DESIGN OF A 60,000 TPA FORMALDEHYDE PRODUCTION PLANT VIA THE

VAPOUR-PHASE DEHYDROGENATION OF METHANOL USING SILVER

CATALYST
Onuorah, P. C., Lawson, O. T., Ujile, A. A. (Ph.D.)
onuorahpaschal@gmail.com
Department of Chemical/Petrochemical Engineering, Rivers State University of Science and
Technology.

1. INTRODUCTION Furthermore, Formaldehyde in a 37% wt.

Formaldehyde (CH2O), organic compound
representing the simplest form of the
aldehydes, occurs in nature and it is
formed from organic material by
photochemical processes in the
atmosphere. Formaldehyde is an important
metabolic product in plants and animals
(including humans), where it occurs in low
but measurable concentrations (Gayathri &
Muthamilarasi, 2005). It was discovered in
1859 by a Russian chemist Aleksandr
Butlerov, but in 1869, a German chemist
August Hofmann developed a practical
method to synthesize Formaldehyde from
Methanol. Formaldehyde is a colorless gas
with a distinctive pungent order highly
flammable with a flashpoint of 500 oC; the
heat of combustion is 134.1kcal/mol or
4.47kcal/g. It is soluble in a variety of
solvents and is miscible with water
(Arreeyah & Kittisupakorn, 2014).
Formaldehyde is an important industrial
chemical and is employed in the
manufacture of many industrial products
and consumer articles. Formaldehyde is a
very important intermediate in the
synthesis of several resins such as Urea
formaldehyde, Melamine formaldehyde,
Phenol formaldehyde, Polyoxymethylene
and Methylenediphenol diiosocyanate etc.
This versatility of formaldehyde has led to
much increase in its demand.
solution with water (Formalin) is used to
prevent decay of animal matter. In 2012,
Formaldehyde production capacity was
more than 40.9 million tons and its
consumption exceeded 40.8 million tons
(Merchant Research and Consulting Ltd.,
2014) and is estimated to reach 80 million
tons by 2020, showing that there is a
growing demand for Formaldehyde
ranging from embalming to antiseptics to
its vast use as a resin and so on. In Nigeria,
the demand for Formaldehyde is met
entirely through import, as there are no
local producers. Because Methanol is
manufactured from Synthesis gas which
can either be a product of the Fischer-
Tropsch synthesis or direct product from
methane, there have been extensive efforts
to develop a one-step process that partially
oxidizes methane to formaldehyde.
This work is a fully integrated and detailed
report on the design of a 60,000 TPA
Formaldehyde production plant. The
design equations developed for the reactor,
absorber, distillation column and Pipelines
were solved using a POLYMATH 7.1
program and an excel spreadsheet.
2. RELEVANCE TO LOCAL NEED
Because of its low cost and high purity,
Formaldehyde has become one of the most
important industrial and research chemical
in the world. Formaldehyde is a building
block in the synthesis of many other The catalyst used in this process is Silver
compounds of specialized and industrial with a bulk density of 1500 kg catalyst per
significance. Its vast relevance range is as unit reactor volume. They are spherical in
described above. shape with a diameter of 1mm and
porosity of 0.5.
3. PROCESS DESIGN/SELECTION
The reactor effluent (343oC, 1.7 atm) and a
Computations and simulations in this work fresh stream of Water (30 oC, 1.2 atm) is
were done using the following as basis: sent to the Absorber. Absorption of 99%
formaldehyde is expected a Formaldehyde-
PLANT LOCATION: Lekki Free Trade
in-water solution is recovered. This is sent
Zone (LFTZ), Lekki, Lagos State, Nigeria.
to the Distillation Column which separates
PLANT CAPACITY: 60,000 TPA the overhead methanol stream (68.3oC, 1.2
CH2O. atm), recycled back to feed mixing point
from the bottom Formaldehyde stream,
PLANT ATTAINMENT/OPERATING pumped out and mixed with Deionized
FACTOR: 335 days/year (8,040 hrs a water, forming a 37 wt. % Formaldehyde
year). stream which is sent for storage.
RAW MATERIAL/FEED: MeOH and The Plant Block Diagram, Process Flow
O 2. Diagram, Piping and Instrumentation
Diagram and Plant Layout are shown in
The Reactor is a Packed-bed Reactor
Appendix A. Plant land space is 6.48
designed as a shell-and-tube reactor with
hectares (64,800m2 , 16.012 acres) and
catalysts packed in the tubes. It receives
power generation using 500 GE 1.5sle
two streams, a mixture of fresh Methanol
wind turbines was proposed.
(25oC, 1 atm) and recycled Methanol
(68.3oC, 1.2 atm) pumped to 3 atm and
vaporized to 150oC, as well as fresh Air
(25oC, 1 atm) compressed to 3 atm and
heated by medium-pressure steam to a
temperature of 150oC. Reactions occur at
very high temperatures (600 – 650oC). The
first exothermic reaction produces around
50 - 60% of the total Formaldehyde
formed. The rest is produced by the second
endothermic reaction. A conversion is
about 87.4%. The vapour-phase
dehydrogenation occurs as follows:
Figure 1.1: Aerial view of the Lekki Free
1 Trade Zone (LFTZDC, 2014)
𝐶𝐶3 𝐶𝐶 + 𝐶2 → 𝐶𝐶𝐶𝐶 + 𝐶2 𝐶
2
4. MATERIAL & ENERGY
𝐶𝐶3 𝐶𝐶 → 𝐶𝐶𝐶𝐶 + 𝐶2 BALANCE
 Mass and energy balance was based on the Formaldehyde produced = 22200 TPA,
Conservation Principle: Hydrogen produced = 596.222 TPA,
Water produced = 7991.728 TPA,
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = 𝐶𝐶𝐶𝐶𝐶 − Nitrogen produced = 11687.402 TPA. At
𝐶𝐶𝐶𝐶𝐶𝐶 + 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 − 87.4% conversion, Methanol supplied =
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 1.1 27105.759 TPA and Oxygen = 7097.84
TPA.
At steady state: 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 =
0 1.2 Material balance around mixing points and
unit operations are shown in the tables
From stoichiometry, at a concentration of
below.
37 wt. % Formaldehyde in Water, pure

Component Moles in Mole Moles in Mole Moles out Mole

Fresh Fraction Recycled Fraction Fraction
Stream Stream
Methanol 91.96 1.0000 13.257 0.95 105.217 0.9934
Water 0 0 0.698 0.05 0.698 0.0066
Total 91.96 1.0000 13.955 1.0000 105.915 1.0000

Table 1.1: Material Balance around streams 1, 2 & 15.

