Thesis Group 09 PDF

“Production of 150MTPD polymer grade propylene
by OLEFLEX process.”
Project Advisor:
Dr. Usman Saeed
Group Members:
Zia-ur-Rehman Hashmi 2017-CH-740
Rehan Mansoor 2017-CH-733
Muhammad Akmal 2017-CH-722
Muhammad Bilal 2017-CH-736
Session 2017-2021
DEPARTMENT OF CHEMICAL ENGINEERING

Muhammad Nawaz Sharif University of Engineering and
Technology, Multan
“Production of 150MTPD polymer grade propylene by
OLEFLEX process.”
This report is submitted to department of Chemical Engineering,

Muhammad Nawaz Sharif University of Engineering & Technology,
Multan, Pakistan. For partial fulfillment of the requirements of
BACHELOR’S DEGREEIN CHEMICAL ENGINEERING

Year:2021
Date of Approval: _________________
________________
External Examiner
Engr. Tahir Hameed
________________ ___________________
Internal Examiner In-Charge Department

Dr. Usman Saeed Dr. Asim Umer

Technology, Multan
Undertaking:
We certify that the work entitled “Production of 150MTPD polymer grade

propylene by OLEFLEX process” has not been presented elsewhere for
assessment. Where material has been used from other sources it has been
properly acknowledged / referred.
Name Registration No. Signature
Muhammad Akmal 2017-CH-722 __________________
Rehan Mansoor 2017-CH-733 __________________
Muhammad Bilal 2017-CH-736 __________________
Zia-ur-Rehman 2017-CH-740 __________________

Technology, Multan
“Starting with the name of ALLAH the Most Gracious and Ever Merciful”
Acknowledgements
Dedicated to Our Beloved Parents, Respected Teachers & sincere fellows.

Thanks to ALLAH, “Who taught us with pen and told us what we did not know”
and guided us by the Holy Prophet Hazrat Muhammad (Peace Be upon Him)
after whom no further guidance is needed.
We acknowledge our indebtedness to our beloved advisor, Engr. Usman Saeed for
their timely guidance, encouragement, sympathetic attitude and professional assistance
without whom this project would not have been completed. We are indebted to our
HOD Dr- Asim Umar who provided us his knowledge and facilities to complete the
project a special acknowledgment to beloved teachers.
A general debt of gratitude is due to all the teachers of chemical engineering
department, UET Multan for their kind help. There is a deep contribution from our
teachers to whatever we have achieved and whatever we intend to achieve in our lives.
We are also thankful to the non-teaching staff of the department for their intellectual
and moral support. We intend our special thanks to our sweet parents for their
unlimited love, kindness and support throughout our studies and who pray for our
success and bright future deeply.
Preface
The project deals with the design of Propylene production plant. The plant we
designed is based on OLEFLEX process which is an advanced de-hydrogenation
process of Propane. Pakistan is importing Propylene from many other countries.
Because of high demand of propylene in the production of poly-propylene and
polymers, many of the neighbor countries like China, Iran, and Indonesia also import
it.
The basic demand of poly-propylene is increasing with time because of high
usage, propylene is Building block of poly-propylene. It offers a way to make Pakistan
self-supported in poly-propylene and to export the excess propylene to China (major
consumer of Propylene) and other countries such as, Indonesia and Malaysia.
Propylene also a basic need of our civilization. It is used 37% in packaging, 14% in
agriculture, 6% in health care. Automotive applications of propylene have been
growing strongly where there has been a drive to replace metals with plastics to reduce
the weight of motor. Thus, it can be concluded that the demand of propylene is bound
to increase in the upcoming years. In an average, China is importing 2.8 million metric
tons of Propylene a year. We will also produce propylene to fulfil the basic demand of
PAKISTAN and then can Export to the China.
Table of Contents
1 Introduction ................................................................................................................................................ 2
1.1 Structure of Propylene: ......................................................................................................................... 2
1.2 Project Background: ............................................................................................................................. 3
1.3 Project Objective: ................................................................................................................................. 3
1.4 Safety Data of Propylene: ..................................................................................................................... 3
1.4.1 Identification: ...............................................................................................................................3
1.4.2 Potential Hazards: .........................................................................................................................4
1.5 Exposure controls/personal protection: ................................................................................................ 5
1.5.1 Appropriate engineering controls: ................................................................................................5
1.5.2 Environmental exposure controls: ................................................................................................5
1.5.3 Hygiene measures:........................................................................................................................5
1.5.4 Eye/face protection: ......................................................................................................................5
1.5.5 Respiratory protection: .................................................................................................................5
1.5.6 Body protection: ...........................................................................................................................6
1.6 Physical properties: .............................................................................................................................. 6
1.7 Applications of propylene: ................................................................................................................... 6
1.8 About Propylene: .................................................................................................................................. 9
2 Market Analysis and Capacity Selection: .............................................................................................. 11
2.1 Worldwide Consumptions of Propylene: ........................................................................................... 11
2.2 Worldwide Demand of Propylene by Applications: ........................................................................... 11
2.3 Worldwide Production capacity of Propylene 2018-2030: ................................................................ 11
2.4 Trade of Propylene: ............................................................................................................................ 12
2.4.1 Exports:...................................................................................................................................... 12
2.4.2 Imports:...................................................................................................................................... 12
2.5 Market Analysis (Asia Pacific): ......................................................................................................... 12
2.6 Price difference between propane/propylene: .................................................................................... 13
2.7 Global market share by the end-use industry 2019: ........................................................................... 13
2.8 Market analysis (Asia pacific-2018): ................................................................................................. 13
2.9 Price analysis & CAGR: ..................................................................................................................... 14
2.10 Capacity selection:.............................................................................................................................. 14
2.11 Raw Material: ..................................................................................................................................... 15
3 Process Selection:...................................................................................................................................... 17
3.1 Commercial PDH Technologies: ........................................................................................................ 17
3.2 Comparison between CATOFIN & OLEFLEX: ................................................................................ 18
3.3 Selected process: ................................................................................................................................ 18
3.4 OLEFLEX (moving-bed) from UOP:................................................................................................. 19
4 Process Description: ................................................................................................................................. 21
4.1 Dehydrogenation of Propane: ............................................................................................................. 21
4.2 Feed Preparation section:.................................................................................................................... 21
4.3 Dehydrogenation process: .................................................................................................................. 21
4.4 Product purification section: ............................................................................................................... 21
4.5 Process Flow Diagram:....................................................................................................................... 23
5 Material Balance: ..................................................................................................................................... 25
5.1 Material Balance Around De-propanizer: .......................................................................................... 25
5.2 Material Balance Around Reactor: ..................................................................................................... 26
5.3 Material Balance Around Knockout Drum: ....................................................................................... 27
5.4 Material Balance Around Propane/Propylene Splitter: ...................................................................... 28
5.5 Material Balance Around Mixer: ........................................................................................................ 29
6 Energy Balance: ........................................................................................................................................ 31
6.1 Energy balance Around Distillation Column (DC-101): .................................................................... 31
6.2 Energy Balance of Reactor (R-101): .................................................................................................. 35
6.3 Energy Balance across Furnace (F-101):............................................................................................ 36
6.4 Energy Balance across Heat Exchanger (H-101): .............................................................................. 37
6.5 Energy balance across other Heat Exchangers: .................................................................................. 38
6.6 Energy Balance across Compressor (C-101): ..................................................................................... 38
6.7 Energy Balance across Compressor (C-102): ..................................................................................... 39
6.8 Energy Balance across Propane-Propylene Splitter (PP-101): ........................................................... 40
7 Equipment Design: ................................................................................................................................... 45
7.1 Design of Reactor (R-101): ................................................................................................................ 45
7.1.1 Introduction: .............................................................................................................................. 45
7.1.2 Reactor Selection Criteria:......................................................................................................... 45
7.1.3 Moving Bed Reactor: ................................................................................................................ 46
7.1.4 Catalyst Properties (Pt-Sn/Al2O3): ........................................................................................... 46
7.1.5 Reaction Kinetics: ..................................................................................................................... 46
7.1.6 Design Steps: ............................................................................................................................. 47
7.1.7 Kinetics of the reactions: ........................................................................................................... 47
7.1.8 Design Equation: ....................................................................................................................... 48
7.1.9 Calculate Weight of the Catalyst: .............................................................................................. 49
7.1.10 Calculate Volume of the Catalyst: ............................................................................................. 49
7.1.11 Calculate Volume of Reactor: ................................................................................................... 49
7.1.12 Calculate Residence Time and WHSV:..................................................................................... 50
7.1.13 Length and Diameter Calculations: ........................................................................................... 50
7.1.14 Bed Height Calculations: ........................................................................................................... 51
7.1.15 Minimum Fluidization velocity: .............................................................................................. 51
7.1.16 Terminal Fluidization Velocity: .............................................................................................. 52
7.1.17 Fluidization Velocity: ................................................................................................................ 52
7.1.18 Pressure Drop due to Catalytic Bed:.......................................................................................... 52
7.1.19 Pressure Drop due to Fluidization: .......................................................................................... 53
7.1.20 Mechanical Design of Reactor: ................................................................................................. 53
7.1.21 Specification Sheet of Reactor: ................................................................................................. 56
7.2 Design of Distillation Column (Depropanizer): ................................................................................. 57
7.2.1 Distillation: ................................................................................................................................ 57
7.2.2 Advantages of Distillation: ........................................................................................................ 57
7.2.3 Types of Distillation: ................................................................................................................. 57
7.2.4 Column Selection: ..................................................................................................................... 58
7.2.5 Internal Plates Selection: ........................................................................................................... 58
7.2.6 Design Steps: ............................................................................................................................. 59
7.2.7 Feed Condition: ......................................................................................................................... 59
7.2.8 Top Conditions: ......................................................................................................................... 60
7.2.9 Bottom Conditions: ................................................................................................................... 61
7.2.10 Reference Component: .............................................................................................................. 62
7.2.11 Relative Volatilities: .................................................................................................................. 62
7.2.12 Minimum number of stages: ...................................................................................................... 62
7.2.13 Minimum reflux ratio: ............................................................................................................... 63
7.2.14 Actual Reflux Ratio: .................................................................................................................. 63
7.2.15 Theoretical Number of Stages: .................................................................................................. 63
7.2.16 Efficiency: ................................................................................................................................. 63
7.2.17 Tray Efficiency: ......................................................................................................................... 63
7.2.18 Actual number of trays: ............................................................................................................. 63
7.2.19 Vapor & Liquid flow Rate in Distillation Column: ................................................................... 64
7.2.20 Top section diameter calculations: ............................................................................................ 64
7.2.21 Flooding velocity calculation: ................................................................................................... 65
7.2.22 Bottom section diameter calculations: ....................................................................................... 66
7.2.23 Flooding velocity calculation: ................................................................................................... 66
7.2.24 Height of Distillation column: ................................................................................................... 68
7.2.25 L/D Ratio: .................................................................................................................................. 68
7.2.26 Distillation Column Plate Design: ............................................................................................. 68
7.2.27 Weeping:.................................................................................................................................... 69
7.2.28 Actual minimum vapors velocity: ............................................................................................. 70
7.2.29 Pressure Drop: ........................................................................................................................... 71
7.2.30 Plate pressure drop: ................................................................................................................... 71
7.2.31 Down comer liquid backup: ...................................................................................................... 72
7.2.32 Residence Time: ........................................................................................................................ 72
7.2.33 Entrainment: .............................................................................................................................. 72
7.2.34 Perforated Area:....................................................................................................................... 73
7.2.35 Specification Sheet of Distillation Column: .............................................................................. 75
7.3 Design of Heat Exchanger: ................................................................................................................. 76
7.3.1 Types of Heat Exchanger: ......................................................................................................... 76
7.3.2 Selection criteria: ....................................................................................................................... 76
7.3.3 Transfer Process: ....................................................................................................................... 76
7.3.4 Pass arrangement: ...................................................................................................................... 76
7.3.5 Flow arrangement: ..................................................................................................................... 76
7.3.6 Phase of fluid: ............................................................................................................................ 77
7.3.7 Geometry of construction: ......................................................................................................... 77
7.3.8 Shell and Tube Heat Exchanger: ............................................................................................... 77
7.3.9 Types of shell and tube Heat Exchanger: .................................................................................. 77
7.3.10 Design steps of Heat Exchanger: ............................................................................................... 77
7.3.11 Design Calculation: ................................................................................................................... 78
7.3.12 True Temperature: ..................................................................................................................... 78
7.3.13 Provisonal Area : ....................................................................................................................... 78
7.3.14 Tube Specification: .................................................................................................................... 79
7.3.15 Shell configuration: ................................................................................................................... 79
7.3.16 Shell side heat transfer coefficient: ........................................................................................... 79
7.3.17 Tube side heat transfer coefficient: ........................................................................................... 80
7.3.18 Tube wall temperature: ............................................................................................................. 81
7.3.19 Overall heat transfer coefficient: ............................................................................................... 81
7.3.20 Pressure Drop calculation: ......................................................................................................... 82
7.3.21 Specification sheet of Heat Exchanger: ..................................................................................... 83
7.4 Design of Knock out vessel: ............................................................................................................... 84
7.4.1 Design Methodology: ................................................................................................................ 84
7.4.2 Process conditions: .................................................................................................................... 84
7.4.3 Calculations for settling velocity: .............................................................................................. 84
7.4.4 Calculations of volumetric flow rate for liquid and vapors: ...................................................... 85
7.4.5 Calculations of Area: ................................................................................................................. 85
7.4.6 Calculations of Diameter: .......................................................................................................... 86
7.4.7 Calculations of volume of liquid: .............................................................................................. 86
7.4.8 Specification Sheet of Knockout Drum: .................................................................................... 86
8 Process Simulation: .................................................................................................................................. 88
8.1 Steady State Simulation:..................................................................................................................... 88
8.2 Dynamic Simulation: .......................................................................................................................... 88
8.3 Distillation Simulation: ...................................................................................................................... 89
8.3.1 Add Components: ...................................................................................................................... 89
8.3.2 Applying Fluid Package: ........................................................................................................... 90
8.3.3 Open simulation environment and add Feed conditions: .......................................................... 90
8.3.4 Add Distillation Column and add specific conditions: .............................................................. 91
8.3.5 Results: ...................................................................................................................................... 91
9 Cost estimation: ........................................................................................................................................ 93
9.1 Types of Capital Cost Estimates:........................................................................................................ 93
9.2 Production of 150 tons/day of propylene: .......................................................................................... 93
9.3 Cost Index:.......................................................................................................................................... 94
9.4 Purchase Cost of Major Equipment’s: ................................................................................................ 94
9.5 Total Equipment Cost: ........................................................................................................................ 95
9.6 Total Capital Investment (TCI): ......................................................................................................... 95
9.6.1 FCI (Fixed capital investment): ................................................................................................. 95
9.6.2 WCI (Working Capital Investment): ......................................................................................... 95
9.7 Direct Cost: ......................................................................................................................................... 96
9.8 Depreciation Cost: .............................................................................................................................. 96
9.9 General Expenses: .............................................................................................................................. 97
9.10 Net Profit: ........................................................................................................................................... 97
9.11 Let the tax rate is 30%: ....................................................................................................................... 98
9.12 Rate of Return: ................................................................................................................................... 98
9.13 Payback Period: .................................................................................................................................. 98
10 Process Instrumentation and Control: ................................................................................................. 100
10.1 Design Steps of Control Scheme: ..................................................................................................... 100
10.2 Control Schemes on Knock out vessel: ............................................................................................ 100
10.3 Pressure Control Scheme:................................................................................................................. 101
10.3.1 Disturbance: ............................................................................................................................. 101
10.3.2 Control Variables: ................................................................................................................... 101
10.3.3 Manipulated Variable: ............................................................................................................. 101
10.4 Description: ...................................................................................................................................... 101
10.5 Level Control Scheme: ..................................................................................................................... 101
10.5.1 Disturbance: ............................................................................................................................. 101
10.5.2 Control Variables: ................................................................................................................... 101
10.5.3 Manipulated Variable: ............................................................................................................. 102
10.6 Description: ...................................................................................................................................... 102
11 HAZOP Study: ....................................................................................................................................... 104
11.1 Definition of HAZOP Term: ............................................................................................................ 104
11.1.1 Hazard: .................................................................................................................................... 104
11.1.2 Harm: ....................................................................................................................................... 104
11.1.3 Risk:......................................................................................................................................... 104
11.2 Guide word: ...................................................................................................................................... 105
11.3 HAZOP study of Heat Exchanger: ................................................................................................... 106
12 References: .............................................................................................................................................. 107
List of Figures:
Figure 1.1: 3D-Propylene structure........................................................................................................ 2

