3.1 Mass Transfer Equipment Design: H O CH Cooh CH

3.
1 Mass Transfer Equipment Design
The continuous distillation column with reflux works by returning a portion of the
condensate to the still and rising to vapour via a number of stages or trays, while the
balance of the condensate flows downward via the same series of stages or trays.
By applying and withdrawing heat, a distillation column is frequently used to

separate a mixture containing two or more components into their individual
components based on their varying volatility or boiling point. utilised in a distillation
column to chill and condense the vapour at the column's top, while reboilers heat
and vaporise the components, and a reflux drum is used to recycle the liquid back
into the column and store the condensed vapour leaving the column's top.
Components with a high volatility and a low boiling point can readily be vaporised,
whereas components with a low volatility and a high boiling point remain liquid.
Distillation Column D-1
S16 = 256.250kg/hr
ṁ H2O = 108.090 kg/hr
S15 = 25813.800 kg/h ṁ CH3COOHCH3 = 148.160 kg/hr

X H O = 0.422
2
ṁCH3COOH = 25261.230kg/hr
X CH COOH CH 3 =¿0.578
S16
3
ṁC2H5COOH = 296.320 kg/hr

T = 35 °C
ṁ H2O = 108.090 kg/hr
P = 120 kPa
ṁ CH3COOHCH3 = 148.160 kg/hr
X CH =0.972 Distillation
3 COOH
Column
XC 2 H 5COOH =¿9.245×10 -3 S18 = 25557.550kg/hr
S15
XH 2 O = 0.0139 ṁCH3COOH = 25261.230kg/hr
X CH 3 COOH CH 3 =¿4.623×10 -3 ṁC2H5COOH = 296.320 kg/hr
X CH 3 COOH =0.988
T = 120°C S18
XC 2 H 5COOH =¿0.0116
P = 300 kPa T = 126 °C
Specification Sheet of Distillation Column D-1
Equipment No: D-1

Function: To separate methyl acetate,
Distillation Column Data Sheet
water, acetic acid and propionic acid to
their boiling point.
Operating data
Material Stream 15 Stream 16 Stream 18
Total mass flow 25813.800 256.250 25557.550
rate (kg/h)
Total Molar Flow 432.656 8.000 424.656
Rate (kmol/h)
Mass flow rate of components (kg/h)
Acetic acid 25261.230 25261.230
Propionic acid 296.320 296.320
Water 108.090 108.090
Methyl acetate 148.160 148.160
Temperature (℃ ¿ 120 35 126
Technical Data
Number of trays 25
Feed stage from bottom 15
Pressure (kPa) 101
Height (m) 4.93
Inside diameter (m) 0.189
Reflux ratio 1.042
Tray spacing (m) 0.31
Type of material for construction Carbon steel
PLATE SPECIFICATION
Hole size (mm) 0.146
Active holes 49
Plate thickness (mm) 5
Plate pressure drop (mm liquid) 66.25
Type of material for plate Stainless steel 304

MECHANICAL DESIGN DATA
Design pressure (kPa) 1.11
Design temperature (℃ ¿ 55
Wall thickness (mm) 5
Type of ends Torispherical

End thickness (mm) 5
Fenske equation is used in estimating the minimum stages required at total reflux.
First step, identifying the light and heavy key components:
Light Key (LK) - most volatile component: methyl acetate
Heavy key (HK) - least volatile component: water
Using Fenske equation to identify the minimum stage:
XLK X HK
N min =
log [ ][
XHK D XHK ] B
From (Sinnott et al, 2005), pg 524
log ∝LK
Vapor pressure of inorganic & organic liquid :

From Table 2.8, Perry’s Chemical
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C5 Handbook 8th Edition Process, (2-55)
where T is the temperature in K.

P¿
K= P
Top Product (393.15 K , 130 kPa ¿:
Methyl acetate :
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5 ,
(−5618.6)
= 61.267+ −5.6473∈ ( 393.15 ) +2.1080 x 10−17(393.15)6
393.15
= 13.316
P = 606557.992 Pa
= 606.558 kPa
P
¿
606.558 kPa
Ki = = = 4.666
P 130 kPa
Water:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5 ,
(−7258.2)
= 73.649+ −7.3037∈ ( 393.15 )+ 4.1653 x 10−6 (393.15)2
393.15
= 12.197
P = 198285.134 Pa
= 198.285 kPa
P ¿ 198.285 kPa
Ki = = = 1.525
P 130 kPa
Light Key (LK) - most volatile component: acetic acid
Heavy key (HK) - least volatile component: propionic acid
Bottom product (393.15 K, 130kPa):
Acetic acid:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5
(−6304.5)
= 53.27+ −4.2985∈( 393.15 )+ 8.8865 x 10−18 (393.15)6
393.15
= 11.587
P = 107676.913 Pa = 107.677 kPa
P ¿ 107.677 kPa
Ki = = = 0.828
P 130 kPa
Propionic acid:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5
(−7149.4)
= 54.552+ −4.2769∈ ( 393.15 ) +1.1843 x 10−18(393.15)6
393.15
= 10.820
P = 50011.087Pa = 50.011 kPa
P ¿ 50.011 kPa
Ki = = = 0.385
P 130 kPa
The relative volatility for top and bottom product, α = K i/Kj
The average volatility, α average = (Ki x Kj)1/2

The relative volatility within the distillation column for average, bottom and top are
calculated and are shown in Table 3.1.
Table 3.1.1:Distillation Column D-2
Relative volatility Value

αtop 3.060
αbottom 2.151
αaverage (αLK,HK) 2.565
x LK X HK ∝LK = average relative volatility of the light
N min =
log
[ ][ ]
X HK D X LK B key with respect to the heavy key
log∝ LK x LK = light key concentration
X HK = heavy key concentrations
0.250 0.991
=
log [ ][
0.750 9.419 ×10−3 ]
log2.565
= 3.777
≈ 4 stages
Theoretical stages:
Most of the columns are designed to operate between 1.2 and 1.5 times of the
minimum reflux ratio since it is approximately the region of minimum operating cost
(Douglas,1988). Besides, referring to the first estimates, the operating reflux ratio for
the analytically method is equated as:
Reflux ratio, R = 1.2Rmin
1.25
Hence, Rmin = = 1.042
1.2
Thus, the actual theoretical stage could be determined by following equation,

N −N min R−R min
= 0.75(1− )
N +1 R+1
N −4 1.250−1.042
N +1
= 0.75 (1− 1.250+1
)
N = 14.658
N≈ 15
This is determined by taking the quotient of the number of theoretical trays to the tray
efficiency. Typical values for tray efficiency range from 0.5 to 0.7 (Douglas, 1988).
These values depend on the type of trays being used, as well as the internal liquid
and vapor flow rates.
So, by assumed that the tray efficiency is 0.6 (taking the average), the actual number
of stages is calculated as follow:
N
Nactual = e
15
=
0.6
= 25 stages
Feed-point location:
ND B X f , HK X b , LK 2 From (Sinnott et al, 2005), pg

Log [ ] = 0.206 log [( ) ( )( )] 526
NB D X f , LK X d , HK
Where
ND = number of stages above the feed, including any partial condenser,
NB = number of stages below the feed, including the reboiler,
B = molar flow bottom product,
D = molar flow top product,
X f,HK = concentration of the heavy key in the feed,

X f,LK = concentration of the light key in the feed,
X d,HK = concentration of the heavy key in the top product,
X b,LK = concentration of the light key if in the bottom product.
B = 424.656 kmol/h
D = 8.000 kmol/h
Xf, HK = (4 kmol/h) (1/296.320 h/kg) (990 kg/m3) = 13.364 kmol/m3
Xf, LK = (2kmol/h) (1/148.160 h/kg) (932 kg/m3) = 12.581 kmol/m3
Xb, LK = 0.988 (420.656kmol/h) (1/25261.230h/kg) (1049 kg/m3) = 17.259 kmol/m3
Xd, HK = 0.422 (6.000kmol/h) (1/108.090h/kg) (997 kg/m3) = 23.355 kmol/m3
NR 5.250 13.364 17.259 2