Component Moles in Mole Moles in Mole Moles out Mole

Methanol Fraction Air Stream Fraction Fraction
Stream
Methanol 105.217 0.9934 0 0 105.217 0.4434
Water 0.698 0.0066 0 0 0.698 0.0029
Oxygen 0 0 27.588 0.21 27.588 0.1163
Nitrogen 0 0 103.783 0.79 103.783 0.4374
Total 105.915 1.0000 131.371 1.0000 237.286 1.0000

Table 1.2: Material Balance around streams 6, 7, & 8.

Componen Moles Mole Moles Mole Moles Mole Moles Mole

t in Fractio Consum Fractio Generat Fractio in Fracti
Feed n ed n ed n Produc on
t
Methanol 105.21 0.4434 91.96 0.7692 0 0 13.257 0.0440
7
Oxygen 27.588 0.1163 27.588 0.2308 0 0 0 0
Formaldeh 0 0 0 0 91.96 0.50 91.96 0.3049
yde
Water 0.698 0.0029 0 0 55.176 0.30 55.874 0.1852
Hydrogen 0 0 0 0 36.784 0.20 36.784 0.1219
Nitrogen 103.78 0.4374 0 0 0 0 103.783 0.3440
3
Total 237.28 1.0000 119.548 1.0000 183.920 1.0000 301.658 1.0000
6

Table 1.3: Material balance around the Reactor.

Componen Moles Mole Moles in Mole Moles Mole Moles in Mole

t in inlet fracti inlet fracti in fracti outlet fracti
gas on liquid on outlet on liquid on
stream stream gas stream
stream
Methanol 13.257 0.0440 0 0 0 0 13.257 0.0514
Formaldeh 91.96 0.3049 0 0 0.276 0.0014 91.684 0.3557
yde
Water 55.874 0.1852 153.267 1.0000 56.334 0.2857 152.807 0.5929
Hydrogen 36.784 0.1219 0 0 36.784 0.1866 0 0
Nitrogen 103.78 0.3440 0 0 103.78 0.5264 0 0
3 3
Total 301.65 1.0000 153.267 1.0000 197.17 1.0000 257.748 1.0000
8 7

Table 1.4: Material Balance around the Absorber.

Component Column Mole Distillate Mole Bottoms Mole

feed fraction fraction fraction
Methanol 13.257 0.0514 13.257 0.95 0 0
Formaldehyde 91.684 0.3557 0 0 91.69 0.3761
Water 152.807 0.5929 0.698 0.05 152.109 0.6240
Total 257.748 1.0000 13.955 1.0000 243.793 1.0000

Table 1.5: Material Balance around the Distillation Column.

Component Moles in Mole Moles in Mole Moles out Mole

Formaldehyde Fraction D. Water Fraction Fraction
Stream Stream
Formaldehyde 91.96 0.3761 0 0 91.96 0.37
Water 152.109 0.6240 4.003 1.0000 156.112 0.63
Total 91.96 1.0000 13.955 1.0000 247.795 1.0000
 Table 1.6: Material Balance around streams 17, 18 & 19.

For energy balance we have that: capacities of the various components in the
system were calculated using the
𝐶 = 𝐶𝐶∆𝐶 = expression: 𝐶𝐶(𝐶) = 𝐶 + 𝐶𝐶 + 𝐶𝐶2 +
𝐶𝐶𝐶𝐶𝐶 1.3 The heat
𝐶𝐶3 1.4
The constants used in equation 4.4 were obtained from Sanhoob et al, (2012).

Streams In Heat Load Streams In Heat Load

(KJ/hr) (KJ/hr)
Stream 3 45429.141 Stream 20 356284.82
Methanol Vaporizer (E- 3913003.535 Distillation Column 512229.568
101) Condenser (E-104)
Air Heater (E-102) 49.21 Product Cooler 274.636
(E-106)
Absorber Effluent Heater 119326.682 Packed-Bed 4426996.718
(E-103) Reactor (R-101)
Distillation Column 719619.09
Reboiler (E-105)
Air Compressor (C-101) 495316.15
Methanol Feed Pump (P- 1107.32
101)
Distillation Column 606.84
Reflux Pump (P-102)
Distillation Column 1727.787
Bottoms Pump (P-103)

Total 5296185.755 Total 5295785.742

Table 1.7: Heat flow into the System Table 1.8: Heat flow out of the System

Heat flow in – Heat flow out = (5296185.755 – 5295785.742) KJ/hr = 400.013 KJ/hr

Percentage error = 0.0076%, acceptable.

Equipment Heat In Heat Out Error % Error

(105 KJ/hr) (105 KJ/hr) (105 KJ/hr)
Absorption Column 0.298414 0.29943 -0.001016 -0.034
Distillation Column 1.492697 1.491699 0.000998 0.067
Total 1.791111 1.791129 -0.000018 0.033

Table 1.9: Component Heat Balance.