Figure 1.2: Hazard Symbol ................................................................................................................... 4
Figure 2.1: Global consumption of Propylene ..................................................................................... 11
Figure 2.2: Global demand by application .......................................................................................... 11
Figure 2.3: Production capacity in 2018-30 ........................................................................................ 12
Figure 2.4: Market Analysis ............................................................................................................... 12
Figure 2.5: Price difference between Propane/Propylene .................................................................... 13
Figure 2.6: Global market share........................................................................................................... 13
Figure 4.1: PFD of Propylene Production ........................................................................................... 23
Figure 5.1: Schematic diagram representing material balance around De-Propanizer ........................ 25
Figure 5.2: Schematic diagram representing material balance around reactor .................................... 27
Figure 5.3: Schematic diagram representing material balance around Knockout drum ...................... 27
Figure 5.4: Schematic diagram representing material balance around PP-Splitter ............................. 29
Figure 5.5: Schematic diagram representing material balance around Mixer ..................................... 29
Figure 6.1: Schematic diagram representing energy balance around Distillation Column ................. 31
Figure 6.2: Block diagram representing energy balance of Reactor .................................................... 35
Figure 6.3: Schematic diagram representing energy balance around Furnace .................................... 36
Figure 6.4: Schematic diagram representing energy balance across Heat Exchanger ......................... 37
Figure 6.5: Schematic balance representing energy balance across compressor ................................. 38
Figure 6.6: Schematic diagram representing energy balance across Compressor ............................... 39
Figure 6.7: Schematic diagram representing energy balance around PP-Splitter ................................ 40
Figure 7.1: Block Diagram of Reactor selection ................................................................................. 45
Figure 7.2: Schematic diagram of UOP Moving Bed Reactor ............................................................ 46
Figure 7.3: Graph for rate equation of main reaction .......................................................................... 49
Figure 7.4: Flooding velocity for Sieve plates .................................................................................... 65
Figure 7.5: Flooding velocity for sieve plate ...................................................................................... 67
Figure 7.6: Wire length ........................................................................................................................ 69
Figure 7.7: Weep point correlation ..................................................................................................... 70
Figure 7.8: Vapor pressure correlation ................................................................................................ 71
Figure 7.9: Entrainment calculation..................................................................................................... 73
Figure 7.10: Perforated area correlation .............................................................................................. 73
Figure 8.1: Add components ................................................................................................................ 89
Figure 8.2: Applying fluid package ..................................................................................................... 90
Figure 8.3: Feed conditions.................................................................................................................. 90
Figure 8.4: Add Distillation column specifications ............................................................................. 91
Figure 8.5: Results of distillation column ............................................................................................ 91
Figure 10.1: Control loop on knockout drum .................................................................................... 100
List of Tables:
Table 1-1: Physical Properties ............................................................................................................... 6

Table 1-2: Application of Propylene...................................................................................................... 8
Table 2-1: Market analysis data ........................................................................................................... 14
Table 2-2: Feed Composition............................................................................................................... 15
Table 3-1: Summary of Review and Screening of Alternative Processes ........................................... 17
Table 3-2: Comparison between Catofin and Oleflex ......................................................................... 18
Table 5-1: material balance around distillation column ...................................................................... 26
Table 5-2: Material balance around reactor ......................................................................................... 27
Table 5-3: material balance around Knockout Drum .......................................................................... 28
Table 5-4: Material balance around PP-splitter ................................................................................... 29
Table 6-1: Cp calculation for feed stream of Distillation column ....................................................... 32
Table 6-2: Cp calculation for vapors stream of Distillation column ................................................... 32
Table 6-3: Cp calculation for Top Liquid stream of Distillation column ............................................ 33
Table 6-4: Cp calculation for Bottom liquid stream of Distillation column ........................................ 34
Table 6-5: Energy balance across Heat Exchanger.............................................................................. 37
Table 6-6: Energy balance across other Heat Exchanger .................................................................... 38
Table 6-7: Cp calculation for feed stream of PP-Splitter ..................................................................... 40
Table 6-8: Cp calculation for vapors stream of PP-Splitter ................................................................. 41
Table 6-9: Cp calculation for Top liquid stream of PP-Splitter ........................................................... 42
Table 6-10: Cp calculation for Bottom liquid stream of PP-Splitter ................................................... 43
Table 7-1: Selection of head on the basis of operating pressure [28] .................................................. 54
Table 7-2: Specification sheet of Reactor ............................................................................................ 56
Table 7-3: Selection of Distillation Column ........................................................................................ 58
Table 7-4: Internal Plates Selection ..................................................................................................... 59
Table 7-5: Feed Conditions of Distillation column ............................................................................. 60
Table 7-6: top conditions of Distillation column ................................................................................. 60
Table 7-7: Bottom conditions of Distillation column .......................................................................... 61
Table 7-8: Specification sheet of Distillation column ......................................................................... 75
Table 7-9: Specification sheet of Heat Exchanger ............................................................................... 83
Table 7-10: Process Conditions ........................................................................................................... 84
Table 7-11: Specification sheet of Knockout drum ............................................................................. 86
Table 9-1: Total equipment cost .......................................................................................................... 95
Table 9-2: Direct cost........................................................................................................................... 96
Table 9-3: Indirect cost ........................................................................................................................ 96
Table 11-1: Guided words ................................................................................................................. 105
Table 11-2: HAZOP study of heat exchanger.................................................................................... 106
Chapter # 01
Introduction to PROPYLENE
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1 Introduction
Propylene, also called propene, a colorless, flammable, gaseous hydrocarbon, C3H6, obtained from
petroleum; large quantities of propylene are used in the manufacture of resins, fibers, and elastomers
(see polyolefin), and numerous other chemical products. See glycol; propyl alcohol. [1]
Propylene (C3H6) is a colorless fuel gas with a naturally pungent smell. Although similar to propane,
it has a double bond which gives it a combustion advantage i.e., it burns hotter. This fuel gas is
extremely flammable and non-toxic. Propylene is obtained during the refining of gasoline. But it can
also be produced by splitting, cracking and reforming hydrocarbon mixtures. [2]
1.1 Structure of Propylene: [3]

The PROPYLENE molecule contains a total of 8 bond(s) There are 2 non-H bond(s), 1 multiple
bond(s) and 1 double bond(s).
Images of the chemical structure of PROPYLENE are given below:
Figure 1.1: 3D-Propylene structure [4]
The 2D chemical structure image of Propylene is also called skeletal formula, which is the standard
notation for organic molecules. The carbon atoms in the chemical structure of PROPYLENE are
implied to be located at the corner(s) and hydrogen atoms attached to carbon atoms are not indicated
each carbon atom is considered to be associated with enough hydrogen atoms to provide the carbon
atom with four bonds.
The 3D chemical structure image of PROPYLENE as shown above displays both the three-
dimensional position of the atoms and the bonds between them. The radius of the spheres is therefore
smaller than the rod lengths in order to provide a clearer view of the atoms and bonds throughout the
chemical structure model of PROPYLENE.
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1.2 Project Background:
Final year design project team has been assigned to design a Polymer grade Propylene plant
using dehydrogenation of Propane having production capacity of 150 metric tons per day. The team
needs to incorporate safety aspects, site location, conceptual design, Material balance, Energy
balance and preliminary economic evaluation in the early design of project of plant.
1.3 Project Objective:

The objectives of this design project include following:
 To apply appropriate design codes in a detailed design work

 To present a piping and instrumentation diagram (P&ID) and control strategy packages.
 To integrate chemical engineering skills and knowledge in a detailed design of a chemical
plant.
 To propose detailed economic evaluation of proposed chemical plant.
 To generate cost effective process options while maintaining operability, safety and
environment friendliness of the design.
 Make the necessary decisions, judgments and assumptions in design problems.
 Performing instrumentation and control study.
 Performing process design of major process units.
 Performing mechanical design of major process units.
 Performing economic evaluation including capital cost estimation.
 Considering the environment and safety issues related to plant. Material safety data sheet
(MSDS) for all the chemicals involved must be part of the safety and environment discussion.
 Preparing the group and individual reports as per the standard format and conducting the oral
presentations.
1.4 Safety Data of Propylene: [5]

1.4.1 Identification:
propylene; 1-Propene; propylene in gaseous state, impure; propylene liquefied, impure; propene,
pure; propylene, pure; Methyl ethene; Methyl ethylene; prop-1-ene; 1-Propylene; R 1270.
3|Page
1.4.2 Potential Hazards:
 Eye contact:
Immediately flush eyes with plenty of water, occasionally lifting the upper and lower eyelids. Check
for and remove any contact lenses. Continue to rinse for at least 10 minutes. Get medical attention if
irritation occurs.
 Inhalation:
Remove victim to fresh air and keep at rest in a position comfortable for breathing. If not breathing,
if breathing is irregular or if respiratory arrest occurs, provide artificial respiration or oxygen by
trained personnel. It may be dangerous to the person providing aid to give mouth-to-mouth
resuscitation. Get medical attention if adverse health effects persist or are severe. If unconscious,
place in recovery position and get medical attention immediately. Maintain an open airway. Loosen
tight clothing such as a collar, tie, belt or waistband.
 Skin contact:
Flush contaminated skin with plenty of water. Remove contaminated clothing and shoes. To avoid
the risk of static discharges and gas ignition, soak contaminated clothing thoroughly with water
before removing it. Get medical attention if symptoms occur. Wash clothing before reuse. Clean
shoes thoroughly before reuse.
 Hazard pictograms:
Figure 1.2: Hazard Symbol [6]
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1.5 Exposure controls/personal protection:
Exposure limits- 500 ppm 8 hours.
1.5.1 Appropriate engineering controls:

Use only with adequate ventilation. Use process enclosures, local exhaust ventilation or other
engineering controls to keep worker exposure to airborne contaminants below any recommended or
statutory limits. The engineering controls also need to keep gas, vapor or dust concentrations below
any lower explosive limits. Use explosion-proof ventilation equipment.
1.5.2 Environmental exposure controls:

Emissions from ventilation or work process equipment should be checked to ensure they comply
with the requirements of environmental protection legislation. In some cases, fume scrubbers, filters
or engineering modifications to the process equipment will be necessary to reduce emissions to
acceptable levels.
1.5.3 Hygiene measures:

Wash hands, forearms and face thoroughly after handling chemical products, before eating, smoking
and using the lavatory and at the end of the working period. Appropriate techniques should be used
to remove potentially contaminated clothing. Wash contaminated clothing before reusing. Ensure
that eyewash stations and safety showers are close to the workstation location.
1.5.4 Eye/face protection:

Safety eyewear complying with an approved standard should be used when a risk assessment
indicates this is necessary to avoid exposure to liquid splashes, mists, gases or dusts. If contact is
possible, the following protection should be worn, unless the assessment indicates a higher degree of
protection: safety glasses with side shields.
1.5.5 Respiratory protection:

Based on the hazard and potential for exposure, select a respirator that meets the appropriate standard
or certification. Respirators must be used according to a respiratory protection program to ensure
proper fitting, training, and other important aspects of use. Respirator selection must be based on
known or anticipated exposure levels, the hazards of the product and the safe working limits of the
selected respirator.
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1.5.6 Body protection:
Personal protective equipment for the body should be selected based on the task being performed and
the risks involved and should be approved by a specialist before handling this product. When there is
a risk of ignition from static electricity, wear antistatic protective clothing. For the greatest protection
from static discharges, clothing should include anti-static overalls, boots and gloves.
1.6 Physical properties: [7]
Property Value
Molecular weight 42.081 kg / kmol
Freezing point -185.25 °C
Boiling point -47.7 °C
Flash point -107.8 °C
Critical temperature 91.8 °C
Auto-ignition temp. 455 °C
Density 0.5139 g/cm³ (at 20 °C)
Solubility Water: 384 mg/l
Oxidizing properties None
Table 1-1: Physical Properties
1.7 Applications of propylene: [8]
Product Application Application Description
 Polypropylene is used to make many well-known

Polypropylene plastic products.
 Polypropylene resins can be injection molded and
extruded (into fibers, film, and sheets) to make a
variety of products.
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 Polypropylene may also be blow-molded or
thermoformed, but these processes are less often
used.
 Polypropylene is extremely corrosion resistant,
lightweight, flexible, and formed or welded.
Propylene Oxide  Used mainly as a chemical intermediate in the

production of polyurethane polyols and propylene
glycols.
 Used in the manufacture of propylene glycol, which
helps to make antifreeze, resins for reinforced
plastics, pharmaceuticals, packaging materials, dyes,
and hydraulic fluids, and humectants for foods, drugs,
cosmetics, and pet foods.
 Derivatives of propylene oxide include polyether
polyols; propylene glycol; di- and tri propylene
glycol; poly (propylene glycol); surfactants; glycol
ethers; and isopropanol amines.
Isopropanol  A variety of solvent applications, such as in printing

inks, surface coatings, and as a solvent for resins,
shellacs, and gums.
 As a component of personal care products, such as
after-shaves; and as an antiseptic and disinfectant,
such as rubbing alcohol.
 Used in the production of acetone, methyl isobutyl
ketone (MIBK), iso-propylamines and isopropyl
acetate.
Cumene  Alkylation of benzene with propylene yields cumene.

 Consuming in phenol production for the manufacture
7|Page
phenolic resins, caprolactam and bisphenol A.
Ethylene-Propylene  About half of the worldwide production of EP

Elastomers elastomer goes into the manufacture of automobile
body and chassis parts, hoses, weatherstripping, and
tires.
 Also used to make thermoplastic polyolefin
elastomers, polymer modifiers, and other products
used in automobile components beside used in single-
ply roofing.
Oxo Process Chemicals  Propylene is used to manufacture Iso-butyraldehyde,

which is converted to iso-butanol solvent for surface
coatings.
 Propylene is also used to make n-Butyraldehyde,
which is converted to n-butanol or 2-EH. n-Butanol is
a solvent for lacquers and coatings, and is an
intermediate for several chemicals.
Polygons Chemicals  Refinery production of polymer gasoline also yields

(nonene, dedecene, nonene, dodecene and heptenes and propylene is
heptenes) consumed to yield these polygons chemicals.
 Nonene is used in nonylphenol and iso-decyl alcohol
that act as an intermediate for surfactants, lubricating
oil additives, and phosphate antioxidants.
 Heptenes are consumed to make iso-octyl alcohol,
which is used in the manufacture of another phthalate
ester.
Table 1-2: Application of Propylene
8|Page
1.8 About Propylene: [9]
Propylene is the other name of Propene, also known as methyl ethylene, is an unsaturated organic
compound having the chemical formula 𝐶𝐶3 𝐻𝐻6 . It has one double bond, and is the second simplest
member of the alkene class of hydrocarbons. It is a colorless gas with a faint petroleum-like odor.
Propylene is a byproduct of oil refining and natural gas processing. During oil refining, ethylene,
Propylene, and other compounds are produced as a result of cracking larger hydrocarbons. A major
source of propylene is naphtha cracking intended to produce ethylene, but it also results from
refinery cracking producing other products. Propylene can be separated by fractional distillation from
hydrocarbon mixtures obtained from cracking and other refining processes; refinery-grade propylene
is about 50 to 70%.
Propylene can also be produced in an on-purpose reaction (for example, in propane dehydrogenation,
metathesis or syngas-olefins plants).
Commercially, Propylene is traded in three grades:
 Polymer grade (PG): min. 99.5% of purity.
 Chemical Grade: (CG) 90-96% of purity.
 Refinery Grade (RG): 50-70% of purity.
9|Page
Chapter # 2
Market analysis of Propylene.
10 | P a g e
2 Market Analysis and Capacity Selection:
2.1 Worldwide Consumptions of Propylene:
Figure 2.1: Global consumption of Propylene [10]
2.2 Worldwide Demand of Propylene by Applications:
Figure 2.2: Global demand by application [11]
2.3 Worldwide Production capacity of Propylene 2018-2030:

In 11 years, the global production capacity of propylene is expected to expand from 130 million
metric tons in 2019 to approximately 192 million metric tons by 2030, mostly due to propylene
production plants expected to open in Asia and the Middle East during that timeframe.
11 | P a g e
Figure 2.3: Production capacity in 2018-30 [12]
2.4 Trade of Propylene: [13]