Log [ N ] = 0.206 log [( 419.400 ) ( 12.581 ) 23.355 ]
( )
S
NR
=0.414
NS
N R = 0.414NS
N = N R+ NS
25= 0.414 NS+ N S

N S = 17.680
Ns ≈ 18
Since the sieve tray is cheaper than the bubble cap and valve tray, the tray
distillation column with sieve tray is chosen with the ratio of construction using mild
steel is Bubble Cap: Valve: Sieve = 3.0: 1.5: 1. The sieve tray is chosen due to the
highest capacity of sieve trays which offers the lowest pressure drop and low fouling
tendency.
Plate-design procedures
Determination of column diameter:
Vapour flooding velocity, f in the range of 0.70~0.90, (Sinnott et al., 2005), page
567
f = 0.80
ρ L= Σ𝜌𝑖𝑥𝑖 ρ
ρ L= ρCH 3 COOH X CH 3 COOH + ρC 2 H 5 COOH X C 2 H 5 COOH + ρH 2 O X H 2 O + ρCH 3 COOHcH 3 X CH 3 COOHCH 3
ρ L= (1049 kg/m3) (0.979) + (990 kg/m3) (0.0115) + (997 kg/m3) (4.187×10 -3) +
(932) (5.740×10 -3)
= 1047.873 kg/m3
Ideal gas law:
PV = nRT
m
PV = M RT
m RT
P = v M
RT
P =ρ M
PM
ρ=
RT
P M mix
ρV = RT
1 x̄ 60.05 ( 0.979 )+74.08 ( 0.0115 ) +18.02 ( 4.187 ×10−3 ) +74.08 (5.740 ×10−3 ) 101.325 kPa
kPa L x 1 ¯¿ x 1000 L ¿
8.314 x 298 K
mol K 1 m3
1 kg
x
1000 g
= 2.460 kg/m
Net vapour velocity at flood condition:
L ρV 0.5
Flooding correlation, FLV = ( ¿( )
V ρL
0.5
25557.550
=( ) ( 2.460 )
256.250 1047.873
= 4.832
∝ 0.2
Vnf = Csb ( ) ¿
20
Csb = Souders and Brown factor at flood conditions in m/s from Fig. 15-5 (Sinnott et
al., 2002)
0.46 or 0.61m is use as standard tray spacing of large diameter column
∝=¿Surface tension in dyne/cm: (Perry’s Handbook 8th Edition

Table 2-309)
Acetic acid = 27.59 dyne/cm
Propionic acid = 27.21 dyne/cm
Water = 72 dyne/cm
Methyl acetate = 22.6 dyne/cm
ρ L = densities of the liquid stream
ρV = density of vapour stream

0.2
27.59 ( 0.979 ) +27.21 ( 0.0115 ) +72 ( 4.187 ×10−3 ) +22.6 ( 5.740× 10−3 )
Vnf = 0.069m/s ( 20 )
¿
= 1.519 m/s
By assuming there are 80% of flooding,
Vn = 0.8 Vnf
= 0.8 (1.519)
= 1.215 m/s
Plate area:
ṁv
Net area, An =
Vn
Where,
An = net area available for vapour-liquid disengagement
ṁ v = volumetric flow rate of the vapour
3.2 Heat Transfer Equipment Design
Vn = actual vapour velocity
kg 1h
256.250 x
h 3600 s
An = kg
2.460 3
m
1.215 m/s
= 0.0238 m2
By assuming the down comer occupies 15% of the cross-sectional area of the
column,
An 0.0238
Column cross-sectional area, Ac = = = 0.028 m 2
0.85 0.85
Ac = An + Ad
Cross-sectional area of downcomer, Ad = 0.15Ac

= 0.15(0.028)
= 4.2 × 10 -3 m2
Active or bubbling area, Aa = Ac –2 Ad

= 0.028 -2 (4.2× 10 -3)
= 0.0196 m2
Total area of all the active holes, Ah = 0.10 Aa

= 0.10 (0.0196)
= 0.96 × 10 -3 m2
4 A C 12 4 (0.028) 12
Column diameter, D = ( ) =( ) = 0.189 m
π π
Determination of column height:
Column height, Hc = (No. of trays - 2) Hs + ΔH

Where,
Hc = actual column height
Hs = plate spacing
ΔH = additional height required for column operation
Column height, Hc = (15-2) (0.31) + 0.45 m (top) + 0.45 m (bottom)

= 4.93 m
Vapour disengagement uses addition of 1 m at the top of the distillation column while
liquid level and reboiler return is used in bottom of the column (Seider et al., 2003).
H 4.93 m
Height to diameter ratio= = = 26.085
D 0.189 m
LW 25557.550 kg/h 1h
Maximum volumetric liquid rate, V L= = 3 x = 6.775 x10−3 m3/s
ρL 1047.873 kg/m 3600 s
V w 256.250 kg/h 1h
Maximum volumetric vapour rate, V V = = 3 x = 0.0289 m3/s
ρv 2.460 kg/m 3600 s
VV 0.0289 m3 /s
Maximum volumetric velocity through hole, V H = = = 30.104 m/s
Ah 0.96 ×10−3 m2
110
Design pressure, Pi = 1.01 bar ×
100
= 1.11 bar
Design pressure has to be 10% more than the maximum operating pressure which is
1 bar.
Design temperature = 25℃ +30℃

= 55 ℃
Design temperature should be set 30℃ above operating temperature which is 25℃.
Standard Weir height, hw = 50 mm
Standard Hole diameter, dH = 5 mm
Standard Minimum plate thickness = 5 mm
Weir length, 𝑙𝑤 = 0.77 D

= 0.77(0.189m)
= 0.146 m
π d h2 π ( 5 mm )2
Area of hole, A H = = = 19.6350 mm2 = 1.96 × 10−5 m2
4 4
Ah 0.96 ×10−3
Number of holes = = = 48.980
AH 1.96× 10−5 m 2
≈ 49 holes
By referring Francis weir formula from (Sinnott et al., 2005), page 572
Where,
l w = weir length, m
m = weir crest, mm liquid
LW = liquid flow-rate, kg/s.
LW 2 /3
Weir liquid crest, how = 750 [ ]
ρ Ll
W
kg 1 h 2/ 3
25557.550 x
h 3600 s
= 750 [ ]
kg
1047.873 3 x 0.146 m
m
= 0.129 m 2 s 2
Dry plate drop:
Where,
C0 = orifice coefficient which is a function of the plate thickness, hole diameter and
hole to perforated area ratio.
Vh = velocity through the holes, m/s.
V H 23 ρV
hd = 51 ( ) ( )
C0 ρL
3
30.104 23 2.460 kg/m ¿
= 51( ) (
0.8430 1047.873 kg/m 3
= 4.192 mm liquid
Residual head (head loss due to bubble formation and other losses):
Using the Simple equation from Hunt et al. (1955),
12.5 x 103 12.5 x 103

hr = ρL
= = 11.929 mm liquid
1047.873
Total plate drop, hT = hd + (hw + how) + hr

= [4.192 + 50 +0.129+11.929] mm liquid
= 66.25 mm liquid
Material of construction: carbon steel

