Production of Olefins From Methanol

Production of Olefins from Methanol (MTO) by Using
UOP/Hydro Technology
Session (2017-2021)
Project Supervisor
Mr. Muhammad Umar Mushtaq
Group Members
Sami Ullah UW-17-Ch.E-BSc-021

Dawar Abbas UW-17-Ch.E-BSc-009
Bilal Sarfraz UW-17-Ch.E-BSc-002
Touseef Iqbal UW-17-Ch.E-BSc-005
Department of Chemical Engineering

Wah Engineering College
University of Wah
Wah Cantt
Certificate
This report is submitted to the department of Chemical Engineering, Wah Engineering

College University of Wah for the partial fulfilment of the requirements for the
bachelor’s degree in Chemical Engineering.
Internal Examiner:
Sign:
Name:
External Examiner:
Sign:
Name:
Department of Chemical Engineering

University of Wah
Dedicated To
Our
Beloved Parents,
Respected Teachers,
Sincere Friends
&
Group Members
Acknowledgement
All praise is due to Almighty Allah, who has kept us going through this mission.
Mr. Muhammad Umar Mushtaq, our final year project supervisor, deserves special
recognition for his unwavering cooperation and recommendations toward the completion
of the final year project.
We are also grateful to the head of department Asst. Prof. Dr. K.S Baig, Asst. Prof .Dr.
Saleem Iqbal, and coordinator Mam Rabia Sabir for their profound gratitude and super
guidance in connection with the project.
In this project, I would like to express my gratitude to the members of my team.