5. EQUIPMENT DESIGN/SIZING DESIGN ITEM SPECIFICATION

Products Formaldehyde,
Water and Column Pressure Drop
Hydrogen (mmH2O per meter 42

Vertical Packing)
Orientation

Number of Tubes 140 Column Diameter (m) 1.1

Length of Tubes (m) 6 Column Height (m) 13.5

Total Catalyst Weight 1798

Orientation Vertical
(kg)

Catalyst Weight per 12.843 Table 1.11: Absorber Design Summary

Tube (kg)
DESIGN ITEM SPECIFICATION
Reactor Volume (m3) 1.199
Maximum Operating 393
Reactor Height (m) 7.5
Temperature (K)
Reactor Diameter (m) 0.457
Maximum Operating 121.59

Table 1.10: Reactor Design Summary Pressure (KPa)

Tray type SS Sieve Trays

DESIGN ITEM SPECIFICATION
Flow Type Gas – Liquid

Maximum Operating Counter – flow

101.325
Pressure (KPa) Number of 28 plus Reboiler

Maximum Operating Trays/Stages

438
Temperature (K) Feed Tray 4 (from the

Random (Ceramic Reboiler)

Type of Packing INTALOX® Number of Tray Single Pass
Saddles)
Passes
Packing Size (mm) 51
Downcomer Type Segment: Vertical

Packing Bulk Density Apron

609
(kg/m3 )
Hole Type Punched
Number of Holes 375 Minimum Shell 6
Thickness (mm)
Tray Spacing (mm) 500
Inlet & 100 Drain 25
Plate Thickness (mm) 3
Outlet Nozzle
Weir Height (mm) 50 Nozzle (mm)
Diameter
Weir Length (mm) 389
(mm)
Hole Diameter (mm) 6
Nozzle Thickness (mm) 6
Column Diameter 526 Head Type Torispherical
Domed Heads (both
(mm)
ends)
Column Height (m) 14.1
Minimum Head 6
Thickness (mm)
Table 1.12: Absorber Design Summary.
Number of Baffles 32
The Heat exchangers and Pipeline design Baffle cut 25 Baffle 6
datasheets are shown after the mechanical (%) Thickness (Standar
design tables shown below.
(mm) d)
6. MECHANICAL DESIGN Diameter of Tie Rods 10

MATERIAL PROPERTIES (mm)

Diameter of Spacers 8
Equipment Number R-101
(mm)
Equipment Service Combines Methanol
Flange Material IS 2004-1962 Class
and Oxygen in
2 Carbon Steel
stoichiometric
Gasket Material Asbestos
proportions to yield
Gasket Thickness (mm) 10
desired products
Bolt 317 Minimum 5634.03
Material of 321 Design 334
Material Stainless Bolting 9
Construction Stainless Pressure
Steel Area
Steel (KPa)
(mm2)
Material 8030 Material 220
Number of 13 Bolt 24
Density Allowable
Bolts Diameter
(kg/m3) Stress
(mm)
(MPa)
TUBE SIDE
SHELL SIDE
Minimum Tube 10 Diameter Thickness
Thickness (mm) (mm) (mm)
Tube Nozzle 100 Nozzle 6
Head Type Hemispherical Minimum 6
Diameter Thickness
Domed Head Head
(mm) (mm)
Thickness
Vessel Steel Support IS 2004-
(mm)
Support Saddles Material 1962
Class 2 Axial Stress due to Pressure 6957.5
Carbon (KPa)
Steel
Prepared by: Team PASON, Rivers State Diameter of Manhole (mm) 500

University of Sci. and Tech. © 2015

Vessel Skirt Skirt 1100
Support Diamete
Table 1.13: Reactor Mechanical Datasheet.
r (mm)
Equipment T-101
Skirt 15 Skirt 1000
Equipment Service Separates Thickness Height
Formaldehyde (mm) (mm)
from Off-gases
in Reactor Diameter of 200 Thickne 2

products using Nozzles ss of

Water as an (mm) Nozzles

absorbent. (mm)

Material of 304 Stainless Design 151 Bolts used on Skirt 18

Constructio Steel Pressure .8

Prepared by: Team PASON, Rivers State
n (KPa)
University of Sci. and Tech. © 2015

Material 8030 Material 135

Density Allowabl Table 1.14: Absorber Mechanical
(kg/m3) e Stress Datasheet

(MPa) Equipment Number T-102

Separates light
Shell 1112 Minimum 6 Equipment Service
end products from
(Outer) Shell
 heavy end Weight of
Weight of 19.2
products using Liquid 70.364
Shell (KN) 75
differences in (KN)
boiling points Stress due
Weight of
Material 13 to Weight
Design Head and
of 304 Stainless 3. 1.928 of 389
Pressure Attachmen
Constructi Steel 67 Attachmen
(KPa) ts (KN)
on 2 ts (KPa)
Material Material Diameter of Manhole
13 500
Density 8030 Allowable (mm)
5
(kg/m3) Stress (MPa) Skirt
Vessel
Hole Pitch (mm) 15 Skirt Diameter 526
Support
Shell Minimum (mm)
(Outer) Shell Skirt Skirt
538 6
Diameter Thickness Thickness 4 Height 400
(mm) (mm) (mm) (mm)
Minimum Diameter of Nozzles (mm) 200
Hemispheric
Head Thickness of Nozzles (mm) 2
Head Type al Domed 6
Thickness Prepared by: Team PASON, Rivers State
Head
(mm) University of Sci. and Tech. © 2015
Axial Stress due to Table 1.15: Distillation Column
5830
Pressure (KPa) Mechanical Datasheet.