Design stress, f = 145 N/mm2
Tensile strength = 510 N/mm2
Joint factor, J = 1
Mechanical design:
Design of domed ends:
Crown radius, Rc = D = 0.189m
Knuckle radius, Rk = 0.006 Rc = 0.006 (0.189) = 1.134 × 10 -3 m
1
Stress cone factor, CS = ¿)
4
1
= ¿ )
4
= 3.977
By refrring to (Sinnott et al, 2005), page 819,

pi R cs
Dome end thickness, e = C
2 Jf −Pi (C S −0.2)
= 1.1 x̄ ¿ ¿
= 2.285 mm
Ah dh 2
Hole pitch, = 0.9[ ¿ ¿
Ap lp
Based on ( Sinnott et al . , 2005 ) , page 574 , l p is in normal range of 2.5 to 4.0 diameter
2
5 mm
= 0.9 [ 5 mm x 4 ]
= 0.0563
Distillation Column D-2
S20 = 25186.335 kg/hr

S19 = 25557.550 kg/h ṁCH3COOH = 25185.446 kg/hr
1.1 X CH COOH =0.997
ṁCH3COOH = 25261.230 kg/hr S20 3
ṁC2H5COOH = 296.320 kg/hr X C H COOH =0.003

2 5
X CH COOH =0.9880
3
T = 121 °C
X C H COOH =0.0116 P = 120 kPa
2 5
Distillation
Column
T = 126°C
P = 130 kPa S21 = 294.772 kg/hr
S19 ṁC2H5COOH = 295.431 kg/hr
ṁCH3COOH = 75.784 kg/hr
X C H COOH =0.997
2 5
X CH COOH =0.003
3
T = 123 °C
S21 P = 120 kPa
.5
kg/
hr
Specification Sheet of Distillation Column D-2
Equipment No: D-2

Function: To separate pure acetic acid
Distillation Column Data Sheet
and propionic acid according to their
boiling point.
Operating data
Material Stream 19 Stream 20 Stream 21
Total mass flow 25557.550 25186.335 294.772
rate (kg/h)
Total Molar Flow 424.656 419.406 5.250
Rate (kmol/h)
Mass flow rate of components (kg/h)
Acetic acid 25261.230 25185.446 75.784
Propionic acid 296.320 0.888 295.431
Temperature (℃ ¿ 126 121 127
Technical Data
Number of trays 45
Feed stage from bottom 32
Pressure (kPa) 101
Height (m) 8.65
Inside diameter (m) 1.873
Reflux ratio 1.25
Tray spacing (m) 0.31
Type of material for construction Carbon steel
PLATE SPECIFICATION
Hole size (mm) 1.963 ×10−5
Active holes 9829
Plate thickness (mm) 5
Plate pressure drop (mm liquid) 63.809
Type of material for plate Stainless steel 304

Design pressure (kPa) 1.11
Design temperature (℃ ¿ 55
Wall thickness (mm) 5
Type of ends Torispherical

End thickness (mm) 5
The minimum stages required at total reflux were estimated using Fenske
equation
Firstly, the light and heavy key components were identified:
Light Key (LK) - most volatile component: Acetic acid
Heavy key (HK) - least volatile component: propionic acid
Using Fenske equation to identify the minimum stage:
XLK X HK
N min =
log [ ][
XHK D XHK B ] From (Sinnott et al, 2005), pg 524
log ∝LK
Vapor pressure of inorganic & organic liquid :
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5 From Table 2.8, Perry’s Chemical Handbook 8th
where T is the temperature in K. Edition Process, (2-55)
¿
P
K=
P
Top Product (394.15K , 120 kPa ¿:
Acetic acid:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5 ,
(−6304.5)
= 53.27+ −4.2985∈( 394.15 )+ 8.8865 x 10−18 (394.15)2
394.15
ln P = 11.61714
P = 110986.0231 Pa
= 110.9860 kPa
P ¿ 110.9860 kPa
Ki = = = 0.9249
P 120 kPa
Propionic acid:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5
(−7149.4)
=54.552+ −4.2769∈ ( 394.15 ) +1.1843 x 10−18(394.15)6
394.15
ln P = 10.8558
P = 51832.7611 Pa
= 51.8328 kPa
P ¿ 51.8328 kPa
Ki = = = 0.4319
P 120 kPa
Bottom product (400.15K , 120 kPa ¿:
Propionic acid:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5
(−7149.4)
=54.552+ −4.2769∈ ( 400.15 )+ 1.1843 x 10−18 (400.15)6
400.15
ln P = 11.0569
P = 63377.46 Pa
= 63.3775 kPa
P ¿ 63.3775 kPa
Ki = = = 0.5282
P 120 kPa
Acetic acid:
¿ P=C 1 +C2 /T + C3 ∈T +C 4 T C 5 ,
(−6304.5)
= 53.27+ −4.2985∈( 400.15 ) +8.8865 x 10−18 (400.15)2
394.15
ln P = 11.7577
P = 127735.2954 Pa
= 127.7353 kPa
P ¿ 127.7353 kPa
Ki = = = 1.06447
P 120 kPa
The relative volatility for top and bottom product, α = Ki/Kj

The average volatility, αaverage (α LK, HK) = (Ki x Kj) 1/2
The relative volatility within the distillation column for average, bottom and top are
calculated and are shown in Table 3.1
Table 3.1.2: Relative volatility within the distillation column
Relative volatility Value

αTop 2.1412
αBottom 2.0155
α LK, HK 2.0774
Minimum equilibrium stages:
x LK X HK
N min =
log
[ ][ ]
X HK D X LK B
log ∝ LK
Where,
∝LK = average relative volatility of the light

key with respect to the heavy key
x LK = light key concentration
X HK = heavy key concentrations
0.999 0.240
N min =
log [ ][
2.86 e−5 0.760 ]
log (2.07739)
log 110611.89
=
log 2.0774
= 15.8850
≈ 16 stag e
Theoretical stages:
Most of the columns are designed to operate between 1.2 and 1.5 times of the
minimum reflux ratio since it is approximately the region of minimum operating cost
(Douglas,1988). Besides, referring to the first estimates, the operating reflux ratio for
the analytically method is equated as:
Reflux ratio, R = 1.2Rmin

1.25
Hence, Rmin = = 1.042
1.2
Thus, the actual theoretical stage could be determined by following equation,
N −N min R−R min
= 0.75(1− )
N +1 R+1
N −16 1.250−1.042
= 0.75 (1− )
N +1 1.250+1
N −16
= 0.3853
N +1
N - 16 = 0.3853 N + 0.3853
0.61474 N= 16.3853
N= 26.6540
N≈ 27
This is determined by taking the quotient of the number of theoretical trays to the tray
efficiency. Typical values for tray efficiency range from 0.5 to 0.7 (Douglas, 1988).
These values depend on the type of trays being used, as well as the internal liquid
and vapor flow rates.
So, by assumed that the tray efficiency is 0.6 (taking the average), the actual number
of stages is calculated as follow:
N
Nactual =
e
27
=
0.6
= 45 stages
Feed-point location:
ND B X f , HK X b , LK 2 From (Sinnott et al, 2005), pg 526
Log [ ] = 0.206 log [( ) ( )( )]
NB D X f , LK X d , HK
Where
ND = number of stages above the feed, including any partial condenser,
NB = number of stages below the feed, including the reboiler,
B = molar flow bottom product,
D = molar flow top product,
X f,HK = concentration of the heavy key in the feed,
X f,LK = concentration of the light key in the feed,
X d,HK = concentration of the heavy key in the top product,
X b,LK = concentration of the light key if in the bottom product.
B = 5.250kmol/h
D = 419.400 kmol/h
Xf, HK = (4 kmol/h) (1/296.320 h/kg) (990 kg/m3) = 13.3639 kmol/m3
Xf, LK = (420.656 kmol/h) (1/25261 h/kg) (1049 kg/m3) = 17.4682 kmol/m3
Xb, LK = 0.240 (5.250 kmol/h) (1/75.784 h/kg) (1049 kg/m3) = 17.4409 kmol/m3
Xd, HK = 2.86 ×10−5 (419.400 kmol/h) (1/0.888 h/kg) (990 kg/m3) = 13.3726 kmol/m3
NR 5.250 13.3639 17.4409 2