In 2019, Propene (propylene) were the world's 437th most traded product, with a total trade of
$7.25B. Between 2018 and 2019 the exports of Propene (propylene) decreased by -11.4%, from
$8.19B to $7.25B. Trade in Propene (propylene) represent 0.04% of total world trade.
2.4.1 Exports:
In 2019 the top exporters of Propene (propylene) were South Korea ($1.49B), Japan ($749M),
United States ($715M), Netherlands ($700M), and Chinese Taipei ($542M).
2.4.2 Imports:
In 2019 the top importers of Propene (propylene) were China ($2.72B), Germany ($871M), Belgium
($730M), Netherlands ($469M), and Mexico ($280M).
2.5 Market Analysis (Asia Pacific):
Figure 2.4: Market Analysis [14]
12 | P a g e
2.6 Price difference between propane/propylene:
Figure 2.5: Price difference between Propane/Propylene
2.7 Global market share by the end-use industry 2019:
% use
18%
37% packaging
7% automation
construction
5% life style
4% heath care
6% electrical
9% agricultural
14%
Figure 2.6: Global market share [8]
2.8 Market analysis (Asia pacific-2018): [15]

COUNTRY POTENTIAL (MT) PRICE $/MT
1 Azerbaijan 35001.973 549
2 China -2840604 1103
3 Egypt -70499 1078
4 India 44938 809
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5 Indonesia -101612 1056
6 Japan 563027 996
7 Malaysia -15664 1145
8 Pakistan -1040 1103
9 Rep. of Korea 1561534 1004
10 Russian Federation 101889 815
11 Saudi Arabia 322701 960
12 Turkey -21707 1150
13 United Arab Emirates -191 2320
Total potential per Annum -422,226 $1,083.69
Per day Need -1156.78
Table 2-1: Market analysis data
2.9 Price analysis & CAGR: [16]

 Propylene (avg) price: $1086.69/MT
 LPG (avg) price: $574/MT
 Compound annual growth rate (CAGR) of Asia Pacific: 2.95%
2.10 Capacity selection:

Capacity of our plant is based on the availability of Raw material “LPG” in Pakistan. Our plant is
located in Multan. So, the nearest available source of LPG is Parco.
We will purchase LPG from “Parco Pearl Gas Limited (PPGL). PPGL is producing 85000 MT
Annually. On the behalf total available RAW MATERIAL and market situations we decided the
capacity of our plant “150 MTPD”.
14 | P a g e
2.11 Raw Material: [8]
component %Age
Propane 85-95
Butane 7-10
Pentane 3-5
Table 2-2: Feed Composition
15 | P a g e
Chapter # 03
Process Selection
16 | P a g e
3 Process Selection: [8]
The main processes for the production of Propylene are given below:
 Propane Dehydrogenation.
 Metathesis.
 Methanol-to-Olefins (MTO).
 Olefins Conversion Technology (OCT).
Metathesis of from
Dehydrogenation of propane
Ethylene & Butene
Reaction C3H8  C3H6 + H2 C2H4 + C4H8  2C3H6
Type of process Continuous process Continuous process
Butane and ethylene are

Safety Propane is flammable. flammable, and ethylene also
may cause dizziness
By-product Hydrogen No by-product
Operating Temperature: 560 - 650 ºC Temperature: 90-100ºC

Condition Pressure: 1.2 atm – 1.8atm Pressure: 100 – 110 bar
Overall
86% percent of conversion 90% percent of conversion
Conversion
Selectivity 90% 85%
Flammability Flammable Flammable
Table 3-1: Summary of Review and Screening of Alternative Processes
3.1 Commercial PDH Technologies: [17]

There are two available commercial PDH technologies:
 CATOFIN (fixed–bed) from ABB Lummus Global.

 OLEFLEX (moving–bed) from UOP.
17 | P a g e
Each technology has its own advantages and disadvantages. Differences arise in the utilized catalyst,
technology process, operating conditions (temperature and pressure) and performance.
CATOFIN and OLEFLEX are the only commercials proven PDH technologies
3.2 Comparison between CATOFIN & OLEFLEX: [18]

CATOFIN OLEFLEX
Reactor system horizontal fixed bed vertical, moving catalyst
Catalyst chromium oxide Platinum
catalyst life max. 3 years max. 5 years
recycling of catalyst dump out & land filling platinum recovery
catalyst regeneration cyclic regeneration continuous cat. Regeneration.
regeneration time 10-20 minutes 7 days
Rex. Operating Cond. 600 C, 0.3-1.0 bar 600 C, 1.2-2.0 bar
conversion 45-50% 35-40%
selectivity 80-90% 80-90%
technology Old Advance
Table 3-2: Comparison between Catofin and Oleflex
3.3 Selected process:

OLEFLEX- is our selected process on the behalf of following factors.
 Reactor:
Gas reactions are easy to handle in vertical reactors so the OLEFLEX process is suitable.
 Catalyst life:
Platinum as long life (5 years) as compare to chromium oxide.
 Catalyst Recycling:
Platinum is recoverable on the other hand chromium will be dumped out.
 Catalyst regeneration:
Continuous regeneration is most suitable for continuous process, which OLEFLEX provides.
18 | P a g e
 Regeneration Time:
OLEFLEX process provide slow regeneration of catalyst which required less energy.
3.4 OLEFLEX (moving-bed) from UOP:

UOP OLEFLEX is a continuous catalytic dehydrogenation process technology utilized for the
production of light olefins from their corresponding paraffin; and specifically used to convert
propane (feedstock) into propylene. The OLEFLEX process uses a platinum-based catalyst (DeH-14)
to promote the dehydrogenation reaction.
DeH-14 catalyst maintains high activity and allows for high productivity and selectivity which is
characterized by lower platinum costs than previously used catalysts. Besides propane
dehydrogenation, OLEFLEX unit can be used for dehydrogenation of Iso-butane, normal butane, or
Iso-pentane feedstock separately or as mixtures.
OLEFLEX technology was commercialized in 1990, and by 2002 more than 1,250,000 MTA of
propylene was produced from various OLEFLEX units located in different places in the world.
19 | P a g e
Chapter # 4
Process description and process flow diagram
20 | P a g e
4 Process Description: [9]
4.1 Dehydrogenation of Propane:
Propane is dehydrogenated in the presence of Pt-Sn/Al2 O3 catalyst in R-101.
C3 H8 ⇔ C3 H6 + H2 (Main Reaction)
C3 H8 → C2 H4 + CH4 (Side Reaction)
The flowsheet can be broadly divided into the following sections: depropanizer column, reactor,
section, effluent cooling and compression, Knockout drum and the propylene-propane splitter
column.
4.2 Feed Preparation section:

First task is to separate our basic Raw Material “Propane”. As the raw material is purer the product
will have less by-products. For achieving 99% purity of propane. LPG is feed to Depropanizer DC-
101 where 99% pure propane is obtained from the top section.
Propane also has the properties of “Refrigerant” so we are utilizing its refrigerant property to liquefy
of product stream. CD-101 is used for this purpose. Here the liquid propane is gasified and the
gaseous product get liquefy.
Gaseous propane is then sent to the “Waste Heat Recovery Unit” where we are utilizing the waste
heat of our reactor outlet to preheat our raw material. For this purpose, HE-101 is used. Outlet
temperature of HE-101 is 348°C.
We need temperature of 600˚C in Reactor. So, the pre-heated propane gas is sent to the Furnace.
Furnace F-101 add more heat to it by burning furnace oil and raise the temperature of feed to the
600°C.
4.3 Dehydrogenation process:

In Reactor R-101, propane is converted to propylene and some by-products of methane and ethane.
The reactor is moving bed catalytic reactor. In which, platinum catalyst is moving continuously from
top to bottom connected with CCR and feed gas is contacting it counter currently from bottom to
top.
4.4 Product purification section:

This section contains waste heat recovery, cooling, compression, liquefaction, knock out and
propane/propylene splitter.
21 | P a g e
From the outlet of reactor, hot gas is passed through waste heat recovery unit where its temperature
decreases to 221.05°C. Then it is sent to the cooler HE-102 where it is cooled to ambient
temperature 35°C.
In compression section, the cooled gas is sent to the series of compressors (C-101 & C-102) where
its pressure increased from 1atm to 19atm.
After compression, compressed and cooled gas is sent to the condenser, where it gets liquefied. On
this stage just propane and propylene get liquefied. Hydrogen, Methane and ethane will not liquefy
because the operating temperature is higher than the critical temperatures of the components.
Outlet stream of the condenser is sent to the knock out V-101. Where the gases and liquids will
separate out on the basis of density difference by giving them disengaging space. Top gaseous
stream is sent to the furnace where it will mix with fuel to heat up our feed propane.
Downstream of the knock out is sent to propane/propylene splitter (PP-101) here our final product
propylene is obtained from top and unreacted propane from bottom section. Unreacted propane is
recycled to the system after some treatments.
22 | P a g e
4.5 Process Flow Diagram:
T=567°C
8 P=1.3atm
R-101
CCR
T=55°C T=600°C
5 P=5atm T=348°C
T=44°C E-101 P=1.8atm
T=44.75°C T=44.75°C P=4atm
P=15atm P=6atm 7
P=15atm
T=48.35°C
P=15atm 2 3 PV-101 4 6
LPG MX-101 CD-101 F-101 T=311.15°C
1 DC-101
9 P=1.1atm
14 T=54°C
P=19atm
3 13 12 11 10
T=105.45°C
E-104 T=80.43°C C-102 T=35°C T=164°C T=35°C E-102
P=15atm P=9atm E-103 P=9atm C-101
P=19atm P=1atm
17
T=26°C T=23°C 19
T=30°C
15 P=19atm P=15atm P=15atm
18 T=36.85°C
P=15atm
T=23°C
PV-102 16 P=15atm 20 21
V-101 PP-101
T=167°C T=44.75°C
P=15atm E-105 P=15atm
Figure 4.1: PFD of Propylene Production [9]
23 | P a g e
Chapter # 5
Material Balance
24 | P a g e
5 Material Balance:
Mass balance (Material balance) are very important techniques to use during the design of chemical
engineering processes. They are direct application of the law of conservation of mass “mass neither
be created nor destroyed”. Chemical engineer invested this law in the design of chemical processes.
The purpose of mass balance is to produce 150 MTPD propylene from LPG source. The LPG
consists of 85-95% propane, 7-10% butane and 3-5% pentane. The propylene is produced by Oleflex
process.
5.1 Material Balance Around De-propanizer:

 Feed basis (7903.0207 kg/hr)
 𝐶𝐶3 𝐻𝐻8 : Light key component 99.99% in top.
 𝐶𝐶4 𝐻𝐻10 : Heavy key 99.99% in bottom.
 𝐶𝐶5 𝐻𝐻12 : Heavier than heavy key 100% in bottom.
Assumption:
 Steady state process (no accumulation)

 No reaction involved (no generation and consumption)
General Mass Balance:
F=D+W
Component Mass Balance:
F × xf = Dxd × Wxw
Propane
LPG
F DC-101
Butane
Pentane
Figure 5.1: Schematic diagram representing material balance around De-Propanizer
25 | P a g e
Components Inlet kg/hr Distillate kg/hr Bottom kg/hr
Propane 6851.250349 6844.399098 6.851250349
Butane 802.6641677 0.802664168 801.8615035
Pentane 249.1062444 0 249.1062444
Table 5-1: material balance around distillation column
5.2 Material Balance Around Reactor:

Basis:
150MTPD Propylene produced by 16858.12 kg/hr of propane entered in reactor.
Assumption:
 Steady state process.
Conversion:
 C3 H6 = 40%
Selectivity:
 90%
Reactions:
C3 H8 ⇔ C3 H6 + H2 (Main Reaction)
C3 H8 → C2 H4 + CH4 (Side Reaction)

General Mass balance Equation for Chemical Reaction:
I𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 − 𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 + 𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 − 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = Accumulation
For steady state:
I𝑛𝑛𝑛𝑛𝑛𝑛𝑛𝑛 − 𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 + 𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺𝐺 − 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = 0
Component Mole Balance:
No of final moles = initial moles – moles consumed
𝒏𝒏𝒏𝒏 = 𝒏𝒏𝒏𝒏 − 𝒏𝒏(𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄𝒄)
Moles consumed= conversion*moles of limiting reactant*stoichiometric coefficient.
26 | P a g e
Outlet
Inlet
Figure 5.2: Schematic diagram representing material balance around reactor
Components Inlet (Gas IN) kg/hr Outlet (Gas out) kg/hr

Propane 16858.125 10114.875
Propylene 0 6364.101019
Hydrogen 0 304.8960944
Ethylene 0 47.13588761
Methane 0 26.95399777
Table 5-2: Material balance around reactor
5.3 Material Balance Around Knockout Drum:

Gas out
Inlet
Liquid out
Figure 5.3: Schematic diagram representing material balance around Knockout drum
27 | P a g e
Feed: 16857.29 kg/hr
Assumption:
 Hydrogen, Methane and Ethylene are in gas phase they will remove from top.
 Propane and propylene are liquid phase they will remove from the bottom.
Note: Hydrogen, methane and ethylene are above at their critical temperature. So, these three
components are in gas phase.
F=D+W
𝐹𝐹 × 𝑥𝑥𝑓𝑓 = 𝐷𝐷𝑥𝑥𝑑𝑑 × 𝑊𝑊𝑥𝑥𝑤𝑤

Propane 10114.875 0 10114.875
Propylene 6364.101019 0 6364.101019
Hydrogen 304.8960944 304.8960944 0
Ethylene 47.13588761 47.13588761 0
Methane 26.95399777 26.95399777 0
Table 5-3: material balance around Knockout Drum
5.4 Material Balance Around Propane/Propylene Splitter:

Assumption:
 Propane and propylene are azeotrope.
 A ACN solvent is added with the ratio of 1:1 feed: solvent.
 99% pure propylene will be at top product.
 99% pure propane with solvent will be exit from the bottom.
 99% pure propane will be recycled to the mixer.
28 | P a g e
F=D+W

𝐹𝐹 × 𝑥𝑥𝑓𝑓 = 𝐷𝐷𝑥𝑥𝑑𝑑 × 𝑊𝑊𝑥𝑥𝑤𝑤
F PP-101
Figure 5.4: Schematic diagram representing material balance around PP-Splitter

Propane 10114.875 101.14875 10013.72625
Propylene 6364.101019 6300.460008 63.64101019
Solvent (ACN) 16415.33501 30.93332375 16384.39668
Table 5-4: Material balance around PP-splitter
5.5 Material Balance Around Mixer:
Figure 5.5: Schematic diagram representing material balance around Mixer
Propane out to Distillation Column is = 6844.399 kg/hr

Propane Recycle to PP-Splitter = 10013.726 kg/hr
29 | P a g e
Chapter # 6
Energy Balance
30 | P a g e
6 Energy Balance: [19]
“The First Law of Thermodynamics is a statement of energy conservation. Although energy cannot
be created or destroyed, it can be converted from one form to another.”
For example, internal energy stored in molecular bonds can be converted into kinetic energy,
potential energy can be converted too kinetic or too internal energy, etc. Energy can also be
transferred from one point to another, or from one body to a second body. The general energy
balance for a process can be expressed as
Accumulation of Energy in System = Energy input to System – Energy Output from System.
6.1 Energy balance Around Distillation Column (DC-101):
Top Stream
Bubble Temperature 44.75℃
Feed Stream
Dew Temperature 46℃
Bubble Temperature 48℃
Dew Temperature 59℃ Mole Fraction
Propane = 0.999
Mole Fraction Butane = 0.0000089
Propane = 0.9
Butane = 0.08 Bottom Stream
Pentane = 0.02 Bubble Temperature 105.45℃

Dew Temperature 113.15℃
Mole Fraction
Propane = 0.0089
Butane = 0.793
Pentane = 0.1984
Figure 6.1: Schematic diagram representing energy balance around Distillation Column
31 | P a g e
Feed Stream:
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 155.367 0.9 66.52
Butane 13.8104 0.08 75.21
Pentane 3.4526 0.02 93.97
Table 6-1: Cp calculation for feed stream of Distillation column
Average Cp =∑(𝐶𝐶𝑝𝑝 × 𝑥𝑥)
Cp avg. = 67.76 kJ/kmol. K
𝑇𝑇𝑓𝑓 = 321.5𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
n = F = 172.63 kmol/hr
∆𝑯𝑯𝒇𝒇 = 𝒏𝒏 × 𝑪𝑪𝒑𝒑 × ∆𝑻𝑻
kJ
∆𝐇𝐇𝐟𝐟 = 273139.1544
hr
∆𝐇𝐇𝐟𝐟 = 75.8719 kW
Top Stream:
a) Enthalpy of vapors at top
Propane 155.21163 0.9999 30.7973
Butane 0.0138104 0.0000889 25.9615
Table 6-2: Cp calculation for vapors stream of Distillation column
𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑 = 319.15𝐾𝐾
32 | P a g e
R = 0.80617
D = 155.225 kmol/hr
L = 125.138 kmol/hr
V = 280.363 kmol/hr
∆𝐇𝐇𝐯𝐯 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓
kJ
∆𝐇𝐇𝐯𝐯 = 181320.56
hr
∆𝐇𝐇𝐯𝐯 = 50.366 kW
b) Heat of Condensation
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 𝐧𝐧𝐧𝐧
kJ
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 3649.633
hr
∆𝐇𝐇𝐯𝐯 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓 + 𝐧𝐧𝐧𝐧
kJ
∆𝐇𝐇𝐯𝐯 = 184970.1935
hr
∆𝐇𝐇𝐯𝐯 = 𝟓𝟓𝟓𝟓. 𝟑𝟑𝟑𝟑𝟑𝟑 𝐤𝐤𝐤𝐤
c) Enthalpy of Liquid at Distillate