Heat Exchanger Design Datasheets

Equipment E-101 (Methanol Vaporizer)

Equipment Service Evaporates liquid Methanol at 3 bar and 3384
kg/hr to 150oC
Tube-side Data Shell-side Data
Heat Duty (KW) 1086 MOC Carbon MOC Carbon
Steel Steel
Overall Heat 500 Number of Tube 2 Number of Shell 1
Transfer Coefficient Passes Passes
(W/m2o C)
LMTD (o C) 66.45 Tube Pitch (m) 0.025 Shell Diameter (m) 0.428
Temp. Difference 0.85 Bundle diameter 0.374 Baffle Spacing (m) 0.171
Correction Factor, (m)
Ft
True Temperature 56.48 Bundle Diameter 0.054 Cross-flow Area 0.015
Difference, (oC) Clearance (m) (m2)
Provisional Area 38.49 Tube Cross- 2.011E-4 Shell-side Flowrate 5.527
2 2
(m ) sectional Area (m ) (kg/s)
Thermal 54.5 Tube-side Flowrate 0.94 Shell Equivalent 0.014
Conductivity (kg/s) Diameter (m)
2o
(W/m C)
Exchanger Head Split Tube-side Velocity 0.075 Shell-side Velocity 0.415
Ring (m/s) (m/s)
Tube Outer 0.02 Tube-side Prandtl 10.907 Shell-side Prandtl 1.087
Diameter (m) Number Number
Tube Inner 0.016 Tube-side Reynolds 1794.353 Shell-side Reynolds 19,479.216
Diameter (m) Number Number
Number of Tubes 160 Tube-side Heat 115.201 Shell-side Heat 3278.191
Transfer Coefficient Transfer
(W/m2o C) Coefficient
(W/m2o C)
Length of Tubes (m) 4 Tube-side Pressure 9956.764 Shell-side Pressure 5845.824
2 2
Drop (N/m ) Drop (N/m )
Overall Heat Transfer Coefficient (W/m 2o C) 85.258
Prepared by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table 5.4: Methanol Vaporizer Design Datasheet.

Equipment E-102 (Air Heater)

Equipment Service Heats compressed air at 3 bar and 2337kg/hr to a
temperature of 150oC
Tube-side Data Shell-side Data
Heat Duty (KW) 117.156 MOC Carbon MOC Carbon
Steel Steel
Overall Heat 116 Number of Tube 2 Number of Shell 1
Transfer Coefficient Passes Passes
(W/m2o C)
LMTD (o C) 64.158 Tube Pitch (m) 0.025 Shell Diameter (m) 0.328
Temp. Difference 0.87 Bundle diameter 0.274 Baffle Spacing (m) 0.131
Correction Factor, (m)
Ft
True Temperature 55.818 Bundle Diameter 0.054 Cross-flow Area 0.009
Difference, (oC) Clearance (m) (m2)
Provisional Area 18.094 Tube Cross- 2.011E-4 Shell-side 5.527
(m2) sectional Area Flowrate (kg/s)
2
(m )
Thermal 54.5 Tube-side 0.649 Shell Equivalent 0.014
Conductivity Flowrate (kg/s) Diameter (m)
2o
(W/m C)
Exchanger Head Split Tube-side 0.048 Shell-side Velocity 0.692
Ring Velocity (m/s) (m/s)
Tube Outer 0.02 Tube-side Prandtl 0.694 Shell-side Prandtl 1.087
Diameter (m) Number Number
Tube Inner Diameter 0.016 Tube-side 26,818.192 Shell-side 11,218.35
(m) Reynolds Number Reynolds Number
Number of Tubes 80 Tube-side Heat 1206.463 Shell-side Heat 2284.055
Transfer Transfer
Coefficient Coefficient
(W/m2o C) (W/m2o C)
Length of Tubes (m) 4 Tube-side 19.494 Shell-side Pressure 5712.526
Pressure Drop Drop (N/m2 )
(N/m2)
Overall Heat Transfer Coefficient (W/m 2o C) 536.237
Prepared by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table 1.16: Air Heater Design Datasheet.

Equipment E-103 (Absorber Effluent Heater)

Equipment Service Heats Absorber effluent at 5930kg/hr to a
temperature of 102oC
Tube-side Data Shell-side Data
Heat Duty (KW) 33.146 MOC Carbon MOC Carbon
Steel Steel
Overall Heat 500 Number of Tube 2 Number of Shell 1
Transfer Coefficient Passes Passes
(W/m2o C)
LMTD (o C) 11.908 Tube Pitch (m) 0.025 Shell Diameter (m) 0.341
Temp. Difference 0.85 Bundle diameter 0.288 Baffle Spacing (m) 0.136
Correction Factor, (m)
Ft
True Temperature 10.122 Bundle Diameter 0.053 Cross-flow Area 0.009
Difference, (oC) Clearance (m) (m2)
Provisional Area 16.55 Tube Cross- 2.011E-4 Shell-side Flowrate 3.762
2 2
(m ) sectional Area (m ) (kg/s)
Thermal 54.5 Tube-side 1.647 Shell Equivalent 0.014
Conductivity Flowrate (kg/s) Diameter (m)
2o
(W/m C)
Exchanger Head Split Tube-side Velocity 0.238 Shell-side Velocity 0.471
Ring (m/s) (m/s)
Tube Outer 0.02 Tube-side Prandtl 1.693 Shell-side Prandtl 2.019
Diameter (m) Number Number
Tube Inner 0.016 Tube-side 12,649.18 Shell-side Reynolds 18,509.10
Diameter (m) Reynolds Number 3 Number 8
Number of Tubes 90 Tube-side Heat 752.47 Shell-side Heat 1000.239
Transfer Transfer
Coefficient Coefficient
(W/m2o C) (W/m2o C)
Length of Tubes (m) 3 Tube-side Pressure 419.777 Shell-side Pressure 1697.307
2 2
Drop (N/m ) Drop (N/m )
Overall Heat Transfer Coefficient (W/m 2o C) 317.269
Prepared by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table 1.17: Absorber Effluent Heater Design Datasheet.