Log [ ] = 0.206 log [( )( )( )]
NS 419.400 17.4682 13.3726
NR
Log [ ] = 0.2475 ×(−1.7881)
NS
NR
=0.42821
NS
N R = 0.4282 NS
N = N R+ NS
45= 0.4282 NS+ N R
N S = 31.51
Ns ≈ 32
Since the sieve tray is cheaper than the bubble cap and valve tray, the tray
distillation column with sieve tray is chosen with the ratio of construction using mild
steel is Bubble Cap: Valve: Sieve = 3.0: 1.5: 1. The sieve tray is chosen due to the
highest capacity of sieve trays which offers the lowest pressure drop and low fouling
tendency.
Plate-design procedures
Determination of column diameter:

Vapour flooding velocity, f in the range of 0.70~0.90, (Sinnott et al., 2005), page
567
f = 0.80
ρ L= Σ𝜌𝑖𝑥𝑖 ρ
ρ L= ρCH 3 COOH X CH 3 COOH + ρC 2 H 5 COOH X C 2 H 5 COOH
ρ L= (1049 kg/m3) (0.988) + (990 kg/m3) (0.0116)
= 1047.8960 kg/m3
Ideal gas law:

PV = nRT
m
PV = RT
M
m RT
P =
v M
RT
P =ρ
M
PM
ρ=
RT
P M mix
ρV =
RT
101.325 kPa
1 kg
= 1 x̄ ¿ ¿ x 1 ¯¿ x 1000 L ¿ x
1000 g
1 m3
= 2.4615 kg/m3
Net vapour velocity at flood condition:

L ρV 0.5
Flooding correlation, FLV = ( ¿( )
V ρL
0.5
294.772
=( ) ( 2.5053 )
25186.355 1043.96
= 5.67 ×10−4
∝ 0.2
Vnf = Csb ( ) ¿
20
Csb = Souders and Brown factor at flood conditions in m/s from Fig. 15-5 (Sinnott et
al., 2002)
0.46 or 0.61m is use as standard tray spacing of large diameter column
∝=¿Surface tension in dyne/cm: (Perry’s Handbook 8th Edition Table 2-
Acetic acid = 27.59 dyne/cm 309)
Propionic acid = 27.21 dyne/cm

ρ L = densities of the liquid stream
ρV = density of vapour stream
0.997 ( 27.59 ) +0.003(27.21) 0.2

Vnf = 0.069m/s ( ) ¿
20
= 1.5165 m/s
By assuming there are 80% of flooding,

Vn = 0.8 Vnf
= 0.8 (1.5165)
= 1.2132 m/s
Plate area:
ṁv
Net area, An =
Vn
Where,
An = net area available for vapour-liquid disengagement
ṁ v = volumetric flow rate of the vapour
Vn = actual vapour velocity
kg 1h
25186.3360 x
h 3600 s
= kg
2.4615 3
m
1.2132m/ s
= 2.3427 m2
By assuming the down comer occupies 15% of the cross-sectional area of the
column,
An 2.3428
Column cross-sectional area, Ac = = = 2.7562 m2
0.85 0.85
A c = An + A d
Cross-sectional area of downcomer, Ad = 0.15Ac

= 0.15(2.7562)
= 0.4134 m 2
Active or bubbling area, Aa = Ac –2 Ad
= 2.7562 -2(0.4134)
= 1.9293 m2
Total area of all the active holes, Ah = 0.10 Aa

= 0.10 (1.9293)
= 0.1929 m 2
4 A C 12 4 (2.7562) 12
Column diameter, D = ( ) = ( ) = 1.8733 m
π π
Determination of column height:
Column height, Hc = (No. of trays - 2) Hs + ΔH

Where
Hc = actual column height
Hs = plate spacing
ΔH = additional height required for column operation
Column height, Hc = (27-2) (0.31) + 0.45 m (top) + 0.45 m (bottom)
= 8.65 m
Vapour disengagement uses addition of 1 m at the top of the distillation column while
liquid level and reboiler return is used in bottom of the column (Seider et al., 2003).
H 8.65 m
Height to diameter ratio= = = 4.6175
D 1.8733m
LW 294.5 kg/h 1h
Maximum volumetric liquid rate, V L= = 3 x = 7.81 x10−5 m3/s
ρL 1047.8960 kg/ m 3600 s
V w 25186.335 kg/h 1h
Maximum volumetric vapour rate, V V = = 3 x = 2.84225 m3/s
ρv 2.4615 kg /m 3600 s
V V 2.8422m 3/s
Maximum volumetric velocity through hole, V H = = = 14.7343 m/s
Ah 0.1929 m2
110
Design pressure, Pi = 1.01 bar ×
100
= 1.11 bar
Design pressure has to be 10% more than the maximum operating pressure which is
1 bar.
Design temperature = 25℃ +30℃
= 55 ℃
Design temperature should be set 30℃ above operating temperature which is 25℃.
Standard Weir height, hw = 50 mm

Standard Hole diameter, dH = 5 mm
Standard Minimum plate thickness = 5 mm
Weir length, 𝑙𝑤 = 0.77 D

= 0.77(1.8733 m)
= 1.4425 m
Domed head width = 𝐷/4
1.8733m
=
4
= 0.4683m
π d h2 π ( 5 mm )2
Area of hole, A H = = = 19.6350 mm2 = 1.96 × 10−5 m2
4 4
Ah 0.1929 m2
Number of holes = = = 9828.83
AH 1.96× 10−5 m2
≈ 9829 holes
By referring Francis weir formula from (Sinnott et al., 2005), page 572
Where,
l w = weir length, m
m = weir crest, mm liquid
LW = liquid flow-rate, kg/s.
LW 2 /3
Weir liquid crest, how = 750 [ ]
ρ Ll
W
2 /3
kg 1h
294.772 x
h 3600 s
= 750 [ ]
kg
1047.896 3 x 1.4425 m
m
= 1.0738 m 2 s 2
Dry plate drop:

Where,
C0 = orifice coefficient which is a function of the plate thickness, hole diameter and
hole to perforated area ratio.
Vh = velocity through the holes, m/s.
V H 23 ρV
hd = 51 ( ) ( )
C0 ρL
3
14.7343 23 2.4615 kg/m ¿
= 51( )(
0.8430 1047.896 kg/m 3
= 0.8068 mm liquid
Residual head (head loss due to bubble formation and other losses):
Using the Simple equation from Hunt et al. (1955),
12.5 x 103 12.5 x 103
hr = = = 11.9287 mm liquid
ρL 1047.8960
Total plate drop, hT = hd + (hw + how) + hr

= [0.8068 + 50 +1.0738+11.9287] mm liquid
= 63.8093 mm liquid
Material of construction: carbon steel

Design stress, f = 145 N/mm2
Tensile strength = 510 N/mm2
Joint factor, J = 1
Mechanical design:
Design of domed ends:
Crown radius, Rc = D = 1.8733 m
Knuckle radius, Rk = 0.006 Rc = 0.006 (1.8733) = 0.01124 m
1
Stress cone factor, CS = ¿)
4
1
= ¿ )
4
= 3.978
By refrring to (Sinnott et al, 2005), page 819,
pi R cs
Dome end thickness, e = C
2 Jf −Pi (C S −0.2)
= 1.1 x̄ ¿ ¿
= 2.5727 mm + 2mm
= 4.5727 mm
Ah dh 2
Hole pitch, = 0.9[ ¿ ¿
Ap lp
Based on ( Sinnott et al . , 2005 ) , page 574 , l p is in normal range of 2.5 to 4.0 diameter
2
5 mm
= 0.9 [ 5 mm x 4 ]
= 0.0563
3.2.1 Condenser Cond-3