Propane 155.21163 0.9999 121.6305
Butane 0.0138104 0.0000889 141.6234
Table 6-3: Cp calculation for Top Liquid stream of Distillation column
Average Cp =∑�𝐶𝐶𝑝𝑝 × 𝑥𝑥�
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 317.9𝐾𝐾
R = 0.80617
33 | P a g e
D = 155.225 kmol/hr
L = 125.138 kmol/hr
∆𝐇𝐇𝐝𝐝 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓
kJ
∆𝐇𝐇𝐝𝐝 = 300611.2121
hr
∆𝐇𝐇𝐝𝐝 = 𝟖𝟖𝟖𝟖. 𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓𝟓 𝐤𝐤𝐤𝐤
Condenser Duty:
Qc = Qv + Q latent + Qd
𝐤𝐤𝐤𝐤
𝐐𝐐𝐜𝐜 = 𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒. 𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒
𝐡𝐡𝐡𝐡
Bottom Stream:
a) Enthalpy of Liquid at bottom
Propane 0.155367 0.008927 78.00425
Butane 13.79659 0.792699 96.5722
Pentane 3.4526 0.198373 117.9452
Table 6-4: Cp calculation for Bottom liquid stream of Distillation column
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 378.6𝐾𝐾
∆𝐇𝐇𝐰𝐰 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓
kJ
∆𝐇𝐇𝐰𝐰 = 140924.6097
hr
∆𝐇𝐇𝐰𝐰 = 𝟑𝟑𝟑𝟑. 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 𝐤𝐤𝐤𝐤
34 | P a g e
Reboiler Duty:
QB = Qc + Hw+ HD –HF
QB = 653978.073 kJ/hr
QB = 181.6606 kW
6.2 Energy Balance of Reactor (R-101):
Figure 6.2: Block diagram representing energy balance of Reactor
Main Reaction:
C3 H8 ⇔ C3 H6 + H2
Side Reaction:
C3 H8 → C2 H4 + CH4
Operating Temperature: 873.15K
Operating Pressure: 1.8atm
Reference Temperature: 298.15K
kJ
∆Hr1 at 25℃ = 125.11
kmol
kJ
∆Hr2 at 25℃ = 82.13
kmol
35 | P a g e
kJ
Q in = n × Cp × ∆T = −36054942.49
hr
kJ
Q out = n × Cp × ∆T = 14419698.03
hr
kJ
∆Hr1 at 600℃ = 50493561.92
hr
kJ
∆Hr2 at 600℃ = 21784632.65
hr
kJ
∆Hr = 72278194.57
hr
𝐐𝐐 = 𝐐𝐐𝐢𝐢𝐢𝐢 − 𝐐𝐐𝐨𝐨𝐨𝐨𝐨𝐨 + ∆𝐇𝐇𝐫𝐫
Q = −36054942.49 − 14419698.03 + 72278194.57
kJ
Q = 21803554
hr
Q = 6056.54 kW
6.3 Energy Balance across Furnace (F-101):
Propane:
Inlet Temperature: 621.15K
Cp avg: 3.4127 kJ/kg. K
Mass Flow rate: 16858.12kg/hr
Propane:
Outlet Temperature: 873.15K
Cp avg: 3.4127 kJ/kg. K
Mass Flow rate: 16858.12kg/hr
Figure 6.3: Schematic diagram representing energy balance around Furnace
Duty of Furnace:
𝐐𝐐 = 𝐦𝐦 × 𝐂𝐂𝐂𝐂 × ∆𝐓𝐓
𝐐𝐐 = 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏. 𝟏𝟏𝟏𝟏 × 𝟑𝟑. 𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒 × 𝟓𝟓𝟓𝟓𝟓𝟓. 𝟏𝟏𝟏𝟏
36 | P a g e
Q = 30212419.8 kJ/hr
Q = 8392.34 kW
6.4 Energy Balance across Heat Exchanger (H-101):
Hot Stream: (Product gases)

𝐶𝐶3 𝐻𝐻8 , 𝐶𝐶3 𝐻𝐻6 , 𝐻𝐻2 , 𝐶𝐶2 𝐻𝐻4 , 𝐶𝐶𝐻𝐻4
Cold Stream: (Propane gas)
16858.125 kg/hr
𝐶𝐶3 𝐻𝐻8
T = 567℃
16858.125 kg/hr
T = 55℃
Hot Stream: (Propane gas)

Hot Stream: (Product gases) 𝐶𝐶3 𝐻𝐻8
𝐶𝐶3 𝐻𝐻8 , 𝐶𝐶3 𝐻𝐻6 , 𝐻𝐻2 , 𝐶𝐶2 𝐻𝐻4 , 𝐶𝐶𝐻𝐻4 16858.125 kg/hr
16858.125 kg/hr T = 348℃
T = 311.15℃
Figure 6.4: Schematic diagram representing energy balance across Heat Exchanger
Stream Cp avg (kJ/kg. ℃ ) m (kg/hr)

Cold Stream (gas) 2.41 16858.125
Hot Stream (Product gases) 2.76 16858.125
Table 6-5: Energy balance across Heat Exchanger
Heat absorbed by Cold Stream:

𝟑𝟑𝟑𝟑𝟑𝟑
𝑸𝑸𝑪𝑪 = � 𝐦𝐦 × 𝐂𝐂𝐂𝐂 × ∆𝐓𝐓
𝟓𝟓𝟓𝟓
kJ
𝑄𝑄𝐶𝐶 = 11904027.81
hr
𝐐𝐐𝐂𝐂 = 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 𝐤𝐤𝐤𝐤
37 | P a g e
Heat released from Hot Stream:
𝟑𝟑𝟑𝟑𝟑𝟑.𝟏𝟏𝟏𝟏
𝑸𝑸𝑯𝑯 = � 𝐦𝐦 × 𝐂𝐂𝐂𝐂 × ∆𝐓𝐓
𝟓𝟓𝟓𝟓𝟓𝟓
kJ
Q H = −11904027.81
hr
𝐐𝐐𝐇𝐇 = −𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑 𝐤𝐤𝐤𝐤
Heat absorbed = Heat released
kJ kJ
11904027.81 = −11904027.81
hr hr
6.5 Energy balance across other Heat Exchangers:

Heat Flow rate Cp Inlet Temp. Outlet Heat Duty
Exchanger (kg/hr) (kJ/kg.℃) Temp. (℃)
(℃) (kJ/hr)
H-102 16857.96 2.41 311.15 35 11251450
H-103 16857.96 2.14 164 35 4661011
H-104 16857.96 2.02 80.43 54 901102
H-105 16857.96 2.16 165 44.75 4385548
Table 6-6: Energy balance across other Heat Exchanger
In this Heat Exchangers, water is used as a cooling medium and Cp of water is 4.167kJ/kg.℃.
6.6 Energy Balance across Compressor (C-101):

Product gases:
Product gases:
m = 16857.96 kg/hr
m = 16857.96 kg/hr
P = 9 atm
P = 1 atm
T =?
T = 35℃
Figure 6.5: Schematic balance representing energy balance across compressor
38 | P a g e
Outlet Temperature of Compressor:
𝐏𝐏𝟐𝟐 𝐤𝐤−𝟏𝟏
𝐓𝐓𝟐𝟐 = 𝐓𝐓𝟏𝟏 × ( ) 𝐤𝐤
𝐏𝐏𝟏𝟏
T2 = 164℃
6.7 Energy Balance across Compressor (C-102):

Product gases: Product gases:
𝐶𝐶3 𝐻𝐻8 , 𝐶𝐶3 𝐻𝐻6 , 𝐻𝐻2 , 𝐶𝐶2 𝐻𝐻4 , 𝐶𝐶𝐻𝐻4 𝐶𝐶3 𝐻𝐻8 , 𝐶𝐶3 𝐻𝐻6 , 𝐻𝐻2 , 𝐶𝐶2 𝐻𝐻4 , 𝐶𝐶𝐻𝐻4
m = 16857.96 kg/hr m = 16857.96 kg/hr
P = 9 atm P = 19 atm
T = 35℃ T =?
Figure 6.6: Schematic diagram representing energy balance across Compressor
Outlet Temperature of Compressor:
𝐏𝐏𝟐𝟐 𝐤𝐤−𝟏𝟏
𝐓𝐓𝟐𝟐 = 𝐓𝐓𝟏𝟏 × ( ) 𝐤𝐤
𝐏𝐏𝟏𝟏
T2 = 80.43℃
39 | P a g e
6.8 Energy Balance across Propane-Propylene Splitter (PP-101):
Top Stream
Feed Stream
Bubble Temperature 68.85℃ Mole Fraction
Dew Temperature 157℃ Propane = 0.015
Propylene = 0.98
Solvent = 0.0038
Mole Fraction
Propane = 0.3324
Bottom Stream
Propylene = 0.2192
Solvent = 0.4484
Mole Fraction
Propane = 0.422
Propylene = 0.0028
Solvent = 0.574
Figure 6.7: Schematic diagram representing energy balance around PP-Splitter
Feed Stream:
Propane 229.3778 0.3324 71.39
Propylene 151.2381 0.2192 67.04
Solvent (ACN) 309.3731 0.4484 55.71
Table 6-7: Cp calculation for feed stream of PP-Splitter
40 | P a g e
𝑇𝑇𝑓𝑓 = 342𝐾𝐾
n = F = 689.989 kmol/hr
∆𝑯𝑯𝒇𝒇 = 𝒏𝒏 × 𝑪𝑪𝒑𝒑 × ∆𝑻𝑻
kJ
∆𝐇𝐇𝐟𝐟 = 1918373
hr
∆𝐇𝐇𝐟𝐟 = 532.8 kW
Top Stream:
a) Enthalpy of vapors at top
Propane 2.2937 0.0150 30.655
Propylene 149.726 0.9811 32.811
Solvent (ACN) 0.58298 0.00382 22.025
Table 6-8: Cp calculation for vapors stream of PP-Splitter
𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑 = 318𝐾𝐾
n = 152.6025 kmol/hr
∆𝐇𝐇𝐯𝐯 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓
kJ
∆𝐇𝐇𝐯𝐯 = 99167.36
hr
∆𝐇𝐇𝐯𝐯 = 27.55 kW
b) Heat of Condensation
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 𝐧𝐧𝐧𝐧
41 | P a g e
kJ
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 1921.956
hr
∆𝐇𝐇𝐯𝐯 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓 + 𝐧𝐧𝐧𝐧
kJ
∆𝐇𝐇𝐯𝐯 = 101089.315
hr
∆𝐇𝐇𝐯𝐯 = 𝟐𝟐𝟐𝟐. 𝟎𝟎𝟎𝟎 𝐤𝐤𝐤𝐤
c) Enthalpy of Liquid at Distillate

Propane 2.2937 0.0150 63.322
Propylene 149.726 0.9811 58.585
Solvent (ACN) 0.58298 0.00382 40.054
Table 6-9: Cp calculation for Top liquid stream of PP-Splitter
Average Cp =∑�𝐶𝐶𝑝𝑝 × 𝑥𝑥�
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 310𝐾𝐾
n = 152.6025 kmol/hr
∆𝐇𝐇𝐝𝐝 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓
kJ
∆𝐇𝐇𝐝𝐝 = 105942.4
hr
∆𝐇𝐇𝐝𝐝 = 𝟐𝟐𝟐𝟐. 𝟒𝟒𝟒𝟒 𝐤𝐤𝐤𝐤
Condenser Duty:
Qc = Qv + Q latent + Qd
𝐤𝐤𝐤𝐤
𝐐𝐐𝐜𝐜 = 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐. 𝟕𝟕
𝐡𝐡𝐡𝐡
42 | P a g e
Bottom Stream:
a) Enthalpy of Liquid at bottom
Propane 227.0841 0.4226 85.814
Propylene 1.5124 0.0028 82.021
Solvent (ACN) 308.8 0.5746 86.403
Table 6-10: Cp calculation for Bottom liquid stream of PP-Splitter
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 359𝐾𝐾
n = 537.38 kmol/hr
∆𝐇𝐇𝐰𝐰 = 𝐧𝐧 × 𝐂𝐂𝐩𝐩 × ∆𝐓𝐓
kJ
∆𝐇𝐇𝐰𝐰 = 2816782.04
hr
∆𝐇𝐇𝐰𝐰 = 𝟕𝟕𝟕𝟕𝟕𝟕 𝐤𝐤𝐤𝐤
Reboiler Duty:
QB = Qc + Hw+ HD –HF
QB = 1211383 kJ/hr
QB = 336.495 kW
43 | P a g e
Chapter # 07
Equipment design
44 | P a g e
7 Equipment Design:
Estimation of design parameters:
For every engineering process the heart of the process is considered to be its design. As the PFD of
the process describe earlier in chapter number two the major equipment of the plant in our process
are
 Moving bed Reactor.

 Distillation Column.
 Shell and Tube Heat Exchanger.
 Knockout Drum.
7.1 Design of Reactor (R-101):

7.1.1 Introduction:
Reactor is the heart of a chemical process. Reactor is the equipment where the main chemical
reaction takes place. Following the reactor are the preliminary treatment and raw material
preparation steps whereas followed by the reactor are product enrichment and purification steps. The
main objective in this chapter is to determine what type and size of the reactor and mode of operation
would be the best to get the desired yield and purity of Propylene.
7.1.2 Reactor Selection Criteria:
Reactors
Homogeneous Heterogeneous
PLUG Fluidized
C.S.T.R Fixed bed Moving Bed
FLOW bed
Figure 7.1: Block Diagram of Reactor selection
Selection of the appropriate reactor for the process is as important as the accurate temperature and
pressure conditions for carrying out the reaction. Selection of the reactor depends on the following
factors;
 Mode of operations.
45 | P a g e
 Type of flow reactor.
 Catalyst bed (Fixed, Fluidized and moving bed).
 Reaction phase (Homogenous and Heterogeneous).
7.1.3 Moving Bed Reactor: [20]

A number of propane dehydrogenation commercial processes have been developed. These processes
differ in terms of the catalyst, reactor type and catalyst regeneration system. UOP Oleflex
dehydrogenation process is catalyzed by modified Pt alumina-supported catalyst in a moving-bed
reactors with continuous catalyst regeneration. The gas flows from the bottom of reactor are then
distributed equally by plug distributor to the horizontal direction. Meanwhile, the catalyst moves
down towards catalyst collector. The catalyst leaves the reactor is sent to the CCR unit, where the
coked catalysts are regenerated.
Figure 7.2: Schematic diagram of UOP Moving Bed Reactor
7.1.4 Catalyst Properties (Pt-Sn/𝐀𝐀𝐥𝐥𝟐𝟐 𝐎𝐎𝟑𝟑 ): [21]

 Diameter = 1.8mm
 Bulk density = 0.65 g/cm3
 Catalyst density = 1.12 g/cm3
 Catalyst surface area = 200 m2/g
7.1.5 Reaction Kinetics: [22]

Main Reaction:
600℃
C3 H8(g) C3 H6(g) + H2(g)
Pt-Sn/Al2 O3
46 | P a g e
∆H1 = 125.11 KJ/mol
Side Reaction:
600℃
C3 H8(g) C2 H4(g) + CH4(g)
Pt-Sn/Al2 O3
∆H2 = 82.14 KJ/mol
Operating Pressure and Temperature is 1.8atm and 600℃. At these conditions, reaction is
Endothermic.
7.1.6 Design Steps: [23]