We would like to express our heartfelt gratitude to our loving parents; it is only because
of their prayers, selfless sacrifices, support, motivation, and faith in us that we have
achieved such tremendous success in our lives today. Their love and support are the most
valuable gifts we have received in our lives.
Finally, and most importantly, I would like to express my gratitude for the guidance
provided by other supervisors as well as the panels, particularly in regards to our project
presentation, which has improved our presentation skills because of their comments and
suggestions.
i
Preface
The primary goal of this project was to produce olefins using methanol. Olefins are discussed
in this report in terms of their properties, manufacturing process, and applications. Feed drums,
heaters, pumps, reactors, coolers, separators, and distillation columns are all used in the
manufacturing phase.
We work and present our work on "Production of Olefins from Methanol" with these
considerations in mind.
This paper is split in separate chapters. First, an overview of olefins is given, along with their
significance. Following that is a brief overview of the manufacturing process. Following that,
the substance and energy balance is discussed. The previous chapters provide an overview of
various plant equipment, as well as their construction procedures and specification sheets. This
report also includes instrumentation and monitoring, a HAZOP analysis, an EIA, and a cost
estimate for this facility.
ii
List of Figures
Figure 1.1: Comparison between SAPO-32 and ZSM-5 ........................................................ 2
Figure 1.2: Block diagram of MTO ...................................................................................... 3
Figure 1.3: Uses of propylene ……………..………………………………………………… 5
Figure 1.4: Production of ethylene........................................................................................ 7
Figure 1.5: Seafarers-maritime crane operator ...................................................................... 9
Figure 1.6: World consumption of propylene in 2019 ......................................................... 10
Figure 1.7: Propylene in the world ..................................................................................... 11
Figure1.8: World consumption of propylene in 2019…….………………………………....12
Figure 1.9: China propylene consumption…….………………………………… …………13
Figure 1.10: Top 5 Countries Adding Propylene > 79% within 2010-2020 (only China Adding
55% of World)……………………………………………………………………………..…28
Figure 1.11: Coal Chemical Production Chain………………………………………………30
Figure 1.12: China Coal Chemicals Projects……………….………………………………..32
Figure 1.13: Ethylene demand elasticity vs GDP growth……………………………………35
Figure 1.14: propylene demand in over the world………….………………………………..36
Figure 1.15: Global ethylene demand by application………………………….…………….36
Figure 1.16: Annual import data of Ethylene in Pakistan……………………………………37
Figure 1.17: Ethylene demand in Pakistan…………………………………………………..38
Figure 2.1: Production methods…..……………………………………………….…………39
Figure 2.2: Lurgi mto process……..…………………………………………………………40
Figure 2.3: Haldor Topsoe MTO Process…..…………………………………….………….40
Figure 2.4: UOP/Hydro MTO Process………...……………………………………………..40
Figure 2.5: ExxonMobil Process…………………..………………………………………...41
Figure 2.6: Block Flow Diagram……………………………………..……………………...42
Figure 2.7: Growth rate of propylene……………………………………..…………………43
Figure 4.1: Fixed bed reactor………………………………………………………..………55
Figure 4.2: Graph between conversion and rate law…………..…………………………..…61
Figure 4.3: Relation between F and P………………………………………...………….….73
Figure 4.3: Schematic illustration of a shell-and-tube heat exchanger……….…………… 79
Figure 4.4: TEMA designations for shell-and-tube exchangers……………..………….. . 81
Figure 4.5: Distillation column…………………………………..……………………...…...92
Figure 4.6: Mecab theile method………………………………………………………….…97
Figure 5.1: Hemispherical heads………………………….………………….……………. 110
Figure 5.2: Ellipsoidal heads……………………………………….……………………... 110
Figure 5.3: Tori spherical heads………………………………….………………..……….110
Figure 5.4: Brackets supports………………………………………………………………112
Figure 6.1: Rules-of-Thumb for Locating Process Equipment…………………………….119
Figure 6.2: Approximate Frictional Pressure Drop across Process Equipment……………120
Figure 9.1: Google………………………………………………………………………….146
Figure 9.2: Face Shield………………….………………………………………………….146
Figure 9.3: Safety Helmet…………………………………………………………………. 147
Figure 9.4: Safety Shoes…………………………………………………………………... 147
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Figure 9.5: Chemical Resistant Gloves…………………………………….…………….…148
Figure 9.6: Coverall……………………………………………………….………………. 148
Figure 9.7: Apron for Welding…………………………………….……………………….148
Figure 9.8: Cotton Uniform for Electrostatic………………………………………………149
Figure 9.9: Ear Plug…………………………………………………………………….…. 149
Figure 9.10: Earmuffs……………………………………………………….…………….. 149
Figure 9.11: Dust Masker…………………………………………………………………. 150
Figure 9.12: Breathing Apparatus ...………………………………………………………. 150
Figure 9.13: Cartridge…………………………………………………..….……………… 150
Figure 9.14: Safety Belt…………………………………………………………………….151
Figure 9.15: Safety Net……………………………………………………………………. 151
Figure 11.1: Step one components selection………………………………………… …... 180
Figure 11.2: Property method selection……………………………………………………. 181
Figure 11.3: Step 3 simulation, process flow diagram………..…………………………… 181
Figure 11.4: Heat exchanger 1 summary…………………………………… .……………. 181
Figure 11.5: Heat exchanger 2 summary…………………………………………..………. 182
Figure 11.6: Pump (101) summary……………………………………………….……….. 182
Figure 11.7: Reactor (101) summary………………………………………………………. 182
Figure 11.8: Separator (S-101) summary.......................................................................…... 183
Figure 11.9: Distillation column (T-101) summary.............................................................. 183
Figure 11.10: Overall calculations status……………………………………......………… 184
iv
List of Tables
Table-1.1: Physical, chemical and thermodynamic properties of ethylene ……………..….... 6