A condenser is used in a plant which acts as a cooling device to cool down the
plant when the temperature rises in the plant. Besides that, condensers also help in
condensing the vapour that comes out into a liquid. In the production of the acetic
acid plant, condensers, namely Cond-1 ad Cond-2, are used in distillation columns,
D-1 and D-2, in order to produce liquid products.
The shell and tube heat exchanger is frequently used in condensers, where
cooling water flows through the tube side and steam enters the shell side, where
condensation occurs on the outside of the heat transfer tubes.
Specification Sheet of Condenser Cond-3

Equipment No: Cond-1
CONDENSER COLUMN Function: To condense gas to liquid
SPECIFICATION SHEET before entering storage tank.
OPERATING DATA
Operation : Continuous
Type : Fixed-tube shell and tube exchanger
Heat duty : 2833 kW
Overall heat transfer coefficient: 1882.88 W/m2ᵒC
TUBE SIDE SHELL SIDE
Fluid: Cold water Fluid : Top product from
distillation column
Mass flowrate : 22.95 kg/s Mass flowrate: 4.327 kg/s
Temperature: 298.15K to Temperature : 393.15K to
308.15K 373.15K
Pressure drop 0.10 bar Pressure drop 0.10 bar
allowable: allowable:
Pressure drop 0.3320 bar Pressure drop 1.455 bar
calculated: calculated:
Type of Carbon steel Type of material: Carbon steel
material:
Outside diameter: 0.020 m Bundle diameter: 0.1509 m

Inside diameter: 0.016 m Shell diameter: 0.239 m
Length: 4.88 m Number of passes: 1

Number of tubes: 159 Baffle spacing: 0.0956 m
Number of passes: 2 Number of baffle: 50
Arrangement: Square pitch Baffle cuts: 25 %
Pitch: 0.025 m
Wall thickness: 5 mm
Tube wall thickness: 5 mm
Type of ends: Torispherical
End thickness: 2.36 mm
Entering temperature of the vapour = 120 ᵒC = 393.15 K

Leaving temperature of the vapour = 100 ᵒC = 373.15 K
Entering temperature of the cooling water = 25 ᵒC = 298.15 K
Leaving temperature of the cooling water = 35 ᵒC = 308.15 K
Figure 3.1 shows the temperature profile counter-current flow of the cooling water
and the dropping in vapour temperature to form liquid.
T 1= 120 ᵒC
T 2= 100 ᵒC
t 2= 35 ᵒC
t 1= 25 ᵒC
Figure 3.1: Temperature profiles counter-current flow.
Logarithmic mean temperature, Tm
( T 1 −t2 ) −(T 2−t 1)

Tm = (T 1−t 2)
ln
(T 2−t 1)
Where
T1 = hot fluid temperature, inlet
T2 = hot fluid temperature, outlet
t1 = cold fluid temperature, inlet
t2 = cold fluid temperature, outlet
( 120−35 ) −(100−25)
Tm = (120−35)
ln
(100−25)
= 79.90℃
Figure 3.2: Temperature correction factor: one shell pass; two or more even tube
passes.
T 1−T 2 t 2−t 1
R= S=
t 2−t 1 T 1−t 1
120−100 35−25
= =
35−25 120−25
= 2.00 = 0.11
From figure 3.5, F t obtained is 0.99.
ΔT m=F t × ∆ T lm
¿ 0.99 ×79.90 ℃=79.10 ℃
Assuming reflux ratio = 0.179 in distillation column, therefore Lo/D = 0.179
Total before reflux = (Lo/D +1) D

= (0.179 +1) D
= 1.179
Assumed overall coefficient = 7 00 W /m 2 ℃ , since U = 700−1000W /m2 ℃ for hot fluid

= organic vapours and cold fluid = water, Table 12.1 (Sinnott,2005)
Q¿ UA ∆ Tm
Q= Heat transfer per unit time, W
U= the overall heat transfer coefficient, W/m2. ˚C
A= heat transfer area, m2
Tm= the mean temperature difference, the temperature driving force
Q
A=
U ∆ Tm
2833 kW ×1000 W /kW

= (700 W /m 2.˚ C x 79.90 ℃ )
= 50.65 m2
Standard dimensions for steel tubes of each having outer diameter 20 mm, inner
diameter 16.8 mm and wall thickness 1.6 mm are used. Length of tubes for heat
exchanger is 16 ft (4.88 m) long (Sinnott, 2005), page 645.
For tubes:
Surface area of one tube, At
= π d oL
1m
(
¿ π × 20 mm ×
103 mm)× 4.88 m
¿ 0.307 m2
Number of tubes
A
¿
At
48.69 m2
¿
0.307 m2
= 159
π d2
Cross sectional area for 1 tube =
4
π
= 4¿
=3.142 ×10−4 m2
Total tube area, Aa = 161 x 3.142 x 10-4 m2

= 0.0506 m2
Cooling water flowrate, ṁ c
Q
ṁ c = Cp ∆T
Q= Heat transfer per unit time, W
Cp= the specific heat capacity of water, J/kg ℃
∆T= temperature difference of entering and leaving of cooling water, ℃
Cooling water inlet = 25℃
Cooling water outlet = 35℃
kJ
Specific heat capacity of water at 25℃ = 4.18
kg . ℃
kJ
2878.3
s
ṁ c =
kJ
4.18 (35−25)℃
kg .℃
kg
= 68.86
s
Assumed that density of water is 1000 kg/m3
Tube velocity, Tube velocity, Ut
ṁtube
x no of passes
ρtube Aa
68.86 kg /s
= 3 2 x 1
1000 kg/m (0.0506 m )
= 1.361 m/s
Since the optimum velocity of the tube is between 0.8 m /s to 1.3 m/s to ensure the
effective use of the allowable pressure drop. (Muller-Steinhagen, 2000). Hence, 2
passes are used with optimum velocity, Ut of 0.9 m /s.
By using square pitch, Pt = 1.25 do
= 1.25 x 20mm
= 25 mm
1
Nt
Tube bundle diameter , Db =d o ( )
K1
n1
Nt = number of tubes,
Db = bundle diameter, mm,
do = tube outside diameter, mm
For 2 pass and square pitch, (Sinnott, 2005), page 649 (Table 12.4)
K1 = 0.156 and n1 = 2.291
Bundle Diameter Calculation

1
16
Tube bundle diameter , D b =20 mm× ( 0.156 ) 2.291
¿ 150.94 mm
Db
Number of tubes∈the center row , N r =
Pt
150.94 mm
=
25 mm
= 6.03 (~ 6)
Tube side heat transfer coefficient:
Tube side meantemperature ,Tb avg=( 25+35)℃ /2=30 ℃
Tube cross-sectional area
π d i2
¿
4
2
1m
=
π [( 16 mm ) (1000 mm
])
4
= 2.011 x 10-4 m2
Tube per pass