 Specify the reaction kinetics.
 Calculate weight of the catalyst.
 Calculate Volume of catalyst.
 Calculation of Reactor Volume.
 Calculate residence time and weight hour space velocity.
 Length and Diameter Calculation.
 Bed height Calculation.
 Minimum fluidization Velocity Calculation.
 Terminal Velocity Calculation.
 Fluidization Velocity Calculation.
 Pressure Drop Calculation.
7.1.7 Kinetics of the reactions: [24]

Conversion of rate equation from partial pressure to concentration term:
PC3H8 − PH2
PC3H8 −
−ra = k1 ( K1 )
1 + K e Pe
Where;
mol
ra = rate of reaction ( . hr)
kg
47 | P a g e
mol
k1 = 0.0296 ( )
kg. min. bar
K e = 0.9454 (bar −1 )
K1 = 66.64 (bar −1 )
R = 8.314 (J/kmol. K)
T = 873.15 K
kmol
Cao = 0.025
m3
Order of reaction = 1
PC3H8 − PH2
PC3H8 −
−ra = k1 ( K1 )
1 + K e Pe
Cb. Cc
Ca − K
1
−ra = k1 RT( )
1 + K e Pe
2 2
0.01088mol Cao Xa
−ra = RT �Cao (1 − Xa ) − �
kg. min. bar 66.64
7.1.8 Design Equation: [25]

Xa
W dxa
=�
Fao −ra
0
Generate the data between Xa & 1/-ra and calculating the area under the curve by applying Simpson
rule,
48 | P a g e
Xa vs 1/-ra
0.9
0.8
0.7
0.6
0.5
-1/-ra
0.4
0.3
0.2
0.1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Xa
Figure 7.3: Graph for rate equation of main reaction

0.4
dxa 𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘
� = 646.8105
−ra 𝑘𝑘𝑘𝑘. 𝑚𝑚𝑚𝑚𝑚𝑚
0
7.1.9 Calculate Weight of the Catalyst:

W kmol
= 646.8105
Fao kg. min
𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘
Fao = 382.2864
ℎ𝑟𝑟
Weight of catalyst = 4121 kg cat
7.1.10 Calculate Volume of the Catalyst:

Mass
Density =
Volume
Mass of catalyst = 4121 kg cat
Density of catalyst = 1.12 g/cm3 = 1120 kg/m3
Mass
Volume =
Volume
Volume of the catalyst = 3.7 m3
7.1.11 Calculate Volume of Reactor:

𝐕𝐕𝐜𝐜𝐜𝐜𝐜𝐜
𝐕𝐕𝐛𝐛𝐛𝐛𝐛𝐛 = [26]
𝟏𝟏−𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯 𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟
49 | P a g e
Void fraction = 0.8
𝑉𝑉𝑏𝑏𝑏𝑏𝑏𝑏 = 18.5 m3
Assume 20% excess volume of bed
𝑉𝑉𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = 21.85 m3
7.1.12 Calculate Residence Time and WHSV:

From literature WHSV at 600℃ is 4/hr
We know;
1
τ=
s
τ = 0.3hr
Calculate volumetric flow;
Fao = Cao . vo
kmol
Fao = 382.2964
hr
kmol
Cao = 0.025
m3
m3
vo = 15291.86
hr
7.1.13 Length and Diameter Calculations:

Calculate Diameter;
3 4 × 𝑣𝑣𝑣𝑣𝑣𝑣.
𝐷𝐷𝐷𝐷𝐷𝐷 = �
3 × 3.14
D = 2.10m
L = 3 * Diameter
L = 6.30 m
Area = 3.14 * D * L
Area = 41.54 𝑚𝑚2
50 | P a g e
7.1.14 Bed Height Calculations:
Bed Volume = 3.7 𝑚𝑚3
𝜋𝜋
Bed area = × 𝐷𝐷2
4
Bed area = 3.46 𝑚𝑚2
Void fraction = 0.8
𝑊𝑊
Bed height =
𝜌𝜌𝜌𝜌(1−𝜀𝜀)
Bed height = 5.32 m
7.1.15 Minimum Fluidization velocity: [27]
Where;
kg
ρp = 1120
m3
dp = 0.0018m
m
g = 9.8
s2
kg
ρf = 1.11
m3
9.8 × (1120 − 1.11) × (0.8)2 × 0.0018

𝑢𝑢𝑚𝑚𝑚𝑚 = �
1.75 × 1.11
𝒎𝒎
𝒖𝒖𝒎𝒎𝒎𝒎 = 𝟐𝟐. 𝟐𝟐𝟐𝟐
𝒔𝒔
51 | P a g e
7.1.16 Terminal Fluidization Velocity: [27]
kg
μf = 0.0199cp = 0.000199
m. s
9.8 × (1120 − 1.11) × (0.0018)2

ut =
18 × 0.000199
𝐦𝐦
𝐮𝐮𝐭𝐭 = 𝟗𝟗. 𝟗𝟗𝟗𝟗𝟗𝟗
𝐬𝐬
7.1.17 Fluidization Velocity: [27]
(1120 − 1.11) × 9.8 × (0.0018)2 (0.8)3

uf = ×
150 × 0.000199 1 − 0.8
𝟑𝟑. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎
𝐮𝐮𝐟𝐟 =
𝐬𝐬
Relation Between minimum, terminal and fluidized velocity is;
𝒖𝒖𝒎𝒎𝒎𝒎 < 𝒖𝒖𝒇𝒇 < 𝒖𝒖𝒕𝒕
2.28 < 3.042 < 9.91
7.1.18 Pressure Drop due to Catalytic Bed:

Weight of catalyst bed = 4121kgcat
Area of bed = 3.46 𝑚𝑚2
F = w = mg
F = 4121 * 9.8 = 40385.8 N
F
∆P =
A
52 | P a g e
N
∆P = 11672.19
m2
∆P = 0.115atm
7.1.19 Pressure Drop due to Fluidization:
∆𝐏𝐏 = 𝟎𝟎. 𝟏𝟏𝟏𝟏 𝐚𝐚𝐚𝐚𝐚𝐚
Total Pressure Drop:
∆P = 0.115 + 0.16
∆𝐏𝐏 = 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐 𝐚𝐚𝐚𝐚𝐚𝐚
7.1.20 Mechanical Design of Reactor:

Steps:
 Material of construction
 Thickness of shell
 Head selection
 Design Temperature
 Design Pressure
Material of Construction:
 Operating conditions (temperature, pressure, corrosion resistance)

 Tensile strength
 Ease of fabrication
 High service performance
 Cost
According to the conditions suitable material for selection is “Low-alloy steel (SA-387)”
53 | P a g e
Reactor wall thickness: [28]
𝑃𝑃𝑃𝑃𝑃𝑃
t= + 𝐶𝐶𝐶𝐶
𝑆𝑆𝑆𝑆𝑆𝑆−0.6𝑃𝑃
Where;
t = minimum wall thickness
P = Design pressure = 182kPa
r = Inside radius of the cylinder = 1.05m
S = Maximum allowable stress = 6900kPa
E = Joint efficiency (E = 1)
Cc = Corrosion allowance = 0.001m
t = 0.028m
t = 28mm
Selection of Head:
Pressure bar Head type
P < 15 Toro spherical
P > 15 Hemisphere
P> 15 ellipsoidal
Table 7-1: Selection of head on the basis of operating pressure [28]
Hemispherical is stronger in strength than any other but is not economical so, Toro spherical is
selected.
Head Thickness:
𝟎𝟎. 𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖
𝐭𝐭 𝐡𝐡𝐡𝐡𝐡𝐡𝐡𝐡 = + 𝐂𝐂𝐂𝐂
𝐒𝐒𝐒𝐒𝐒𝐒 − 𝟎𝟎. 𝟏𝟏𝟏𝟏
 t = Theoretical thickness of the head
 P = Design pressure =182kPa
 La=inside radius=1.05m
54 | P a g e
 S = Maximum allowable stress = 6900Kpa
 E = Joint efficiency = 1
 Cc = Corrosion allowance = 0.001m
t = 0.025m
t = 25mm
Design Pressure:
Design pressure is mostly 10% excess of the operating pressure.
PD = P *1.1
PD = 1.9 bar
Design Temperature:
Design temperature is mostly used at industrial scale is 10% in excess of operating Pressure.
TD = T *1.1
TD = 949℃
55 | P a g e
7.1.21 Specification Sheet of Reactor:
Identification
Item Reactor
Item number R-101
Type Moving Bed Reactor
Operation Continuous
Orientation Vertical
Catalyst Pt-Sn/Al2O3
Function: Production of 150MTPD polymer grade “propylene” by

OLEFLEX process
Design Data
Operating Pressure 1.8atm
Operating temperature 600℃
Residence Time 0.3hr
Volume of reactor 21.85𝑚𝑚3
Diameter of reactor 2.10m
Length of reactor 6.30m
Fluidization velocity 3.042m/s
Pressure drops 0.275atm
Thickness of reactor wall 0.028m

Table 7-2: Specification sheet of Reactor
56 | P a g e
7.2 Design of Distillation Column (Depropanizer):
7.2.1 Distillation:
A separation process of liquid mixtures based on their boiling points or relative volatility. In simple
distillation process, a volatile compound is evaporated and channeled through a distillation column
into a condenser, where it is eventually captured. Distillation columns consist of an array of trays, in
which the lowest and highest boiling liquids are collected at the top and bottom of the column,
respectively.
7.2.2 Advantages of Distillation:

 Easy to implement:
One of the biggest benefits of fractional distillation is that it’s easy to use. As long as you set up a
fully functional and well-designed system, you can leave it as is to do its job. You only need to check
the system on a regular basis to ensure its functioning properly, find out if it needs repairs, and fix
whatever needs fixing. Modern fractional distillation setups are automated using microprocessors,
which make the process even easier.
 Highly effective and efficient:
Fractional distillation has been proven by countless experiments and actual processes to be effective.
In fact, it’s widely used in many industrial settings to create the products that modern society needs.
Fractional distillation is also highly efficient, especially for systems that use stacked distillation
columns, which produce more output at lower costs.
7.2.3 Types of Distillation:

The three main types of distillation are
 Fractional distillation.
 Azeotropic Distillation.
 Extractive Distillation.
 Vacuum Distillation.
 Steam Distillation.
57 | P a g e
7.2.4 Column Selection:
Comparison between packed and plate column:
Sr No Packed Column Plate Column

Provides continuous contact between Plate column brings the two phases into contact
1
vapor and liquid phases on stage wise basis.
Relatively low pressure drops in
Additional friction generated as the vapor
2 packed column as compared to plate
passes through the liquid on each tray.
column
Because of the liquid on each plate there may
In a packed tower the liquid flows as
3 be an Urge quantity of the liquid in plate
a thin film over the packing
column.
For corrosive liquids, a packed
For corrosive fluids, plate column is usually
4 column will usually be cheaper than
avoided.
the equivalent plate column
5 Small space requirement Relatively large in size and expensive.
Table 7-3: Selection of Distillation Column
Based on above mentioned qualification the best suited column for our process is “Plate Distillation
Column”
7.2.5 Internal Plates Selection:

Different type of plate configuration is available some types of trays are
 Sieve tray.
 Valve Tray.
 Bubble cap Tray.
Sr. No. Factor Sieve Tray Valve Tray Bubble Cap Tray
1 Capacity High High Moderate High
2 Efficiency High High Moderate High
3 Pressure Drop Moderate Moderate High
4 ~1.2 times sieve

Cost Low ~2-3 times sieve trays
trays
5 Maintenance Low Low to moderate Relatively high
58 | P a g e
6 High: tends to collect
Fouling Tendency Low Low to moderate
solids
7 Effect of
Low Low to moderate High
corrosion
8 Entrainment Moderate Moderate High
Table 7-4: Internal Plates Selection
On the behalf of above comparison, I have selected sieve tray.
7.2.6 Design Steps: [23]

 Feed Condition i.e., saturated liquid, sub cooled liquid etc.
 Distillation Top and Bottom Temperature.
 Average Relative volatilities w.r.t reference component.
 Minimum number of stages.
 Minimum reflux.
 Actual reflux.
 Actual number of stages.
 Feed point.
 Distillation column Diameter calculations (Top and Bottom).
 Distillation column Height calculation.
 L/D Ratio.
 Weir Length.
 Weeping.
 Pressure Drop.
 Down Comer liquid backup.
 Residence time.
 Entrainment (ψ).
 Perforated Area.
7.2.7 Feed Condition:
Components M.W A B C D E Composition

Propane 44.097 21.4469 -1462.7 -5.261 3.282E-11 3.7349E-06 0.90
Butane 58.12 27.0441 -1904.9 -7.1805 -6.684E-11 4.219E-06 0.08
59 | P a g e
Pentane 72.15 33.3239 -2422.7 -9.2354 9.019E-11 4.105E-06 0.02
Table 7-5: Feed Conditions of Distillation column
System Pressure = P = 15 bar
𝑩𝑩
𝑳𝑳𝑳𝑳𝑳𝑳 𝑷𝑷 = 𝑨𝑨 + + 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 + 𝑫𝑫𝑫𝑫 + 𝑬𝑬𝑻𝑻𝟐𝟐 [19]
𝑻𝑻
K-Values:
𝑃𝑃𝑖𝑖
𝐾𝐾𝑖𝑖 =
𝑃𝑃
Bubble Temperature:
Σ kixi= 1 Temperature= 47.35 ℃
Dew temperature:
Σ yi/ki= 1 Temperature= 59 ℃
7.2.8 Top Conditions:
Components M.W A B C D E Composition

Propane 44.097 21.4469 -1462.7 -5.261 3.282E-11 3.734E-06 0.999
Butane 58.12 27.0441 -1904.9 -7.1805 -6.684E-11 4.219E-06 0.0008
Distillation top stream Temperature calculation

Table 7-6: top conditions of Distillation column
𝑩𝑩
𝑳𝑳𝑳𝑳𝑳𝑳 𝑷𝑷 = 𝑨𝑨 + + 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 + 𝑫𝑫𝑫𝑫 + 𝑬𝑬𝑻𝑻𝟐𝟐
𝑻𝑻
K-Values:
Pi
Ki =
P
Bubble Temperature:
60 | P a g e
Σ kixi= 1 Temperature= 44.75 ℃
Dew Temperature:
Σ yi/ki= 1 Temperature= 46 ℃
7.2.9 Bottom Conditions:

Distillation bottom stream temperature calculation.
Components M.W A B C D E composition

Propane 44.097 21.446 -1462.7 -5.261 3.282E-11 3.735E-06 0.00892
Butane 58.12 27.044 -1904.9 -7.1805 -6.685E-11 4.219E-06 0.7926
Pentane 72.15 33.324 -2422.7 -9.2354 9.019E-11 4.105E-06 0.1984
Table 7-7: Bottom conditions of Distillation column
𝑩𝑩
𝑳𝑳𝑳𝑳𝑳𝑳 𝑷𝑷 = 𝑨𝑨 + + 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 + 𝑫𝑫𝑫𝑫 + 𝑬𝑬𝑻𝑻𝟐𝟐
𝑻𝑻
K-Values:
Pi
Ki =
Pt
Bubble Temperature:
Σkixi= 1 Temperature= 105.45 ℃
Dew Temperature:
Σyi/ki= 1 Temperature= 113.15 ℃
61 | P a g e
7.2.10 Reference Component:
𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = ∑𝑛𝑛𝑖𝑖=1(𝑥𝑥𝑥𝑥 ∗ 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤ℎ𝑡𝑡)=45.39kg/kgmole
Which is closer to 44kg/kmol, molecular weight of propane. So, Propane is reference

Component.
7.2.11 Relative Volatilities:

𝜶𝜶𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪
𝛂𝛂 =
𝜶𝜶𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓
α11=1; α12 = 0.309 ; α13 = 0.098
𝐇𝐇.𝐤𝐤 𝐇𝐇.𝐤𝐤
𝛂𝛂𝐚𝐚𝐚𝐚𝐚𝐚 = �𝛂𝛂 � � 𝐃𝐃 × 𝛂𝛂 � � 𝐁𝐁
𝐇𝐇.𝐊𝐊 𝐇𝐇.𝐊𝐊
α11 avg=1; α12 avg = 0.35; α13 avg = 0.12
 Light key: propane.

