cost = 24,000 $
Factors:
Cost = 24,000 × 2
Cost = 48,000 $
So,
Cost = 33,600 $
A = 𝜋 4 d2
d 2 = 1.98
Type = sieve
Cost in USD = ?
Cost = 370 $
So,
Cost = 740 $
So,
Cost = 370 × 24
Cost = 8880 $
Cost in year 2018 = $114480 x (Cost index ratio 2018 / cost index in 2003) Cost in
By Lang Method,
Total ISBL of the Plant C= F(∑𝐶𝑒)
Where,
C= Total Plant ISBL Capital cost
∑𝐶𝑒 = Total delivered cost of all equipment items; reactors, tanks etc
F= Lang Factor
Now,
F=3.1 for Solids processing plant
F=4.74 for fluids processing plant
F=3.63 for mixed fluids solid processing plant
Sum of all costs of equipment Ce= Cost of Reactor + Cost of Quencher + Cost of
Absorber + Cost of Adsorber + Cost of Distillation Column + Cost of Heat
Exchanger
Ce= $256770 + $127756 + $267104.6 + $(1.3*349293) + (138267.7172) + 55058.89
Ce= $1299038.11 ~Rs. 149908997.6 OR 14.99 ~ 15 Crores
TOTAL ISBL = 4.74*14.99= Rs.71.056 Crores
OSBL=40% x 71.056=Rs. 28.43 Crores
FIXED CAPITAL COST= 71.056+28.43 = Rs. 99.48 Crores
WORKING CAPITAL COST= 10% x 99.48= RS. 9.9486 Crores
TOTAL INVESTMENT= Working Capital Cost + Fixed Capital Cost =Rs.109.43
Crores
142
CHAPTER 10
PLANT LAYOUT
Site selection is integral part of setting up an efficient industry. There are many
factors that contribute in selecting a proper site for a chemical plant. Major factors
among these are:
• Raw Materials
• Market
• Energy Supply
• Availability of Utilities (Water)
• Climate
• Labor
• Transport Facilities
• Material Handling
• Safety
• Waste Disposals
• Buildings
• Structural Designs
• Federal state and Local Laws and State
For a preliminary survey the factors of utmost importance are: Raw Materials,
Transport, Market and Energy Source.
143
• Design Problems
- Locations of Activities
- Dimensions
- Configurations
- Greenfield to Location of one new machine
• Reasons
- Changes in Demand
- Changes in Product Design
- New Machines
- Bottle Necks
- Too Large Buffers
- Too Long Transfer Times
Restrictions
Methods
• IMMER. The right equipment at the right place to Permit Effective Processing
• APPLE. Short Distances and Short Times
Goals
For our process the basic raw material is Ethanol from Sugarcane. Selected site is in
Chanar Tandlianwala Region district Faisalabad. All the site selection criteria
mentioned above are met here. In this region sugar cane is cultivated in ample
amounts and has many sugar mills situated so ample supply of ethanol is available at
optimum costs. Also the Regulatory bodies set standard rules are also easily met i.e.
related to safety of people and environment.
145
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