161
=
2
= 80.5 (~81)
Physical properties of water at 30 ℃
Density of water = 995.65 kg / m3 Cp = 4.179 kJ/kg.K
μ water =656.84 x 10−6 Pa . s kf = 0.6185 W/m.K
Total flow area = Tube per pass tube cross sectional area
= 81 x 2.011 x 10-4 m2
= 0.016 m2
ṁ
Water mass velocity, Gt =
total flow area
22.95 kg/ s
= 0.0163 m 2
= 1407.975 kg/ m 2 . s
Ġ
Water linear velocity, v = ρt
22.95 kg/m 2 . s
=
995.65 kg /m3
= 0.0231 m/s
ρvd
Reynolds number, ℜ=
μ
995.65(0.0231)(16)
= 656.84 x 10−6
= 560246.392
L 3.88 mm
=
di 1m
16 mm ( )
1000 mm
= 242.5
Cpμ
Pr=
kf
kJ
4.179 . K ( 656.84 x 10−6 Pa . s )
kg kg /m s2 1000 J
= X x
J Pa 1 kJ
0.6185 . m. K
s
= 4.438
The tube side coefficient for water is calculated based on formula below
hi d i 0.33 μ
0.14
= j H ℜ Pr ( )
kf μw
μ
is neglected when calculating heat transfer coefficient (Sinnott 2005), Page 691.
μw
Figure 3.3: Heat transfer factor, jH (Sinnott 2005, pg 664)
j n k f ℜ Pr 0.33
hi =
di
W
0.6185 . K (2 X 10−2)(559120.32)( 4.438)0.33
= m
16 mm /1000 mm
= 706849.25 W/m2K
Tube-side pressure drop:
L μ −m
ρ u2t
[ ( )( ) ]
∆ Pt =N p 8 j f
di μw
+ 2.5
2
Where, (Sinnott 2005, pg 668)

ΔPt= tube-side pressure drop, N/m 2 (Pa)
Np = number of tube-side passes
ut = tube-side velocity, m/s
L = length of one tube
jf = dimensionless friction factor
Figure 3.4: Tube side friction factor (Sinnott 2005, pg 668)

From the graph, jf = 2 x 10−2
( μμ ) is neglected whencalculating pressure drop.

w
992.36 ( 0.9 m/s )2 ¯

∆ Pt =2 [ 8 ( 2 ×10−2 ) ( 242.5 ) ( 1 )+ 2.5 ] x 1 5¿ ¿
2 10 Pa
= 0.332 bar
Shell side coefficient
Assuming baffle spacing of 0.4 times (25% baffle cut), since optimum spacing is
between o.3 to 0.5 times the shell diameter. Pull through floating head is chosen
Where Ds = Db + clearance
From Figure 3.8, clearance obtained for pull through floating head at Db = 0.151 m is
92 mm
Ds = 150.9 + 88
= 239 mm
Figure 3.5: Shell bundle clearance

Approximation is made by using kern’s method to give a reasonably satisfactory
prediction of the heat-transfer coefficient for standard designs.
( pt – d o ) D s l B
Cross flow area , A s=
pt
Where pt = tube pitch,

do = tube outside diameter,
Ds = shell inside diameter, m,
lB = baffle spacing, m.
( pt - do )/pt is the ratio of the clearance between tubes and the total distance between
tube centres.
Baffle spacing, IB = 0.4 DS

= 0.4 (0.239 m)
= 0.0956 m
L
No of baffles, Nb = ( ) -1
Ib
4.88 m
= 0.0956 m −1
= 50.046 (~50 baffles)
( 25−20 ) x 10−3 m × ( 0.239 m )( 0.0956 m)

A s= −3
=4.570 x 10−3 m2
25 x 10 m
Ws
Mass flow rate based on inlet conditions, Gs=
As
Gs =( 17298.31/3600 ) × ( 1/4.570 x 10−3 )
¿ 1051.44 kg /s . m 2
Gs
Side linear velocity, u s=
ρ
1051.44 kg /s . m 2
¿
844.24 kg /m3
= 1.245 m/s
For a square pitch arrangement, equivalent diameter, d e
1.27 2 2
de = d ( p t – 0.785 d o)
o
1.27
= 20 ¿
= 19.749 mm
G s de
ℜ=
μ
1051.44 ( 19.75× 10−3 )

¿
656.84 x 10−6
= 31614.913
At 120℃ or 393.15K of shell side,

Cp = 6.65 kJ/ kg.K
kf = 0.05094 W/m.K
μCp
Pr = k
f
kJ
656.84 x 10−6 kg /ms(6.65 .K)
kg
= 1 kJ
0.05094 W /m . K ( )
1000 J
= 85.748
j h k f ℜ Pr 0.33
h0 =
de
W
0.05094 . K (5 X 10−2 )(31614.913)( 85.73)0.33
= m
19.75 mm /1000 mm
= 17714.818 W/m2K
Shell side friction factor and segmental baffles can be obtained from Figure 3.3 to
calculate the Reynolds number.
Figure 3.6: Shell-side friction factors, segmental baffles.
For the calculated Re number 35521.15,
The friction factor obtained from the graph for 25 percent baffle cut, j f =4.5 ×10−2
Shell side pressure drop:
2
Ds L ρ us μ −0.14
∆ P s=8 j f ( )( ) ( )
de l B 2 μw
Where:
L = tube length,
lB = baffle spacing.
The term (L/lB) is the number of times the flow crosses the tube bundle = (N b + 1),
Where Nb is the number of baffles
−0.14
μ
By neglecting the viscosity correction, ( )
μw
2
Ds L ρ us
∆ P s=8 j f
( )( )
de lB 2
2
239 4.88 844.24 ( 1.245 ) ¯
¿ ( 8 ) ( 4.5 × 10−2 ) ( 19.75 )( 0.0956 )2
( 1 ) x 1 5¿ ¿
10 Pa
= 1.455 bar
kw = 50 W/mᵒC
Overall coefficient:
do
1 1 1
d o ln ( )
di do 1 d 1
= + +
U o ho h od 2kw
+ ( ×
d i hid)(
+ o×
d i hi )
(Sinnott,20
05)
Where
Uo = the overall coefficient based on the outside area of the tube, W/m 2 ᵒC
ho = outside fluid film coefficient, W/m2 ᵒC,
hi = inside fluid film coefficient, W/m2 ᵒC,
hod = outside dirt coefficient (fouling factor), W/m2 ᵒC,
hid = inside dirt coefficient, 5000 W/m2 ᵒC,
kw = thermal conductivity of the tube wall material, W/m ᵒC,
di = tube inside diameter, m,
do = tube outside diameter, m.
do
1 1 1
d o ln ( )
di do 1 d 1
= + +
U o ho h od 2kw
+ ( ×
d i hid)(
+ o×
d i hi )
( 20 ×10−3 ) ln 20 ( 16.8 ) +
1 1 20 1
¿ +
17714.18 5000
+
2 ( 50 ) ( 16.8 ×
5000 )
20 1
+ ( 16.8 ×
706849.25W /m2 K )
¿ 5.311 ×10−4
U = 1882.88 W/m2C
Material of construction = carbon steel
Exchanger type = pull-through floating head
Design pressure is 10% above the normal working pressure for safety (Sinnott,
2005), page 810
Pc =1.1 ×1.01 ¯¿
= 1.11 bar
The designed temperature based on Table 13.2 (Sinnott, 2005) page 812 at T=150
℃
N
For carbon steel, f = 115 , at 150℃
mm2
Design cylinder shell minimum thickness,
Pi D s
e s=
2 J . f −Pi
J is the joint factor, Pi is the internal pressure and f is the design stress,
=1.01 ¯¿ ¿
= 0.1050 mm + 2 mm (add corrosion allowance)
= 2.1050 mm
The minimum thickness obtained from Table pg 814 (Sinnott, 2005) is 5 mm.
Minimum thickness of tube wall,
Pi D i
et =
2 Jf −Pi
= 1.01 ¯¿ ¿
= 7.656 x 10-3 mm + 2 mm (add corrosion allowance)
= 2.01 mm
The minimum thickness is 5 mm, obtained in pg 814 (Sinnott, 2005)
Type of head and closure = Torispherical head
Crown radius, RC = D S=239mm
Knuckle radius, Rk =0.06 Rc
= 0.06 (239 mm)
= 14.34 mm
Stress concentration factor,
1
C s= ¿ )
4
1
C s= ¿ )
4
= 1.77
Design stress, f = 115 N/mm2 (Sinnott, 2005), page 812
P i Rc C s
Minimum thickness,e h=
2 Jf + Pi (C S −0.2)
1
Where Cs = stress concentration factor for torispherical head = ¿) 2/3)]
4
Rc = crown radius
Rk = knuckle radius
¿ 1.01 ¯¿ ¿
= 0.19 mm
3.2.2 Reboiler Design (RB-1)
Reboilers are used in conjunction with distillation columns to vaporize a fraction