 Heavy key: butane.
 Heavier than heavy key: pentane.
7.2.12 Minimum number of stages:

To find minimum number of stages, use Fenske Equation,
𝑳𝑳. 𝑲𝑲𝑫𝑫 𝑯𝑯. 𝑲𝑲𝑩𝑩

𝒍𝒍𝒍𝒍 ��
𝑯𝑯. 𝑲𝑲𝑫𝑫 � � 𝑳𝑳. 𝑲𝑲𝑩𝑩 ��
𝑵𝑵𝒎𝒎𝒎𝒎𝒎𝒎 =
𝐥𝐥𝐥𝐥 (𝜶𝜶𝑳𝑳.𝑲𝑲,𝑯𝑯.𝑲𝑲 )
Nmin = 7.28
𝛂𝛂𝐢𝐢𝐢𝐢 ×𝐙𝐙𝐢𝐢
𝟏𝟏 − 𝐪𝐪 = ∑𝐧𝐧𝐢𝐢=𝟏𝟏
𝛂𝛂𝐢𝐢𝐢𝐢 − 𝛗𝛗
Feed is at its boiling point so q = 1
So, by using iterative method we find the value of
φ = 𝟎𝟎. 𝟑𝟑𝟑𝟑𝟑𝟑
n
αij × DxiD
Vmin = �
αij − φ
i=1
𝐕𝐕𝐦𝐦𝐦𝐦𝐦𝐦 = 𝟐𝟐𝟐𝟐𝟐𝟐. 𝟓𝟓𝟓𝟓 𝐤𝐤𝐤𝐤𝐤𝐤𝐤𝐤/𝐡𝐡𝐡𝐡
62 | P a g e
Lmin = Vmin − D
Lmin = 92.23kgmol/hr
7.2.13 Minimum reflux ratio:

Lmin
R min =
D
R min = 0.584
7.2.14 Actual Reflux Ratio:

R = 1.35 R min
𝐑𝐑 =0.788
7.2.15 Theoretical Number of Stages:

Actual number of stages are calculated by using Gilliland Correlation which are given below
R − R min
X=
R+1
N − Nmin
Y=
N+1
𝐍𝐍 = 𝟏𝟏𝟏𝟏
7.2.16 Efficiency:
𝛂𝛂𝐋𝐋.𝐊𝐊
𝐄𝐄 = 𝟎𝟎. 𝟒𝟒𝟒𝟒𝟒𝟒 (𝛍𝛍𝐋𝐋 � � 𝐚𝐚𝐚𝐚𝐚𝐚)^ − 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐
𝛂𝛂𝐇𝐇.𝐊𝐊
μL = Liquid viscosity of feed mixture = 0.081
7.2.17 Tray Efficiency:

E= 0.681
7.2.18 Actual number of trays:

N=19/0.68
N= 28
Location of Feed Plate:
Kirkbride equation is used for determination of location of feed plate:
63 | P a g e
𝟐𝟐 𝟎𝟎.𝟐𝟐𝟐𝟐𝟐𝟐
𝐍𝐍𝐑𝐑 𝐙𝐙𝐇𝐇.𝐤𝐤 𝐗𝐗 𝐋𝐋.𝐤𝐤,𝐖𝐖 𝐖𝐖
= �� ×� � × � ��
𝐍𝐍𝐒𝐒 𝐙𝐙𝐋𝐋.𝐤𝐤 𝐗𝐗 𝐇𝐇,𝒌𝒌,𝑫𝑫 𝐃𝐃
N = 28
NR
= 0.258
NS
NR = 21
NS = 7
So, the feed point is 7 plate from bottom.
7.2.19 Vapor & Liquid flow Rate in Distillation Column:

Top Section:
Ln
R=
D
Ln = R ∗ D
kmol
Ln = 124.2
hr
Vn = Ln + D
kmol
Vn = 281.68
hr
Bottom Section
Lm = Ln + F
kmol
Lm = 299.35
hr
Vm = Lm − W
kmol
Vm = 281.68
hr
7.2.20 Top section diameter calculations:

kmol
Vn = 281.68
hr
64 | P a g e
ρv = 29.42 kg/m3
ṁ m3
Vapour Volumetric flow = = 0.161
ρ sec
kmol
Ln = 124.2
hr
ρL = 461.41 kg/m3
7.2.21 Flooding velocity calculation:

𝛂𝛂 𝟎𝟎.𝟐𝟐𝟐𝟐 𝛒𝛒𝐋𝐋 − 𝛒𝛒𝐯𝐯 𝟎𝟎.𝟓𝟓
𝐕𝐕𝐧𝐧𝐧𝐧=𝐂𝐂𝐬𝐬𝐬𝐬 � � ( )
𝟐𝟐𝟐𝟐 𝛒𝛒𝐯𝐯
Were,
Csb= Souders and Brown factor
α = surface tension
ρL= density of liquid
ρv= density of vapour
𝐋𝐋 𝛒𝛒𝐯𝐯
𝐟𝐟𝐋𝐋𝐋𝐋 = �
𝐕𝐕 𝛒𝛒𝐋𝐋
Figure 7.4: Flooding velocity for Sieve plates [28]
65 | P a g e
𝐟𝐟𝐋𝐋𝐋𝐋=𝟎𝟎.𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏
Csb= 0.08
α = 4.65 dyne/cm
Plate Spacing= 0.46 (Range 0.41-0.61)
Vnf= 0.077 m/s
Actual velocity = 75 ∗ Vnf
m
Operating Velocity = 0.058
s
ṁvap
Net Area = An = = 2.35 m2
Operationg Velocity
An
Cross sectional Area = Ac = = 2.76 m2
0.80
4 ∗ Ac 4 ∗ 2.76
D 𝑇𝑇𝑇𝑇𝑇𝑇 = � =� = 1.87m
π π
7.2.22 Bottom section diameter calculations:

kmol
Vm = 281.68
hr
ρv = 29.42 kg/m3
ṁ m3
Vapour Volumetric flow = = 0.161
ρ sec
kmol
Lm = 299.35
hr
ρL = 990.41 kg/m3
7.2.23 Flooding velocity calculation:

𝛂𝛂 𝟎𝟎.𝟐𝟐𝟐𝟐 𝛒𝛒𝐋𝐋 − 𝛒𝛒𝐯𝐯 𝟎𝟎.𝟓𝟓
𝐕𝐕𝐧𝐧𝐧𝐧=𝐂𝐂𝐬𝐬𝐬𝐬 � � ( )
𝟐𝟐𝟐𝟐 𝛒𝛒𝐯𝐯
66 | P a g e
Were,
Csb= Souders and Brown factor
α = surface tension
ρL= density of liquid
ρv= density of vapour
𝐋𝐋 𝛒𝛒𝐯𝐯
𝐟𝐟𝐋𝐋𝐋𝐋 = �
𝐕𝐕 𝛒𝛒𝐋𝐋
fLv=0.1834
Figure 7.5: Flooding velocity for sieve plate [23]
Csb= 0.06
α = 8.35 dyne/cm
Plate Spacing= 0.46 Range 0.41-0.61)
Vnf= 0.1432 m/s
Actual velocity = 75 ∗ Vnf
m
Operating Velocity = 0.107
s
ṁvap
Net Area = An = = 1.505 m2
Operationg Velocity
An
Cross sectional Area = Ac = = 1.77 m2
0.80
67 | P a g e
4 ∗ Ac 4 ∗ 1.77
D𝐵𝐵𝐵𝐵𝐵𝐵 = � =� = 1.502m
π π
7.2.24 Height of Distillation column:

𝐇𝐇𝐇𝐇𝐇𝐇𝐇𝐇𝐇𝐇𝐇𝐇 𝐨𝐨𝐨𝐨 𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃𝐃 𝐂𝐂𝐂𝐂𝐂𝐂𝐂𝐂𝐂𝐂𝐂𝐂 = 𝐇𝐇𝐇𝐇 = (𝐍𝐍𝐍𝐍 − 𝟏𝟏)𝐇𝐇𝐇𝐇 + ∆𝐇𝐇
H𝑡𝑡 = (Na − 1)H𝑠𝑠 + 0.15H𝑡𝑡
H𝑡𝑡 = (27 − 1)0.46 + 0.15H𝑡𝑡
H𝑡𝑡 = 14.61 m
7.2.25 L/D Ratio:

L Lenght
= = 10.82
D Diameter
7.2.26 Distillation Column Plate Design:

Weir length:
Column diameter Dc = 1.88m
Column area Ac =2.77 m2
Downcomer area Ad = 0.120*2.77 = 0.3329 m2, at 12%
Net area an = Ac - Ad = 2.77 - 0.3329 = 2.44 m2
Active area Aa = Ac - 2Ad= 2.10 m2
Take weir height 50 mm
Hole diameter 5 mm
Plate thickness 5 mm
68 | P a g e
Figure 7.6: Wire length
lw
= 0.763
Dc
lw = 0.85 ∗ Dc = 0.85 ∗ 1.881
lw = 1.434 m
7.2.27 Weeping:
kg
Maximum liquid flowrate = 5.088
s
Turn down ratio = 0.7
kg
Minimum liquid flowrate = 3.54177
s
L𝑤𝑤
h𝑜𝑜𝑜𝑜 = 750 ∗ [ ]2/3
𝜌𝜌𝐿𝐿 l𝑤𝑤
Were,
L𝑤𝑤 = Maximum liquid flow rate.
𝜌𝜌𝐿𝐿 =Density of liquid.
l𝑤𝑤 =Weir length.
Maximum how = 17.160722 mm liquid
Minimum how = 13.514385 mm liquid
hw + how = 50 + 13.514385 = 63.51438 mm liquid

69 | P a g e
Figure 7.7: Weep point correlation [23]
K 2 = 30.3
𝐊𝐊 𝟐𝟐 − 𝟎𝟎. 𝟗𝟗𝟗𝟗(𝟐𝟐𝟐𝟐. 𝟒𝟒 − 𝐝𝐝𝐡𝐡 )

𝐮𝐮𝐦𝐦𝐦𝐦𝐦𝐦 =
(𝛒𝛒𝐯𝐯 )𝟎𝟎.𝟓𝟓
Were, u𝑚𝑚𝑚𝑚𝑚𝑚 = Minimum design Vapour velocity
dℎ = Dia of hole ( 5mm assumption )
31 − 0.90(25.4 − 5) m
umin = = 2.21
(29.24) 0.5 s
7.2.28 Actual minimum vapors velocity:

Minimum vapour rate
Actual minimum vapour velocity =
Area of hole
Trail – 1
Area of hole = 10% of Active Area (Range 5% to 16%)
Area of hole = 0.10 ∗ 2.11 = 0.211577m2
0.1134
vactual = = 0.53 < vmin
0.211577
Trail – 2
Area of hole = 2% of Active Area
Area of hole = 0.02 ∗ 2.11 = 0.042m2
0.1134
vactual = = 2.6149 > vmin
0.042
So, we take area of hole 2% 0f active area.
70 | P a g e
7.2.29 Pressure Drop:
Dry plate drop:
uh max. ρV
hd = 51
C0 ρL
Plate thicknes
=1
Hole Diameter
Ah
∗ 100 = 7.4
Ap
Figure 7.8: Vapor pressure correlation
C0= 0.825
Bottom Volumertric flow rate m

uh max. = = 3.8928
Area of hole s
hd = 33.1753 mm. liquid
Residual Head:
12.5 ∗ 103
Hr = = 12.612 mm liquid
ρL
Total drop:
ht = hd + (hw + how) + hr
ht = 33.1753 + 63.14 + 12.612 = 109.5 mm liquid
7.2.30 Plate pressure drop:

∆Pt = 9.81 ∗ 103 ht ρL
71 | P a g e
∆Pt = 1061.65Pa
∆Pt = 1.06 kpa
Overall pressure drops:
∆P𝑡𝑡 = 1.06kPa
N = 28
∆P = 1.06 ∗ 28 = 29.72 kpa
7.2.31 Down comer liquid backup:

hap = hw − 10 = 50 − 10 = 40 mm
Aap = lw ∗ hap = 1.43 ∗ (0.04) = 0.0572m2 < 𝐴𝐴d
So, we can use equation
lwd 2
hdc = 166 � � =14.77 mm liquid
ρLAap
hb = (hw + hwo) + ht + hdc
hb = 63.14 + 109.5 + 14.77
hb = 187.83mm liquid
7.2.32 Residence Time:

Down comer Area × hb × ρL
Residence time =
Lwd
Residence time = 12.20 s
7.2.33 Entrainment:
𝐔𝐔 𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯 𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟 𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫
𝐧𝐧=
𝐧𝐧𝐧𝐧𝐧𝐧 𝐚𝐚𝐚𝐚𝐚𝐚𝐚𝐚
Un=0.0762=0.532 m/s
0.143
%Age flooding,
u𝑣𝑣
%age flooding = ∗ 100 = 53.47%
u𝑓𝑓
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f𝐿𝐿𝐿𝐿 = 0.1825
Figure 7.9: Entrainment calculation
Entrainment = ψ = 0.005
7.2.34 Perforated Area:

Weir length l𝑤𝑤
= = 0.7636
COlumn dia Dc
θ = 99°
Figure 7.10: Perforated area correlation
Angle subtended by the edge of plateθ = 180° − 100° = 80°
Unperforated edge strip length and Calming zone width = 50mm
Area of unperforated edge strip = Length ∗ Width = 1.837 ∗ 50 ∗ 10−3
= 0.12 m2
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Mean length, Calming zone = Weir length + Width of Calming zone
Mean length, Calming zone = 1. 031 m + 50 ∗ 10−3 = 1. 481 m
Area of Calming zone = (1.081 m ∗ 50 ∗ 10−3 ) = 0. 0741 m2
Total Area of Perforation

= Active Area − Area of unperforated edge strip − Area of calming zone
Total Area of Perforation = Ap = 1. 09 m2 − 0.0541 m2 − 0.092 m2 = 1. 944m
Total number of holes:

π 2 π
Area of one hole = 𝐷𝐷 = (5 ∗ 10−3 )2 𝑚𝑚2 = 0.000019𝑚𝑚2
4 4
Aℎ 0.0422
Number of holes = = = 2150.9056 holes
Area of one hole 0.000019
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7.2.35 Specification Sheet of Distillation Column:
Table 7-8: Specification sheet of Distillation column
Identification
Item Distillation
No. required 1
Tray type Sieve Tray
Operation Continuous
Function
Separation of Propane from LPG
Material Feed Top Bottom

handled
Quantity 7903.0201 kg/hr 6845.2017 kg/hr 1057.8189 kg/hr
Composition of 90% 99.99% 0.89%

Propane
Temperature 48.35℃ 46℃ 105.45℃
Design Data
Number of trays 28
Feed plate from bottom 7
Pressure 15 atm
Height of column 14.61 m
Diameter of column 1.68 m
Reflux ratio 0.78
Tray spacing 0.46 m
Flooding velocity 0.70 m/s
Material of construction Stainless steel
Pressure Drop 0.293 atm
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7.3 Design of Heat Exchanger:
Heat exchanger is a device that is used to transfer heat between two fluids at different
temperature.
7.3.1 Types of Heat Exchanger:

There are different types of heat exchanger:
 Double pipe heat exchanger.