Equipment E-106 (Final Product Cooler)

Equipment Service Cools down final product at 5565.245kg/hr to a
temperature of 30oC
Tube-side Data Shell-side Data
Heat Duty (KW) 30.827 MOC Carbon MOC Carbon
Steel Steel
Overall Heat 250 Number of Tube 2 Number of Shell 1
Transfer Coefficient Passes Passes
(W/m2o C)
LMTD (o C) 8.372 Tube Pitch (m) 0.025 Shell Diameter (m) 0.341
Temp. Difference 0.9 Bundle diameter 0.288 Baffle Spacing (m) 0.136
Correction Factor, (m)
Ft
True Temperature 7.375 Bundle Diameter 0.053 Cross-flow Area 0.009
Difference, (oC) Clearance (m) (m2)
Provisional Area 16.72 Tube Cross- 2.011E-4 Shell-side 6.004
2
(m ) sectional Area Flowrate (kg/s)
(m2)
Thermal 54.5 Tube-side 1.546 Shell Equivalent 0.014
Conductivity Flowrate (kg/s) Diameter (m)
(W/m2o C)
Exchanger Head Split Tube-side Velocity 0.192 Shell-side Velocity 0.671
Ring (m/s) (m/s)
Tube Outer 0.02 Tube-side Prandtl 3.014 Shell-side Prandtl 3.643
Diameter (m) Number Number
Tube Inner 0.016 Tube-side 4,822.691 Shell-side 11,671.998
Diameter (m) Reynolds Number Reynolds Number
Number of Tubes 90 Tube-side Heat 351.355 Shell-side Heat 3579.681
Transfer Transfer
Coefficient Coefficient
(W/m2o C) (W/m2o C)
Length of Tubes (m) 3 Tube-side 372.382 Shell-side Pressure 4520.601
Pressure Drop Drop (N/m2 )
(N/m2)
Overall Heat Transfer Coefficient (W/m 2o C) 231.056
Prepared by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table 1.18: Final Product Cooler Design Datasheet.

Equipment E-104 (Distillate Condenser)

Equipment Service Condenses top product of Distillation Column at
1.2 bar to 68oC
Tube-side Data Shell-side Data
Heat Duty (KW) 139.465 MOC Carbon MOC Carbon Steel
Steel
Overall Heat 700 Number of Tube 4 Number of 1
Transfer Coefficient Passes Shell Passes
 (W/m2oC)
LMTD (o C) 13.61 Tube Pitch (m) 0.025 Shell Diameter 0.899
(m)
Temp. Difference 0.98 Bundle diameter 0.692 Baffle Spacing 0.899
Correction Factor, (m) (m)
Ft
True Temperature 13.33 Bundle Diameter 0.095 Cross-flow 0.231
Difference, (oC) Clearance (m) Area (m2)
Heat transferred 1692.89 Tube Cross- 9.64E-2 Shell-side 13.318
from Vapour (KW) sectional Area (m2) Flowrate
(kg/s)
Trial Area (m2 ) 181 Tube-side Flowrate 0.122 Shell 0.02
(kg/s) Equivalent
Diameter (m)
Tube Outer 0.02 Tube-side Velocity 1.8 Shell-side 0.058
Diameter (m) (m/s) Velocity (m/s)
Tube Inner Diameter 0.016 Tube-side Reynolds 28,776 Shell-side 19,479.216
(m) Number Reynolds
Number
Length of Tubes (m) 6 Tube-side Heat 8303.448 Shell-side 1400
Transfer Heat Transfer
Coefficient Coefficient
(W/m2o C) (W/m2o C)
Number of Tubes 480 Tube-side Pressure 267.002 Shell-side 17.328
Drop (N/m2 ) Pressure Drop
(N/m2)
Number of tubes in 28 Condenser Pull-through
centre row Head Floating Head
Overall Heat Transfer Coefficient (W/m 2o C) 700
Prepared by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table 1.19: Distillate Condenser Design Datasheet.

Equipment E-105 (Bottoms Reboiler)

Equipment Service Heats up bottom product of Distillation at 1 bar
to 120oC
Total Heat Duty, including 5% for heat loss (KW) 1998.31
Mean Temperature Difference (oC) 115 True Temperature Difference, (o C) 13
Required Provisional Area (m2) 63.65
Inner Diameter (m) 0.016 Outer Diameter (m) 0.02
Tube Length (m) 6
Number of Tubes 168 Tube Pitch (m) 0.03
Heat Flux based on estimated Area 31.4 Nucleate Boiling Coefficients 1852.57
(KW/m 2) (W/m2o C)
Overall Heat Transfer Coefficient (W/m 2o C) 1000
Prepared by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table 1.20: Bottoms Reboiler Design Datasheet.

7. ECONOMICS AND COST (1708 17

ANALYSIS m3/h)
7.1. CAPITAL COST
Driver 4900 168 137.5 0.6 812,449.
Equipm A B S n Ce ($) 00 00 9 275
ent E-101 2400 46 38.49 1.2 27,674.3
P-101 6900 206 1.8 0.9 7,249.63 0 06
(1.8 L/s) 3 E-102 2400 46 18.09 1.2 25,485.2
Driver 950 177 0.5 0.6 2,117.76 0 4 49
0 5 E-103 2400 46 16.55 1.2 25,334.4
P-102 6900 206 1.1 0.9 7,107.77 0 9
(1.1 L/s) 5 E-104 2400 46 181 1.2 47,548.9
Driver 950 177 0.5 0.6 2,117.76 0 81
0 5 E-105 2400 46 63.65 1.2 30,719.1
P-103 6990 206 3.57 0.9 7,637.54 0 75
(3.57 3 E-106 2500 340 16.72 0.9 29,289.3
L/s) 0 51
Driver 950 177 0.5 0.6 2,117.76 T-101 1500 68 1105. 0.8 41,282.6
0 5 0 91 5 8
C-101 3800 49 1708 0.8 22,688.0 Packing 0 180 12.83 1.0 23,093.0
s 0 62
Methanol 0.25 27.106 6776.44
T-102 1500 68 1199. 0.8 43,163.3
0 58 5 13 ANNUAL OPERATING LABOUR COSTS
Sieve 110 380 0.526 1.8 229.552
Number Shift per Operator Annual
Tray
For 28 6,427.45 of day rate operating

trays 6 operators ($/hr) labour cost,

R-101 2400 46 52.11 1.2 29,285.2 per shift million $/yr

0 8 21
9 3 2.1 0.05065

1,192,78 Table 1.22: Material and Personnel Cost.