of the bottom product, whereas a vaporizer vaporizes the entire feed. There are
three primary types of reboilers used in industry: forced circulation reboilers,
thermosiphon reboilers, and kettle reboilers. In the distillation column of the acetic
acid production plant, a kettle reboiler is utilized, which is essentially a pool boiling
with a design based on nucleate boiling data. Two opposing actions occur, and the
rising vapor has a propensity to blanket the top tubes, particularly when the tube
spacing is near. This will result in a decrease in the rate of heat transmission.
CH3COOH CH3COOH
C2H5COOH C2H5COOH
RB-1
S18 S19
123℃
120℃ 126℃
Consider a kettle type reboiler is used in purification column
3.4 Auxiliary Equipment Design
Maximum tolerances for carbon steel and stainless steel are 6m/s and 7m/s,
respectively, according to the 1997 NORSOK standard. The optimum range for gas
lines is between 15 and 30 metres per second (Sinnott et al. 2006). As necessary,
the following pipe sizing refers to SCH 80. Due to its great corrosion resistance,
carbon steel will be employed in lines with reactants and products as significant
components. Stainless steel can be utilised as the principal component of a stream
alongside other significant components. For lines composed entirely of liquid or gas,
the computation might begin by assuming a velocity. For pure liquid or pure gas
pipelines, Q = VA is used to determine the cross-sectional area. After determining
the area, it is feasible to determine the diameter of the pipe. For a liquid-gas mixture,
the effects of velocity on corrosion by the component in the pipe line must first be
determined by:
C
Ve=
√ ρm
C= Empirical Constant. ρm= average density. After determined the corrosion
velocity, same procedure is repeated to obtain the diameter of the pipe. After
determined the diameter, referred to SCH 80 table and pick the diameter which is
bigger than the calculated data to ensure have space allowance.
3.3.1 Storage Tank
Storage tanks are essentially containers that may hold liquids and compressed
gases. In refineries, chemical and petrochemical operations, storage tanks are used
to hold crude oil, intermediate and refined products, gas, chemicals, and water.
The quantity, volatility, chemical properties, and corrosiveness of a substance

are frequently considered while determining the kind, size, and construction material
of a storage tank. The tank design basis is comprised of the tank's capacity, service,
design code, materials, design conditions, external loads, appurtenances, and
connections required for a specific storage tank application.
Often cylindrical in shape, perpendicular to the ground, with flat bottoms and a
fixed flat or floating roof, storage tanks are used. Numerous environmental
restrictions apply to the construction and operation of storage tanks, most of which
are dependent on the nature of the fluid contained therein.
Vertical, horizontal, open top, closed top, flat bottom, cone bottom, slope bottom,
and dish bottom are the most common shapes of storage tanks. To handle the
hydraulic hydrostatic pressure caused by the confined liquid, large tanks are typically
vertical cylinders. The majority of storage tanks are constructed to tolerate a range of
temperature and pressure variations.
Distillate Storage Tank (T-3):
S21 = 25186.334kg/h
ṁC2H5COOH = 0.888kg/hr
X CH COOH =0.997 T-3
3
X C H COOH =0.003 S21

2 5
T = 121°C
P = 120 kPa
Specification Sheet of Storage Tank (T-3)
Distillate Storage Tank
Application : To store distillate liquid
Identification Item : T3
Item No. : -
No. required : 1
Function : Storage of methyl acetate and water
Type Material : Carbon steel
Construction
Configuration : Single vertical standing, cylindrical shape vessel
Material Temperature, ℃ : 25
Pressure, kPa : 101.325
Mass flowrate, : 256.25
kg/hr
Design data Design : 35
Temperature, ˚C
Design Pressure, : 130
kPa
Diameter : 2.546 m
Height : 1.273 m
Volume : 6.480 𝑚3
Thickness of wall : 222.271 mm
Type of head : Cone roof shape
Thickness of head : 222.271 mm
Material of : Carbon steel
construction
Each of the density value in distillate liquid properties was obtained from the Heat
Transfer Books (Holman, 2010).
Table 3.3.1: Properties of distillate liquid
Composition in Mole fraction Density (kg/m3) Mass flower (kg/hr)

distillate liquid
Water 0.422 997 108.090
Methyl acetate 0.578 932 148.160
1
Average density, ρaverage = 0.422 0.578
+
997 932
1
=
1.0521×10−3
= 950.474 kg/m3
By assuming the total composition of distillate liquid is equal to 1,
Dalton’s Law = Actual density, ρτ =¿ (Xdistillate) ×¿ρaverage)
100
= × 950.474 kg/m3
100
= 950.474 kg/m3
108.090+ 148.160
Average mass flowrate, ṁaverage = = 256.25 kg/hr
2
Volumetric flowrate, ṽ = mass flowrate, ṁ ÷ Actual density , ρτ
256.25 kg / hr
=
950.474 kg /m3
= 0.270 m3/hr
Volume of tank, Vtank = volumetric flowrate, ṽ x time, τ
= 0.270 m3/hr × 24 hr/day × 1 day
= 6.480 m3
Calculation diameter of tank:

π D ² hL
Volume of tank, Vtank =
4
Table 3.3.2: Properties of tank diameter from Coulson & Richardson’s Chemical
Engineering, pg 650 (Sinnott, 2005).
hL
Tank diameter (m) Ratio of height to diameter, ( )
D
D<18 0.5
18<D<29 0.4
29<D<53 0.3
D>53 0.25
hL
Based on table, the ratio of = 0.5
D
π D ²(0.5 D)
Volume =
4
π D ³0.5
6.48 =
4
D = 2.546 m
So,
Height, hL = 0.5D = 0.5(2.546) = 1.273 ≈ 1 m
Calculation thickness of tank wall:

ρL HL gDt
es =
2 ft J 10³
Where,
hL = Liquid depth, m
es = Tank thickness required at depth hL, m
PL = Liquid density, kg/m3
J = Joint factor (if applicable)
g = Gravitational acceleration, 9.81 m/s2
ft = Design stress for tank material, N/mm2
DT = Tank diameter, m
kg
e =
s
( 950.474
m3)
(1.2735 m)(9.81)(2.546)
136 N 3
2( )(1)(10 )
mm 2
=0.0436 m
≈ 43.648 mm
Refering to El-samanody et al. (2016), the corrosion allowance of floating roof design
data is 3 mm.
So,
Total thickness = 43.648 mm + 3 mm = 46.648 mm
Calculation cone roof:
By assuming the diameter of cone is same with diameter of tank,
2.546
Radius cone, r = = 1.2730 m ≈ 1 m
2
22
Bottom surface area of tank = πr ² = ( ) × (1.2730)² = 0.926 m²
7
By refering to the Coulson & Richardson’s Chemical Engineering, page 650 (Sinnott,
2005), the equation calculation for height of cone roof tanks is:
1
¿ × Tank height
3
1
¿ × (0.926)
3
= 0.309 m
≈ 0.3 m
Distillate Storage Tank (T- 4):
S21 = 25186.334kg/h
ṁC2H5COOH = 0.888kg/hr
X CH COOH =0.997 T-4
3
X C H COOH =0.003
2 5
S21
T = 121°C
P = 120 kPa
Specification Sheet of Distillate Storage Tank (T-4)