 Shell and tube heat exchanger.
 Plate and frame heat exchanger.
 Spiral type heat exchanger.
 A cooled; cooler and condenser.
 Plate and fin type heat exchanger.
7.3.2 Selection criteria:

Selection process consists of factor related to heat transfer application.
 Thermal Requirements.
 Operation Maintains.
 Cost.
 Material compatibility.
 Environmental, Health and safety consideration.
7.3.3 Transfer Process:

 Indirect contact (double pipe, shell and tube, coil type).
 Direct contact (cooling tower).
7.3.4 Pass arrangement:

 Single pass arrangement.
 Multiple pass arrangement.
7.3.5 Flow arrangement:

 Parallel flow
 Counter flow
 Cross flow
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7.3.6 Phase of fluid:
 Gas-Gas.
 Liquid-Liquid.
 Gas-liquid.
7.3.7 Geometry of construction:

 Tubular heat exchanger (double pipe, shell and tube, coil type).
 Plate heat exchanger (gasket, spiral, plate coil).
 Extended surface exchanger (tube fin, plate fin).
 Regeneration (fixed matrix, rotary).
7.3.8 Shell and Tube Heat Exchanger:

Shell and tube heat exchanger are commonly used in heating or cooling process fluids gases.
Shell and tube heat exchanger come in many variations to meet process requirement in almost
every industry.
7.3.9 Types of shell and tube Heat Exchanger:

 Fixed tube.
 U type.
 Floated Head.
7.3.10 Design steps of Heat Exchanger: [29]

The main steps of design heat exchanger are summarized follows:
 Obtain the required thermo physical properties of hot and cold fluid at caloric
temperature of streams.
 Perform energy balance and find out the heat duty (Q) of the exchanger.
 Calculate the LMTD.
 Assume overall heat transfer coefficient (u).
 Calculate provisional area and number of tubes.
 Specify the shell and tube configuration.
 Calculate hi and ho.
 Calculate the overall heat transfer coefficient (u).
 Calculate pressure drop.
77 | P a g e
7.3.11 Design Calculation:
LMTD (Log mean temperature difference)
 LMTD = (T1-T2)/ln (TI/T2)

 LMTD = 219-256.15/ln(219/256.19)
 LMTD = 237°C
7.3.12 True Temperature:

 R=0.87
 S=0.57
 Ft=0.75
 T=Tm (Ft)
 T=178 °C=451k
7.3.13 Provisonal Area :

A=Q/UTm
Assume
U=340 W/m^2.k=1224 KJ/m^2 hr k
Q=11902740 KJ/hr
A = 21.56𝑚𝑚2 = 231𝑓𝑓𝑓𝑓 2
Caloric Temperature
tc/th=1.14
kc=0.3
Fc=0.48
Tc=Tout+Fc(T)
Tc =706 K
tc=tout+Fc(T)
tc=761 K
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7.3.14 Tube Specification:
Selecting:
Tube length
L= 18 ft
BWG=16
O.D=0.0254m I.D=0.022m
Tube Pitch = 1.25(O.D) = 0.03125 m
Clearance = Pt - O.D
C=0.00625 m
Surface area of one tube = 3.14*O.D*L = 0.43 𝑚𝑚2
Number of tubes=Nt= provisonal area/surface area of one tube=52
Nt=52, n=2
Tube per passes=Nt/2=26
7.3.15 Shell configuration:

Bundle Dia = Db = do (Nt/K1)^1/n1
For triangular pitch and two tube passes
K1 = 0.175 n1 = 2.285
Db = 0.27m
Shell bundle clearance = 0.00625m
Shell dia = Db+C = 0.28m
7.3.16 Shell side heat transfer coefficient:

Baffle spacing = 0.4*Ds = 0.112 m
Flow area = I.D*C'*B/pt = 0.16 𝑚𝑚2
Mass velocity=Gs= masss flow rate/flow area
Gs = 105350.75 kg/ 𝑚𝑚2 hr
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For triangular pitch
Equivalent Dia = 4*(0.5pt*0.86pt-0.5πdo/4)/0.5πdo
De= 0.019 m
Now
Viscosity = 0.00002 kg/ms
Heat capacity = 2.6 kJ/kg.k
Thermal conductivity = 0.087 W/m K
𝐃𝐃𝐞𝐞 ×𝐆𝐆
Re = = 27800
𝛍𝛍
Jh=80
𝟏𝟏
𝑪𝑪𝒑𝒑 × 𝝁𝝁 𝟑𝟑
𝑷𝑷𝒕𝒕 = � �
𝒌𝒌
Pr=0.6
1
k Cp × μ 3
ho = jh � � � � ∅e
D k
𝒉𝒉𝒐𝒐
= 791 kJ/𝒎𝒎𝟐𝟐 hr K
∅𝒆𝒆
7.3.17 Tube side heat transfer coefficient:

𝑵𝑵𝒕𝒕 × 𝒂𝒂𝒕𝒕
Flow area of tube = = 0.04 𝒎𝒎𝟐𝟐
𝒏𝒏
Mass velocity = Gs = mass flow rate/flow area
Gs =426639.22 kg/𝑚𝑚2 hr
Viscosity = 0.00008 kg/ms
Heat capacity = 2.7 kJ/kg k
Thermal conductivity = 0.552 W/m k
Now
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𝐃𝐃𝐢𝐢 × 𝑮𝑮𝒔𝒔
Re =
𝛍𝛍
Re=32590.4
At this Reynold number;
Jh=95
𝟏𝟏
𝑪𝑪𝒑𝒑 × 𝝁𝝁 𝟑𝟑
𝑷𝑷𝒕𝒕 = � �
𝒌𝒌
Pr=0.8
1
k Cp × μ 3
ho = jh � � � � ∅e
D k
𝒉𝒉𝒐𝒐
= 6865 kJ/𝒎𝒎𝟐𝟐 hr K
∅𝒆𝒆
7.3.18 Tube wall temperature:

𝒉𝒉𝒐𝒐 𝒉𝒉𝒊𝒊𝒊𝒊 𝒉𝒉𝒐𝒐 (𝑻𝑻𝒄𝒄 − 𝒕𝒕𝒄𝒄 )
𝒕𝒕𝒘𝒘 = 𝒕𝒕𝒄𝒄 + × +
∅𝒆𝒆 ∅𝒊𝒊 ∅𝒆𝒆
tw=788 K
µw(shell)=0.000022 kg/ms
µw(tube)=0.00006 kg/ms
𝝁𝝁
∅𝒆𝒆 = ( )𝟎𝟎.𝟏𝟏𝟏𝟏
𝝁𝝁𝒘𝒘
Øe = 0.9
Øi = 1.04
ho = (he/Øe)Øe = 712 kJ/𝑚𝑚2 hr k
hi = (hio/Øi)Øt= 7139 kJ/𝑚𝑚2 hr k
7.3.19 Overall heat transfer coefficient:

Total surface area = Nt*L* surface per length
Total surface area = 52*18*.2618 = 22.7 𝑚𝑚2
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U = Q/A*T = 323 W/𝑚𝑚2 K
7.3.20 Pressure Drop calculation:

Shell side pressure drop:
Using Reynold number = 27800
𝒇𝒇𝒇𝒇𝟐𝟐
f = 0.0019
𝒊𝒊𝒊𝒊𝟐𝟐
No. of crosses = 12L/B = 12(5.48m/0.112m) = 587
Specific gravity propane = 0.9
Density of propane = 0.453kg/𝑚𝑚3
Gs = 21660.90 lb/𝑓𝑓𝑓𝑓 2 hr
Ds = 0.28m = 0.91 ft
Ps = fGsDs(N+1)/5.22*10^10 De*s*Øs
Ps = 0.0019*21660.90*0.91*587/5.22*10^10*0.019*0.453*0.9
Ps = 0.0229 psi
Tube side pressure drop:
Total flow area ; at = 0.04 𝑚𝑚2
At Reynold number = 32590.4
𝒇𝒇𝒇𝒇𝟐𝟐
f = 0.0001
𝒊𝒊𝒊𝒊𝟐𝟐
Tube length = 18 ft N=2
Gs = 87720.2 lb/𝑓𝑓𝑓𝑓 2 hr
Di = 0.022m = 0.072 ft
Øt = 1.04
Specific gravity = 0.52
Pt = f*Gs^2*L*n/5.22*10^10*Di*s*Øt
Pt = 0.16 psi
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𝑉𝑉 2
P= = 0.0052
2𝑔𝑔
𝑉𝑉 2
Pr = 4n/s * = 0.16
2𝑔𝑔
Ptotal = pt + pr = 0.32 psi
7.3.21 Specification sheet of Heat Exchanger:
Type Shell and Tube Heat Exchanger
Bundle Diameter 0.27 m
Overall Heat transfer coefficient 340 W/𝑚𝑚2 . 𝐾𝐾
Heat transfer area of Exchanger 21.56 𝑚𝑚2
Total no. of tubes 52
Diameter of Shell 0.28 m
Inside diameter of tube 0.022 m
Outer diameter of tube 0.0254 m
Total pressure drops (shell side) 0.0229 psi
Total pressure drops (Tube side) 0.32 psi
Table 7-9: Specification sheet of Heat Exchanger
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7.4 Design of Knock out vessel:
7.4.1 Design Methodology: [30]
 Find the densities of the liquid and vapor at the given temperatures.
 Find flow rates of liquid and vapor streams.
 Find vapor velocity using Blackwell’s relation.
 Find the area of the column.
 Using calculated area find the diameter.
 Find the liquid holdup volume.
 Find liquid holdup height and subsequently the total height of column.
7.4.2 Process conditions:

Stream Top (Vapor) Bottom (Liquid)
Temperature (ᵒC) 23 ᵒC 23 ᵒC
Pressure (atm) 15 15
Mass flow rates (kg/hr) 378.98 16478.97
Table 7-10: Process Conditions
7.4.3 Calculations for settling velocity:

Using the Blackwell relation, we can find the vapor settling velocity
(𝝆𝝆(𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍) − 𝝆𝝆(𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗)
𝑼𝑼𝑼𝑼 = 𝑲𝑲𝑲𝑲�
𝝆𝝆(𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗)
Where Kv can be found as
𝑲𝑲𝒗𝒗 = 𝐞𝐞𝐞𝐞𝐞𝐞 [𝑨𝑨 + 𝑩𝑩𝑩𝑩𝑩𝑩𝑩𝑩𝑩𝑩𝑩𝑩 + 𝑪𝑪(𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍)𝟐𝟐 + 𝑫𝑫(𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍)𝟑𝟑 + 𝑬𝑬(𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍)𝟒𝟒 ]
𝑊𝑊𝑙𝑙 𝜌𝜌(𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣)
𝐹𝐹𝐹𝐹𝐹𝐹 = �
𝑊𝑊𝑣𝑣 𝜌𝜌(𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙)
Where Wl and Wv are the liquid and vapor flow rates in kg/hr.
𝑾𝑾𝒗𝒗 = 378.98 𝑘𝑘𝑘𝑘/ℎ𝑟𝑟
𝑾𝑾𝒍𝒍 = 16478.97 𝑘𝑘𝑘𝑘/ℎ𝑟𝑟
𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑜𝑜𝑜𝑜 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 = 820.12 𝑘𝑘𝑘𝑘/𝑚𝑚3
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𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑜𝑜𝑜𝑜 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 = 12.32 𝑘𝑘𝑘𝑘/𝑚𝑚3
378.98 12.32
𝐹𝐹𝐹𝐹𝐹𝐹 = �
16478.97 820.12
𝑭𝑭𝑭𝑭𝑭𝑭 = 𝟎𝟎. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎
𝐾𝐾𝑙𝑙 = exp [𝐴𝐴 + 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 + 𝐶𝐶(𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙)2 + 𝐷𝐷(𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙)3 + 𝐸𝐸(𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙)4 ]
The Constants are given for all the hydrocarbon families.
A = -1.88774
B = -0.81458
C = -0.18707
D = -0.01425
E = -0.001014
𝐾𝐾𝑙𝑙 =0.1510
𝟖𝟖𝟖𝟖𝟖𝟖. 𝟏𝟏𝟏𝟏 − 𝟏𝟏𝟏𝟏. 𝟑𝟑𝟑𝟑

𝑼𝑼𝑼𝑼 = 𝟎𝟎. 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 ∗ �
𝟏𝟏𝟏𝟏. 𝟑𝟑𝟑𝟑
𝑼𝑼𝑼𝑼 = 𝟏𝟏. 𝟐𝟐𝟐𝟐 𝒎𝒎/𝒔𝒔
7.4.4 Calculations of volumetric flow rate for liquid and vapors:

Volumetric Flow rates can be found as:
𝒎𝒎𝒎𝒎𝒎𝒎𝒎𝒎 𝒇𝒇𝒇𝒇𝒇𝒇𝒇𝒇 𝒓𝒓𝒓𝒓𝒓𝒓𝒓𝒓

𝒒𝒒(𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍) =
𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅𝒅 𝒐𝒐𝒐𝒐 𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍
16478.97
= 820.12
= 200.9 m3/h or 0.055 m3/s
7.4.5 Calculations of Area:

Area can be calculated simply as
𝑄𝑄𝑙𝑙 0.55
𝐴𝐴 = = = 0.0457 m2
𝑈𝑈𝑙𝑙 1.22
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7.4.6 Calculations of Diameter:
Now for diameter we can use the already calculated area
𝜋𝜋𝐷𝐷2
𝐴𝐴 =
4
4A
D=� = 0.24 𝑚𝑚
π
7.4.7 Calculations of volume of liquid:

Liquid holds up Volume:
V𝑙𝑙 = 𝑄𝑄𝑙𝑙 × t
Where Ql is the liquid flow rate and t is the holdup time. Suppose a holdup time of 60
seconds.
V𝑙𝑙 = 0.055 × 60= 3.3 m3
7.4.8 Specification Sheet of Knockout Drum:
Settling velocity (𝑼𝑼𝑼𝑼) 1.22 𝑚𝑚/𝑠𝑠
Volumetric flow rate 0.055 m3/s
Calculation of area 0.0457 m2
Calculation of diameter 0.24 𝑚𝑚
Calculation of volume of liquid 3.3 m3
Table 7-11: Specification sheet of Knockout drum
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Chapter # 8
Process simulation
87 | P a g e
8 Process Simulation:
Process simulation is a model-based representation of chemical, physical, biological, and
other technical processes and unit operations in software.
Process simulation is a key activity in Process Engineering covering the whole life cycle of a
process, from Research & Development to conceptual design and plant operation. In this
context, flow sheeting is a systematic description of material and energy streams in a process
plant by means of computer simulation with the scope of designing the plant or understanding
its operation.
Simulation is of two types;
 Steady state Simulation.

 Dynamic Simulation.
8.1 Steady State Simulation:

It is used when,
 There is no recycle stream in process.

 No troubleshooting.
 No changing in properties.
We just add components, fluid package, reactions, temperature, and pressure conditions and
then solve.
8.2 Dynamic Simulation:

It is used when,
 Recycle stream occurs in process.

 Optimization and designing occur.
 Troubleshooting occurs.
 Plant startup and plant shutdown.
 Changing occur in parameters, properties, time etc.
88 | P a g e
8.3 Distillation Simulation:
Steps:
 Add components.
 Apply fluid package.
 Open simulation environment.
 Select Feed stream and add the specific properties feed composition, molar flow,
temperature, pressure.
 Add Distillation column to model pallet.
 Add specific properties of column like number of stages, feed position, and name tags
of other streams.
 Add the operating temperature and pressure of distillation column.
 Add component fraction set go to the spec summary.
 Click run button.
 Match results.
8.3.1 Add Components:
Figure 8.1: Add components
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8.3.2 Applying Fluid Package:
Figure 8.2: Applying fluid package
8.3.3 Open simulation environment and add Feed conditions:
Figure 8.3: Feed conditions
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8.3.4 Add Distillation Column and add specific conditions:
Figure 8.4: Add Distillation column specifications
8.3.5 Results:
Figure 8.5: Results of distillation column
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Chapter # 9
Economic Evaluation of whole Project
92 | P a g e
9 Cost estimation:
The capital needed to supply the necessary plant facilities is called fixed capital investment
while that for the operation of the plant is called the working principal and sum of two Before
the plant to be operated, specified money must be supplied to purchase and install the capitals
is called total capital investment.
It is essential that chemical engineer be aware of the many different types of cost involved in
manufacturing processes. Capital must be allocated for direct plant expenses; such as those
for raw materials, labor, and equipment. Besides direct expenses, many other indirect
expenses are incurred and these must be included if a complete analysis of the total cost is to
be obtained. Some examples of these indirect expenses are administrative salaries, product
distribution costs and cost for interplant communication.
A capital investment is required for any industrial process and, determination of the necessary
investment is an important part of a plant design project. The total investment for any process
consists of fixed capital investment for physical equipment and facilities in the plant plus
working capital, which must be available to pay salaries, keep raw materials and products on
hand, and handle other special items requiring a direct cost outlay. Thus, in an analysis of
cost in industrial processes, capital investment costs, manufacturing cost, and general
expenses, including income taxes must be taken into consideration.
9.1 Types of Capital Cost Estimates:

An estimate of the capital investment for a process may vary from a predesign estimate based
on little information except the size of the proposed project to a detailed estimate prepared
from complete drawings and specifications. Between these two extremes of capital
investment estimates there can be numerous other estimates which vary in accuracy
depending upon the stage of development of the project. These estimates are called by a
variety of names, but the following five categories represent the accuracy range and
resignation normally used for design purposes.
9.2 Production of 150 tons/day of propylene:

 Order of magnitude estimate (ratio estimated based on similar previous cost date,
probable Accuracy of estimate over ± 30%).
 Study estimate (factored estimate) based on knowledge of major items of equipment;
probable accuracy of estimate up to ± 30%.
93 | P a g e
 Preliminary estimate (budget authorization estimate; scope estimate) based on
sufficient data to permit the estimate to be budgeted; probable accuracy of estimate
within ± 20%.
 Definitive estimate (project control estimate). It based on almost complete data but
before completion of drawings and specification, probable accuracy of estimate
within ± 10%.
 Detailed estimate (contractor's estimate). It based on complete engineering drawings,
specifications, and site surveys; probable accuracy of estimate within ± 5%.
9.3 Cost Index:

Cost index is an index value for a given point in time showing the cost at that time relative to
certain base time. If the cost at any time in past is known, the equivalent cost at the present
time can be determined by multiplying the original cost by the ratio of present of index value
to the index value applicable when the original cost was obtained. Cost index can be used to
give a general estimate. Many different types of cost indexes are published regularly. Some
of these can be used for estimating equipment cost; other applies specifically to labor,
construction, materials or other specialized fields. The most common of these indexes are the:
 Marshall and Swift all-industry and process industry equipment index.