8.822
Utility cost
Table 1.21: Estimated Cost of Equipment.
Utilities Description Annual utility
7.2. OPERATING COST AND
INCOME ESTIMATION cost in
million $/yr

ANNUAL RAW MATERIAL COSTS AND

Medium 10 bar, 184oC 1.64x10-5
PRODUCTS VALUES
pressure

Products, co-products and by-products stream

Name of Price Annual Annual Raw water Water supply 2x10-3

material ($/kg) capacity, value, throughout the

million million($/yr) plant

(kg/yr)
Deionized Water to 5.7936x10-4

Formaldehyde 1.01 60 60.6 water dissolve

formaldehyde
Hydrogen 0.72 0.6 0.42
Waste water 1x10-3
Nitrogen 0.12 11.682 1.402 treatment

Total Product Value = USD 62.422 million Waste water 1.88x10-5

disposal
Raw material
 e and
Process 2.2431x10-2
repairs
water
Operating 0.009FCI 90,450
Total utility cost = $766,955.56
supplies

Table 7.3: Utility Cost.

Laboratory 0.15COL 7,597.8
charges
Formaldehyde Production Plant Analysis
Patent and 0.03COM 152,241.081
4
Capacity 6.0x10 TPA
royalties

Fixed $10.05 million

Total Direct Manufacturing Cost =
Capital
$1,546,829.343
Investment
(FCI) Fixed Manufacturing Cost

Cost item Equation used Annual cost Depreciatio 0.1FCI 1,005,000

for calculation ($/yr) n

Direct Manufacturing Cost Local taxes 0.032FCI 321,600

and
Raw CRM 6,776.44
insurance
materials
Plant 0.708COL + 397,661.616
Waste CWT 1,000
overhead 0.036FCI
treatment
cost

Utilities CUT 766,955.56

Total Fixed Manufacturing Cost =

Operating COL 50,652 $1,724,261.616

labour
General Manufacturing Expenses

Direct 0.18COL 9,117.36

Administrati 0.177COL+0.00 99,415.404
supervisory
on costs 9FCI
and clerical
labour Distribution 0.11COM 558,217.297
and selling
Maintenanc 0.06 FCI 603,000
costs Air Products and Chemicals, Inc., (1997),
Material Safety Data Sheet (Nitrogen).
Research 0.05COM 502,500 Pennsylvania, USA: Air Products and
Chemicals, Incorporated.
and
Ajayi, O. O., Fagbenle, R. O., Katende, J.,
Developmen Ndambuki, J. M., Omole, D. O., &
t Badejo, A. A., (2014), Wind Energy
Study and Energy Cost of Wind
Electricity Generation in Nigeria: Past
Total General Manufacturing Expenses =
and Recent Results and a Case Study
$1,160,132.701 for South West Nigeria, Energies
Journal, Vol. 7, pp. 8508 – 8534; doi:
Cost of 0.280FCI+2.73 3,905,200.32 10.3390/en7128508.

manufacturi COL+1.23(CUT Christy Catalytics, (2010), Pressure Drop

Calculations through Fixed Beds of
ng with +CWT+CRM)
PROX-SVERS® Catalyst Support
depreciation Balls. Missouri, USA: Christy
Catalytics LLC.
Cost of 0.180FCI+2.73 2,900,200.32
Committee of Stainless Steel Producers,
manufacturi COL+1.23(CUT (2002), Design Guidelines for the
Selection and Use of Stainless Steel.
ng without +CWT+CRM)
Colorado, USA: American Institute of
depreciation Mining, Metallurgical and Petroleum
Engineers (AIME).
Table 1.23: Plant Analysis with and
Dagde, K. K., & Akpa, J. G., (2014),
without Depreciation. Computer-Aided Design of a Non-
isothermal Plug Flow Reactor for Non-
REFERENCES Catalytic Partial Oxidation of Methane
to Synthesis Gas, Chemical and
Agbetuyi, A. F., Akinbulire, T. O., Process Engineering Research, Vol.
Abdulkareem, A., Awosope, C. O. A., 28, pp. 9 – 20.
(2012), Wind Energy Potential in
Nigeria, International Electrical Drake, R. M., & Walter, R. J., (2010),
Engineering Journal, Vol. 3, (1), pp. Design of Structural Steel Pipe Racks,
595 – 601. Engineering Journal, pp. 241-252.
Airgas USA, LLC., (2014), Nitrogen Fogler, H. S., (2011), Elements of
Safety Data Sheet. Pennsylvania, USA: Chemical Reaction Engineering. (3rd
Information Handling Services, ed.). Massachusetts, USA: Prentice-
Incorporated. Hall International, Incorporated.
Air Products and Chemicals, Inc., (1997), Gayathri, S., & Muthamilarasi, G., (2005),
Material Safety Data Sheet (Oxygen). Manufacture of Formaldehyde from
Pennsylvania, USA: Air Products and Methanol. (B. Tech. Project). Tamil
Chemicals, Incorporated. Nadu, India: Chemical Engineering
Department, SRM University.
 Kandiyoti, R., (2009), Fundamentals of
Reaction Engineering. Frederiksberg,
Denmark: Ventus Publishing ApS.
Khorsidi, J., & Kalbasi, M., (2007), Study
of Methanol to Formaldehyde Reaction
in Fluidized Bed Reactor. In:
Proceedings of the 12 th International
Conference on Fluidization – New
Horizons in Fluidization Engineering,
May, 2007. Vancouver, Canada, pp.
615 – 622.
Sanhoob, M. A., AL-Sulami, A., Al-
Shehri, F., & Al-Rasheedi, F., (2012),
Production of Formaldehyde from
Methanol. Dhahran, Saudi Arabia:
Chemical Engineering Department,
King Fahd University of Petroleum
and Minerals.
Sinnott, R., & Towler, G., (2009),
Chemical Engineering Design Volume
6. New Delhi, India: Reed Elsevier
India Private Limited.