Application : To store distillate liquid
Item : T4
Identification Item No. : -
No. required : 1
Function : Storage of pure acetic acid produced
Construction
Mass flowrate, : 12593.61 kg/ hr
kg/hr
Temperature, ˚C
kPa
Diameter : 9.0198 m
Height : 4.5099 m
Volume : 288.1696 𝑚3
construction
Composition in Mole fraction Density (kg/m3) Mass flower (kg/hr)

distillate liquid
Acetic acid 0.9976 1049 25186.335
Propionic acid 0.0024 990 0.888
1
+
1049 990
1
=
9.53 ×10−4
= 1048.85 kg/m3
100
= × 1048.85 kg/m3
100
= 1048.85 kg/m3
25186.335+ 0.888
2
12593.61kg /hr
=
1048.48 kg /m3
=12.0071 m3/hr
= 12.0071 m3/hr × 24 hr/day × 1 day
= 288.1696 m3

π D ² hL
4
Table 3.3.4: Properties of tank diameter from Coulson & Richardson’s Chemical
hL
D
D<18 0.5
18<D<29 0.4
29<D<53 0.3
D>53 0.25
hL
D
π D ²(0.5 D)
Volume =
4
π D ³0.5
286.0161=
4
D = 9.0198 m
So,
Height, hL = 0.5D = 0.5(9.0198) = 4.5099 ≈ 4m

ρL HL gDt
es =
2 ft J 10³
Where,
kg
e =
s
( 1048.85
m3 )
( 4.5099 m)(9.81)(9.0198)
136 N 3
2( )(1)(10 )
mm 2
=15.38 m
≈ 15387.83 mm
data is 3 mm.
So,

9.0198
Radius cone, r = = 4.45099 m ≈ 4 m
2
22
7
1
¿ × Tank height
3
1
¿ × (4.45099)
3
= 1.5033 m
≈ 1.5 m
Condensate Storage Tank (T- 5):
S23 = 25186.334kg/h

ṁCH3COOH = 75.784 kg/hr
T-5
X C H COOH =0.997
2 5 S23
X CH COOH =0.003
3
T = 127°C
P = 120 kPa
Specification Sheet of Condensate Storage Tank (T-5)

Application : To store condensate liquid
Identification Item : T5
Item No. : -
No. required : 1
Function : Storage of pure acetic acid produced
Construction
Mass flowrate, : 12593.61 kg/ hr
kg/hr
Temperature, ˚C
kPa
Diameter : 3.3016 m
Height : 1.6508 m
Volume : 4.4988 m3
construction
Composition in Mass fraction Density (kg/m3) Mass flow rate

distillate liquid (kg/hr)
Propionic acid 0.997 990 295.431
Acetic acid 0.003 1049 75.784
1
+
1049 990
1
=
1.01×10−3
= 990.1671 kg/m3
100
= × 990.1671 kg/m3
100
= 990.1671 kg/m3
295.431+75.784
2
185.6075 kg/hr
=
990.1671 kg/m3
= 0.1875 m3/hr
= 0.1875 m3/hr × 24 hr/day × 1 day
= 4.4988 m3

π D ² hL
4
Table 3.34: Properties of tank diameter from Coulson & Richardson’s Chemical
hL
D
D<18 0.5
18<D<29 0.4
29<D<53 0.3
D>53 0.25
hL
D
π D ²(0.5 D)
Volume =
4
π D ³0.5
4.4988=
4
D = 3.3016 m
So,
Height, hL = 0.5D = 0.5(3.3016) = 1.6508 ≈ 2m

ρL HL gDt
es =
2 ft J 10³
Where,
kg
e =
s
( 990.1671
m3 )
( 3.3016 m)(9.81)(9.0198)
136 N 3
2( )(1)(10 )
mm 2
=1.0635 m
≈ 1063.48 mm
data is 3 mm.
So,

3.3016
Radius cone, r = = 1.6508 m ≈ 2 m
2
22
7
1
¿ × Tank height
3
1
¿ × (1.6508)
3
= 0.5503 m
≈ 1.0 m
3.5 AutoCAD drawings
Table 3.5.1: AutoCAD drawing for reboiler (RB-1)

3.1 Mass Transfer Equipment Design: H O CH Cooh CH

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3.1 Mass Transfer Equipment Design: H O CH Cooh CH

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3.

1 Mass Transfer Equipment Design

By applying and withdrawing heat, a distillation column is frequently used to

Distillation Column D-1

S15 = 25813.800 kg/h ṁ CH3COOHCH3 = 148.160 kg/hr

ṁC2H5COOH = 296.320 kg/hr

Equipment No: D-1

Tray spacing (m) 0.31

Type of material for construction Carbon steel

Type of material for plate Stainless steel 304

Wall thickness (mm) 5

Type of ends Torispherical

First step, identifying the light and heavy key components:

Light Key (LK) - most volatile component: methyl acetate

Heavy key (HK) - least volatile component: water

Using Fenske equation to identify the minimum stage:

Vapor pressure of inorganic & organic liquid :

where T is the temperature in K.

Top Product (393.15 K , 130 kPa ¿:

Light Key (LK) - most volatile component: acetic acid

Heavy key (HK) - least volatile component: propionic acid

Bottom product (393.15 K, 130kPa):

P = 107676.913 Pa = 107.677 kPa

P = 50011.087Pa = 50.011 kPa

The relative volatility for top and bottom product, α = K i/Kj

The average volatility, α average = (Ki x Kj)1/2

Table 3.1.1:Distillation Column D-2

Relative volatility Value

x LK X HK ∝LK = average relative volatility of the light

Reflux ratio, R = 1.2Rmin

Thus, the actual theoretical stage could be determined by following equation,

ND B X f , HK X b , LK 2 From (Sinnott et al, 2005), pg

ND = number of stages above the feed, including any partial condenser,

NB = number of stages below the feed, including the reboiler,

B = molar flow bottom product,

D = molar flow top product,

X f,HK = concentration of the heavy key in the feed,

X d,HK = concentration of the heavy key in the top product,

X b,LK = concentration of the light key if in the bottom product.

Xf, HK = (4 kmol/h) (1/296.320 h/kg) (990 kg/m3) = 13.364 kmol/m3

Xf, LK = (2kmol/h) (1/148.160 h/kg) (932 kg/m3) = 12.581 kmol/m3

Xb, LK = 0.988 (420.656kmol/h) (1/25261.230h/kg) (1049 kg/m3) = 17.259 kmol/m3

Xd, HK = 0.422 (6.000kmol/h) (1/108.090h/kg) (997 kg/m3) = 23.355 kmol/m3

NR 5.250 13.364 17.259 2

25= 0.414 NS+ N S

Determination of column diameter:

ρ L= ρCH 3 COOH X CH 3 COOH + ρC 2 H 5 COOH X C 2 H 5 COOH + ρH 2 O X H 2 O + ρCH 3 COOHcH 3 X CH 3 COOHCH 3

(932) (5.740×10 -3)

Ideal gas law:

Net vapour velocity at flood condition:

0.46 or 0.61m is use as standard tray spacing of large diameter column

∝=¿Surface tension in dyne/cm: (Perry’s Handbook 8th Edition

Propionic acid = 27.21 dyne/cm

Methyl acetate = 22.6 dyne/cm

ρ L = densities of the liquid stream

ρV = density of vapour stream

By assuming there are 80% of flooding,

Cross-sectional area of downcomer, Ad = 0.15Ac

Active or bubbling area, Aa = Ac –2 Ad

Total area of all the active holes, Ah = 0.10 Aa

Column height, Hc = (No. of trays - 2) Hs + ΔH

Column height, Hc = (15-2) (0.31) + 0.45 m (top) + 0.45 m (bottom)