 Engineering news-record contraction cost index.
 The Nelson-Farrar refinery construction index.
 The chemical engineering plant cost index.
 Other index includes monthly labor view.
9.4 Purchase Cost of Major Equipment’s:

The cost of purchased equipment is used as basis of factorial method of cost estimation and
must be determined as accurately as possible. Cost of different equipment is calculated as
under.
C = Cr[I/Ir] [S/Sr] n
C = current cost of the equipment
Cr = cost of a similar reference equipment
I = current cost index
Ir = cost index for the reference year
94 | P a g e
S = capacity of the equipment
Sr = capacity of the reference equipment
n = cost capacity exponent for the particular type of equipment
9.5 Total Equipment Cost:
Name of Equipment Number of Cost of 1 equipment Total cost ($)

equipment ($)
Reactor 1 $42900 $42900
Heat exchanger 9 $34320 $308280
Distillation 2 $68640 $137280
Knock out vessel 1 $22308 $22308
Compressor 2 $4392.5 $8785
Pumps 5 4582.9 $22192.2
Total Equipment Cost $543067.2
Table 9-1: Total equipment cost
9.6 Total Capital Investment (TCI):

TCI = FCI + WCI
9.6.1 FCI (Fixed capital investment):

Equipment Cost = 22% of FCI
So FCI = $2458488.818
9.6.2 WCI (Working Capital Investment):

Working Capital Investment = 15% of FCI
WCI = $370273.77
TCI = FCI + WCI
TCI = $2821981.591
95 | P a g e
9.7 Direct Cost:
DIRECT COSTS Cost ($)
Equipment 22% of FCI 543067
Installation 8% of FCI 197479.54
Service Facilities 15% of FCI 123424.77
Piping & Instrumentation 8% of FCI 197479.54
Electrical system 4.5% of FCI 111081.93
Buildings 8% of FCI 197879.54
Land 1.5% of FCI 23764.97
Instrumentation cost 5% of FCI 79216.59
Yard improvement 3% of FCI 74054.95
Table 9-2: Direct cost
9.8- Indirect Cost:
Indirect Cost Cost ($)
Engineering And supervision 9% of FCI 222163.86
Legal expenses 7% of FCI 172794.22
Contractor’s fee 2.5% of FCI 617712.29
Contingency 6 % of FCI 148109.909
Construction Expenses 1.5% FCI 37027.97
Table 9-3: Indirect cost
9.8 Depreciation Cost:

Assume that FCI depreciate by straight line method for 15 years assuming 5% of salvage
value at the end of plant life.
Depreciation = D = (V-Vs)/N
96 | P a g e
V = FCI = 2468488.818$
Vs = 0.05* 2468488.818
Vs = 123424.59$
N = No. of years = 15
D = 156337.015$
Fixed Charges = 12% of Product Cost = 321890.86$
Direct Production Cost = 55% of Product Cost = 1475333.31$
Plant Overhead = 10% of Product Cost = 268242.05$
Total Manufacturing Cost = Fixed Charges + Direct Production Cost + Plant Overhead
= 2065466.243$
Raw Material Cost = 650*150*365

= $35587500.11
9.9 General Expenses:

Admin Cost = 5% of Product Cost = 134121.02$
Distribution and Selling Cost = 18% of Product Cost = 482836.30$
Research and Development Cost = 5% of Product Cost = 134121.02$
Financing = 6% of Product Cost = 160945.43$
Total General Expenses = 751078.47$
Total Product Cost = Raw Material Cost + Total General Expenses
= 41242807.605$
9.10 Net Profit:

A- Gross Earning/Income
Wholesale Price of Propylene per ton = 780$
Total Income = Selling Price * Quantity of Product Manufacture
= 780 $/MT * 150 MT/day
97 | P a g e
= $117000/day
Total Income per year = 162900 * 365
= $42705000/year
Gross Income = Total Income – Total Product Cost

= $1462164.4
9.11 Let the tax rate is 30%:

Taxes = (0.3) (Gross Income)
= $438657.22/ year
Net Profit = Gross Income – Taxes
= $1023534/year
9.12 Rate of Return:

Rate of Return = (Net Profit/Total Investment)
= 36%
9.13 Payback Period:

1/ROR = 1/0.360
= 2.77 years
98 | P a g e
Chapter # 10
Process Instrumentation and Control
99 | P a g e
10 Process Instrumentation and Control:
Instruments are provided to monitor the key process variable during plant operation. They
may be incorporated in automatic control loops or used for manual monitoring of the process
operation. They may also be a part of an automatic computer data logging system.
Instruments monitoring critical process variable will be fitted with automatic alarm to alert
the operator to critical and hazardous situation.
It is desirable that the process variable to be monitored be measured directly, often, however,
this is impractical and some dependent variable that is easier to measure is monitored in its
place. For example, in the control of distillation columns the continuous on line, analysis of
the overhead product is desirable but difficult and expensive to achieve reliably, so
temperature is often monitored as an indication of composition.
The temperature instrument may form part of a control loop controlling, say, reflux flow;
with the composition of the overhead checked frequently by sampling and laboratory.
10.1 Design Steps of Control Scheme:

 Identify the control variables.
 Identify the manipulated inputs.
 Generate all feasible control configurations.
10.2 Control Schemes on Knock out vessel:
Figure 10.1: Control loop on knockout drum
100 | P a g e
10.3 Pressure Control Scheme:
To maintain the pressure of our Knock out at desired value we use the following control
scheme.
10.3.1 Disturbance:
Variation in the upstream pressure of the knock out vessel can cause the pressure disturbance
in the vessel.
10.3.2 Control Variables:

Pressure of Knock out vessel.
10.3.3 Manipulated Variable:

 Flow of vapor outlet.
 Temp of inlet stream.
 Pressure of inlet stream.
10.4 Description:
This control scheme will work in order to control the pressure of the column in the following
ways:
 The pressure of the column will not be decreased to 15 Atm.

 If the pressure decreases, the liquid propylene and propane will evaporate and will
flow to the top section.
 To avoid this pressure, decrease, we are using pressure feed-back controller.
 PT- pressure transmitter will sense the pressure and transmit signals to PV- pressure
regulating valve.
 This valve basically controls the flow of top vapors, in this sense it will regulate the
pressure of the column.
10.5 Level Control Scheme:

To maintain the level in our flash column we can use two types of feedback control loops.
10.5.1 Disturbance:
Variation in feed flow rate can change liquid level in knock out vessel.
10.5.2 Control Variables:

Liquid level in vessel.
101 | P a g e
10.5.3 Manipulated Variable:
Flow of liquid outlet.
10.6 Description:
 In vessel we are providing disengaging space for separation.
 When the liquid flow rate is higher in upstream, then it will hold up in the bottom of
the vessel and the liquid level will rise up.
 As the liquid level rise up the disengaging space will be minimized.
 Minimize in disengaging space will decrease the efficiency of separation.
 We have used feedback level controller for this issue.
 LT- level transmitter will sense the level of liquid in vessel and transmit the signals to
controller.
 Controller will analyze and send command to LV- level valve.
 LV is basically a liquid flow control valve; in these manners it will control the level of
in the vessel.
102 | P a g e
Chapter # 11
Hazop Study
103 | P a g e
11 HAZOP Study:
HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards
in a work process. HAZOP's meticulous approach is commonly used with chemical
production and piping systems, where miles of pipes and numerous containers can cause
logistical headaches.
The purpose of the HAZOP is to investigate how the system or plant deviate from the design
intent and create risk for personnel and equipment and operability problems. HAZOP studies
have been used with great success within chemical and the petroleum industry to obtain safer,
more efficient and more reliable plants.
A HAZOP study identifies hazards and operability problems. The concept involves
investigating how the plant might deviate from the design intent.
11.1 Definition of HAZOP Term:

11.1.1 Hazard:
A hazard is a potential source of harm. Substances, events, or circumstances can constitute
hazards when their nature would allow them, even just theoretically, to cause damage to
health, life, property, or any other interest of value.
11.1.2 Harm:
Physical injury or damage to the health of people or damage to property or the environment.
11.1.3 Risk:
In simple terms, risk is the possibility of something bad happening. Risk involves uncertainty
about the effects/implications of an activity with respect to something that human’s value,
often focusing on negative, undesirable consequences. Many different definitions have been
proposed.
A HAZOP study encourages the use of “guide words” to help explore all potential deviations.
Here is an example of how the team could use common guide words to explore deviations
involving the input and mixture of RO water:
Less (Quantitative decrease) – RO water added is less than intended.
104 | P a g e
11.2 Guide word:
Guide Word Description
No or not Complete negation of the intention from the design
More Quantitative increase
Less Quantitative decrease
As well As Qualitative modification or qualitative increase
Part of Qualitative modification or decrease
Other than Complete substitution
Early Something occurred earlier than intended
Late Something occurred later than intended
Before Step was performed before it should have in the process sequence
.
After Step was performed after it should have in the process sequence
Table 11-1: Guided words
105 | P a g e
11.3 HAZOP study of Heat Exchanger:
Unit:
Heat Exchanger
Parameter:
Flow
Guide word Deviation Cause Consequence Action

NO No feed flow Pumps damage NO heat Use of backup
Pipe blockage Exchange pumps
Deficient Regular inspection
product
Less Less feed flow Close of feed Low quality of Regular inspection
valve, and production Use filters, and
failure Pumps and regular inspection
Plugging of compressor
pipe due dust damage
More More feed flow Open of feed Excess of feed Use of flow meter
valve, and and and control valve
failure accumulation
Use backup filters,
Failure of Low quality and regular
filters press of maintenance
production
Table 11-2: HAZOP study of heat exchanger
106 | P a g e
12 References:
1. Britannica, T.E.o.E., Propylene. Encyclopedia Britannica. 2018.
2. Linde, Industrial Gases. 2018.
3. Mol-Instincts, Structure of PROPYLENE (C3H6). 2019.
4. Lide Jr, D.R. and D.J.T.J.o.C.P. Christensen, Molecular structure of propylene. 1961. 35(4): p.
1374-1378.
5. HS, P.T.S.J.A., Safety data sheet. 2021. 1: p. 2119485044-40.
6. 2.7.0, L.T. National Library of Medicine
National Center for Biotechnology Information (Propylene). 2021; Available from:
https://pubchem.ncbi.nlm.nih.gov/compound/Propylene.
7. THERMOPEDIA, PROPYLENE. 2011.
8. acedemia, Design for Production of Propylene. 2019.
9. Agarwal, A., A Design Approach for On-Purpose Propylene Production with Safety and
Sustainability Considerations. 2018.
10. Markit, I., Propylene Chemical Economics Handbook. 2021.
11. statista, Propylene demand and capacity worldwide from 2015 to 2022(in million tons). 2015-
2022.
12. statista, Production capacity of propylene worldwide in 2018 and 2030(in million metric
tons). 2018-2030.
13. oce.world, Observatory of Economic Complexity (OEC) Propene. 2019.
14. Insights, F.B., PolyPropylene Market Size, Share. 2021-2028.
15. undata, Trade of goods , US$, HS 1992, 29 Organic chemicals (Propylene). 1992-2019.
16. Report, S., LPG price increased by Rs10.3 per kg. 2021.
17. Markit, I., Propane Dehydrogenation Process Technologies. 2015.
18. Maddah, H.A.J.A.S.R.J.f.E., Technology, and Sciences, A comparative study between propane
dehydrogenation (PDH) technologies and plants in Saudi Arabia. 2018. 45(1): p. 49-63.
19. Yaws, C.L., The Yaws Handbook of Physical Properties for Hydrocarbons and Chemicals. 2015.
20. Chin, S., et al., Kinetic model and simulation analysis for propane dehydrogenation in an
industrial moving bed reactor. 2011. 52: p. 183-189.
21. Zhang, Y., et al., Propane dehydrogenation on PtSn/ZSM-5 catalyst: Effect of tin as a
promoter. 2006. 7(11): p. 860-866.
22. Komasi, M., et al., Kinetic modelling of propane dehydrogenation over a Pt–Sn/hierarchical
SAPO-34 zeolite catalyst, including catalyst deactivation. 2017. 42(4): p. 344-360.
23. SINNOT, R.K., Chemical Engineerig Design- Coulson & Richardson Volume 6. 2008.
24. Chin, S., et al., REACTOR MODELING AND SIMULATION FOR INTENSIFYING THE PROPYLENE
PRODUCTION IN A PETROCHEMICAL PLANT. 2008. 2: p. H2.
25. Levenspiel, O., Chemical Reaction Engineering, 3rd Edition. 1998.
26. Peng, B., et al., Catalytic Dehydrogenation of Propane to Propene: Catalyst Development,
Mechanistic Aspects and Reactor Design. Reviews in Advanced Sciences and Engineering,
2014. 3: p. 180-195.
27. Anyakora, V., et al., DESIGN AND FABRICATION OF FLUIDIZED-BED REACTOR. 2013. 2: p.
1595-1605.
28. Timmerhaus, M.S.P.K.D., Plant Design and Economics for Chemical Engineering. 1958.
29. D.Q.kern, Process Heat Transfer. 1965.
30. B.K, D., Principles of Mass Transfer and Separation Processes. 2006.
107 | P a g e

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“Production of 150MTPD polymer grade propylene

Rehan Mansoor 2017-CH-733

Muhammad Akmal 2017-CH-722

Muhammad Bilal 2017-CH-736

DEPARTMENT OF CHEMICAL ENGINEERING

This report is submitted to department of Chemical Engineering,

BACHELOR’S DEGREEIN CHEMICAL ENGINEERING

Date of Approval: _________________

Internal Examiner In-Charge Department

DEPARTMENT OF CHEMICAL ENGINEERING

We certify that the work entitled “Production of 150MTPD polymer grade

Name Registration No. Signature

Muhammad Akmal 2017-CH-722 __________________

Rehan Mansoor 2017-CH-733 __________________

Muhammad Bilal 2017-CH-736 __________________

Zia-ur-Rehman 2017-CH-740 __________________

DEPARTMENT OF CHEMICAL ENGINEERING

Dedicated to Our Beloved Parents, Respected Teachers & sincere fellows.

Figure 1.1: 3D-Propylene structure........................................................................................................ 2

Table 1-1: Physical Properties ............................................................................................................... 6

1.1 Structure of Propylene: [3]

Images of the chemical structure of PROPYLENE are given below:

Figure 1.1: 3D-Propylene structure [4]

1.3 Project Objective:

 To apply appropriate design codes in a detailed design work

1.4 Safety Data of Propylene: [5]

Figure 1.2: Hazard Symbol [6]

1.5.1 Appropriate engineering controls:

1.5.2 Environmental exposure controls:

1.5.3 Hygiene measures:

1.5.4 Eye/face protection:

1.5.5 Respiratory protection:

1.6 Physical properties: [7]

Freezing point -185.25 °C

Boiling point -47.7 °C

Flash point -107.8 °C

Critical temperature 91.8 °C

Auto-ignition temp. 455 °C

Density 0.5139 g/cm³ (at 20 °C)

Solubility Water: 384 mg/l

Oxidizing properties None

Table 1-1: Physical Properties

1.7 Applications of propylene: [8]

Product Application Application Description

 Polypropylene is used to make many well-known

Propylene Oxide  Used mainly as a chemical intermediate in the

Isopropanol  A variety of solvent applications, such as in printing

Cumene  Alkylation of benzene with propylene yields cumene.

Ethylene-Propylene  About half of the worldwide production of EP

Oxo Process Chemicals  Propylene is used to manufacture Iso-butyraldehyde,

Polygons Chemicals  Refinery production of polymer gasoline also yields

Figure 2.1: Global consumption of Propylene [10]

2.2 Worldwide Demand of Propylene by Applications:

Figure 2.2: Global demand by application [11]

2.3 Worldwide Production capacity of Propylene 2018-2030:

2.4 Trade of Propylene: [13]

2.5 Market Analysis (Asia Pacific):

Figure 2.4: Market Analysis [14]

Figure 2.5: Price difference between Propane/Propylene

2.7 Global market share by the end-use industry 2019:

Figure 2.6: Global market share [8]

2.8 Market analysis (Asia pacific-2018): [15]

1 Azerbaijan 35001.973 549