LFTZDC, (2014), Lekki Free Trade Zone.
Retrieved from http://www.lftzdc.org/.
Merchant Research and Consulting Ltd.,
(2014), “World Formaldehyde
Production to exceed 52 Mln Tonnes in
2017”. Retrieved from
http://mcgroup.co.uk/news/20140627/f
ormaldehyde-production-exceed-52-
mln-tonnes.html.
R.F.C.S. Project, (2006), Design Manual
for Structural Stainless Steel. (3rd ed.).
West Berkshire, United Kingdom: The
Steel Construction Institute.
APPENDIX
TLV Company, LTD. (2015), Saturated
Steam Tables by Pressure. Retrieved
from
http://www.tlv.com/global/TI/calculato
r/steam-table-pressure.html.
VLE-Calc, (2015), Vapour-liquid
Equilibrium Database, Calculations
and Phase Diagram Drawing.
Retrieved from http://vle-
calc.com/phase_diagram.html.

Nominal Outside Volumetric Viscosity Velocity Reynolds Flow Length Mater

r Pipe Size Diameter flowrate (Ns/m2) (m/s) Number Profile (m) Constr
(inches) (m) (m3/s)
10 0.2731 0.552357447 5.36E-06 2.725228 36019.45611 Turbulent 5 Carbon
6 0.1683 0.001037939 5.38E-04 3.63E-01 32108.2774 Turbulent 7.5 Carbon
6 0.1683 0.001197657 0.000501 0.418963 39577.87835 Turbulent 2 Carbon
6 0.1683 0.001197657 0.000501 0.418963 39577.87835 Turbulent 3 Carbon
10 0.2731 0.552357447 4.97E-06 2.725228 38859.88461 Turbulent 6 Carbon
10 0.2731 0.34343391 0.000188 2.09E+00 1832.823175 Laminar 8.5 Carbon
10 0.2731 0.552357447 2.93E-06 2.725228 65864.09218 Turbulent 6.3 Carbon
10 0.2731 0.618774122 6.81E-05 2.523071 5742.227152 Turbulent 5.125 Carbon
10 0.2731 1.382542029 2.98E-05 3.031646 7055.799827 Turbulent 15 Stainle
10 0.2731 1.382542029 2.98E-05 3.03E+00 7055.799827 Turbulent 5 Stainle
 6 0.1683 0.000770229 0.001021 0.421071 24765.71243 Turbulent 14.14 Carbon
10 0.2731 1.236727749 0.000145 3.614901 863.3377467 Laminar 8 Stainle
5 0.1413 0.002156358 0.00023 0.347398 69483.24602 Turbulent 2 Stainle
5 0.1413 0.002244953 0.000202 3.62E-01 79164.17749 Turbulent 2.18 Stainle
5 0.1413 0.0001594 0.000341 0.18193 24532.28868 Turbulent 18.68 Carbon
5 0.1413 0.002146857 0.00018442 3.46E-01 80425.09387 Turbulent 3 Stainle
5 0.1413 0.002146857 0.00018442 0.345867444 80425.09387 Turbulent 3 Stainle
5 0.1413 2.01906E-05 0.000819619 2.43E-01 17730.3685 Turbulent 15 Stainle
5 0.1413 0.001749408 0.000459201 0.417636745 48486.38492 Turbulent 5 Stainle
5 0.1413 0.001710087 0.000641335 4.08E-01 34716.6402 Turbulent 4.08 Stainle
d by: Team PASON, Rivers State University of Sci. and Tech. © 2015

Table A-1: Pipeline Design Datasheet.

filter
o remove particles that could foul the Reactor (R-101) catalyst.
Deviation Cause Consequences Action Item Owner of Action

Transfers clear Air at atmospheric pressure and ambient temperature to Compressor (C-101).
Flow Partially blocked Possible dangerous Measure and log Operator
filter increase in Pressure differential
Methanol
concentration
S Composition Filter damaged; Impurities; possible Proper maintenance Technicians
incorrectly installed Catalyst poisoning
mpressor (C-101)
o supply Air at 3bar, 2337kg/hr, and 37 oC, to the Heat Exchanger

ransfer Air to Heat Exchanger

Flow Compressor failure Possible dangerous Pressure indicator with Instrument Enginee
increase in Low Pressure Alarm Technicians
Methanol interlocked to shutdown
concentration Methanol flow
Flow Failure of High rate of Temperature indicator Instrument Enginee
 Compressor reaction; High with High Temperature Technicians
controls reaction temperature Alarms attached to
Reactor
F Flow Fall in line pressure MeOH in heat Fit non-return valves on Instrument Enginee
exchanger; hot Lines 7 & 8 Technicians
Formaldehyde gas
in Compressor –
explosion hazard
Temperature Excess compression Possible Catalyst Install Shutdown Valve Instrument Enginee
ratio deactivation and on process flow inline Technicians
product degradation and Blowdown Valves
on compressor unit final
discharge line; install
TSH to protect
compressor case.
dium Pressure Heater (E-102)
o heat compressed Air to a temperature of 150 oC

ransfers/supplies Methanol – Water mixture at 3 bar, 3384kg/hr and 30 oC

Flow Leak as a result of Low product yield; Pressure indicator with Instrument Enginee
impact damage, drop in line Low Pressure Alarm Mechanical Enginee
corrosion, pressure; potential interlocked to shutdown Technicians
deterioration etc. hazard exposure air flow; ensure
corrosion protection and
regularly assess pipeline
integrity

ransfers fresh Methanol mixed with the recycle stream to Pump (P-101)
Flow Check valve stuck As LESS OF in
in the closed Line 3
position
Flow Check valve As NO
partially closed
ransfers mixed Methanol stream to Heat Exchanger
Flow Pump failure Pressure build-up Fit Pressure safety Instrument Enginee
on Line 3; Pump devices on Pump Technicians
damage due to dry discharge line and
run Shutdown Valve
upstream of Pump to
shut-off inflow
Flow Failure of Pump Danger of high Fit analysers (duplicate) Instrument Enginee
controls Methanol with high alarm on Line Technicians
Concentration; 8
flooding of Catalyst
bed
hanol Vaporizer (E-101)
vaporates liquid Methanol at 3 bar and 3384 kg/hr to 150 oC

ransfers Methanol to Reactor (Mixing Tee)

Flow Pressure safety Hot air in Pump (P- Fit non-return valve on Instrument Enginee
device in Line 3 101) – explosion Line 5 Technicians
fails hazard
ctor (R-101)
xidizes Methanol with Air at 3 bar and 343 oC

ransfers feed to Reactor, 150 oC

Flow Non-return valve on No reaction Fit Low Temperature Instrument Enginee
Line 8 stuck in the Alarm on Temperature Technicians
closed position Indicator
Flow Leak due to Fall in reaction rate; Ensure adequate Mechanical Enginee
corrosion, impact potential hazard pipeline protection Instrument Enginee
damage etc.; non- exposure against corrosion, Technicians
return valve on Line impact damage etc.
8 partially closed Pressure indicator with
Low Pressure Alarm
 interlocked to shut-off
inflow

ransfers Reactor products to Throttle valve

S Composition Catalyst particles Possible plugging of Install Filter upstream Instrument Enginee
from Reactor Throttle nozzle of nozzle Technicians
orber
emoves Formaldehyde and unreacted Methanol from Reactor Products

ransfers Reactor products from Throttle valve to Absorber (T-101)

Temperature Throttle valve Inefficient gas- High temperature Instrument Enginee
failure liquid absorption as alarms added to Technicians
a result of high gas Temperature indicator
temperature in Absorber

ransfers Water to the Absorption Column

Flow Flow valve fails Inefficient Pressure indicator with Instrument Enginee
close; gets blocked absorption; gas Low Pressure Technicians
blowby in Line 13 interlocked to shut-off
Product inflow
Flow Partial valve failure As NO/NONE
Flow Flow valve fails Flooding of packed Fit Level indicator with Instrument Enginee
open Absorber bed level Safety Alarms at a Technicians
distance above the
highest operating liquid
level to prevent
nuisance shut-down

ransfers Off-gases to storage

Flow Leakage due to Possible hazard Ensure pipeline is Mechanical Enginee
corrosion, impact exposure protected from Instrument Enginee
damage corrosion, impact Technicians
deterioration etc. damage etc.; install gas
 detector alarms;
Regularly carry-out
pipeline integrity test

ransfers Absorber effluent to Distillation, 89oC

S Composition Inefficient Final product off- Fit analysers (duplicate) Instrument Enginee
absorption spec with high alarm Technicians
Flow Check valve stuck Line pressure build- Pressure indicator Instrument Enginee
in the close position up interlocked with High Technicians
Pressure Alarm
interlocked to shut-off
inflow
orber Effluent Heater
o heat Absorber effluent to a temperature of 102 oC

ransfers Mixed Liquids to Distillation Column

Flow Leak as a result of Potential hazard Ensure pipeline is Mechanical Enginee
corrosion, impact exposure; weeping protected from Technicians
damage, in separating tower; corrosion, exposure to
deterioration etc. inefficient impact damage;
separation regularly assess pipeline
integrity

ransfers Recycled stream to Mixing Valve (MXV-1)

F Flow Drop in liquid level Possible Fresh Fit non-return valves on Instrument Enginee
in Reflux drum (V- Methanol in Reflux Line 15; fit Level safety Technicians
101) drum; uncontrolled devices on Reflux drum
refluxing,
inefficient
separation
er Reservoir (WR-102)
tores Water ready to be deionized
ransfers Deionized Water to Mixing Valve (MXV-2)
F Flow Leak as a result of Hot Formaldehyde Ensure pipeline is Mechanical Enginee
corrosion, impact solution in Water protected from Instrument Enginee
damage, Reservoir; pollution corrosion, exposure to Technicians
deterioration etc. of Water body impact damage;
regularly assess pipeline
integrity; fit non-return
valve on Line 18
Team PASON, Rivers State University of Sci. and Tech. © 2015

Table A-2: HAZOP Study Report.

Methanol Recycl

Water Off Gas

REACTOR

Fresh Methanol 99%

ABSORBER Adsorb

Conversion
87.4%
Air

Mixed
Liquids

DI Water

Figure A-1: Block Flow Diagram.

Figure A-2: Plant Site Layout.
 68.3oC
1.2 atm

30oC
1.3 atm

3 atm 150oC

25oC 87.4%
1 atm Conversion
99%

25oC
1 atm

343oC

102oC

30oC

Figure A-3: Plant Process Flow Diagram.

Figure A-4: Piping and Instrumentation

Diagram 1
Figure A-5: Piping and Instrumentation Figure A-7: Piping and Instrumentation
Diagram 2 Diagram 4

Figure A-6: Piping and Instrumentation Figure A-8: Graph of Conversion against
Diagram 3 Catalyst Weight.
 Figure A-11: Reactor Volume against
Figure A-9: Graph of Flowrates against Catalyst Weight.
Catalyst Weight.

Figure A-10: Rate of formation of

Formaldehyde against Catalyst Weight.