Table-1.2: Pakistan propylene import data in over the world from 2010 to 2019 …….…… 18
Table-1.3: Pakistan propylene export data over the world…………………………………... 18
Table-2.1: MTO Comparison……...…………………………………………………..….… 27
Table-2.2: MTO & MTP Comparison …...…………………………………………….…… 31
Table-4.1: Conversion & Inverse of Rate Law……………………………………………… 59
Table-5.1: Vessel wall thickness…………………...……………………………………… 109
Table-6.1: Pump Characteristics………...………………………………………………… 120
Table-6.2: Characteristics of Compressor and Pump Drivers……………………………… 121
Table-6.3: Standard Electric-Motor Sizes …………………………………………………. 122
Table-7.1: Direct cost ………...…………………………………………………………… 128
Table-7.2: Indirect cost ………...………………………………………………………….. 128
Table-7.3: Fixed cost ……………………………...…………………………………….... 129
Table-8.1: instrument control ………………………...…………………………………… 136
Table-9.1: HAZOP analysis 1………………………………………………...…………….141
Table-9.2: HAZOP analysis 2 ……………………………………………………………... 142
Table-9.3: HAZOP analysis 3…………………………...………………………………… 142
Table-9.4: HAZOP analysis 4 …………………………………………………………….. 143
Table-9.5: HAZOP analysis 5……………………………………………………………....145
Table-9.6: Hazard communication …………………………...…………………………… 146
v
Table of Contents
Acknowledgement….................................................................................................................i
Preface…………………………………………………………………………………....…...ii
List of Figures………………………………………………………………….………..…...iii
List of Tables……………………………………………………….……………………..…..v
Chapter # 1 ………………………………………...………..……………………………….1
1.1 The Project's Objective ................................................................................................. 2
1.2 Analysis ....................................................................................................................... 2
1.2.1 Raw Material Analysis ........................................................................................... 2
1.2.2 Product Analysis .................................................................................................... 3
1.3 Introduction of Propylene ............................................................................................. 4
1.3.1 Environmental safety ............................................................................................. 4
1.3.1.1 Reaction of propylene ......................................................................................... 4
1.3.2 Industrial applications of propylene ....................................................................... 4
1.4 Introduction of Ethylene ............................................................................................... 5
1.4.1 Industrial process ................................................................................................... 6
1.4.2 Industrial applications ............................................................................................ 7
1.4.3 World Wide Production of Ethylene ...................................................................... 7
1.5 Shipping of the products ............................................................................................... 8
The fluid material transportation industry has its own set of requirements ......................... 9
1.5.1 Prerequisite for seafarers ........................................................................................ 9
1.6 World production and consumption of propylene........................................................ 10
1.6.1 Consumption of propylene in 2019 ...................................................................... 10
1.6.2 Propylene market ............................................................................................. 11
1.6.3 Propylene recovery .......................................................................................... 12
1.6.4 China Propylene Supply Outlook ..................................................................... 12
1.7 World production and consumption of Ethylene ......................................................... 14
1.7.1 Coal projects China.............................................................................................. 15
1.7.2 Ethylene global demand: ..................................................................................... 16
1.7.3 Consumption of propylene ................................................................................... 17
1.7.4 Pakistan Balance of Trade ………………………………………………………. 17
1.8 Pakistan propylene import and export data.................................................................. 18

1.9 Pakistan ethylene import and export data .................................................................... 19
1.10 Market Assessment of Olefins .................................................................................. 19
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1.10.1 Size of Olefins market ....................................................................................... 19
1.10.2 Ethylene market patterns, improvements and possibilities: ................................. 19
1.10.3 Olefins Market Segmentation ............................................................................. 19
1.11 Project motivation: ................................................................................................... 20
Chapter # 2 ........................................................................................................................ 22
2.1 PROCESS SYNTHESIS ............................................................................................ 23
2.1.1 Black Box ............................................................................................................ 23
2.1.1.1 Coal to syngas ………………………………………………………………….25
2.1.1.1.1 Process description ………………………………………………………...25
2.1.1.2 Syngas to methanol …………………………………………………………….25

2.1.2 Alternative Processes ........................................................................................... 24
2.1.2.1 Lurgi ............................................................................................................. 24
2.1.2.2 Haldor Topsoe .............................................................................................. 25
2.1.2.3 UOP/Hydro ................................................................................................... 25
2.1.2.4 Exxon/Mobil ................................................................................................. 25
2.2 Process Selection ........................................................................................................ 26
2.3 Process Description .................................................................................................... 27
2.3.1 Block Flow Diagram ............................................................................................... 28
2.4 Plant Capacity Selection .............................................................................................. 30
2.5 Production Methods Comparison: ............................................................................... 31
Chapter # 03 ...................................................................................................................... 32
Material Balance ................................................................................................................. 32
3.1 Material Balance on Reactor:...................................................................................... 33
3.1.1 Overall Material Balance: .................................................................................... 34
3.2 Material Balance around Separator: ............................................................................ 36
3.3 Material Balance around Distillation: ......................................................................... 37
Energy balance .................................................................................................................... 39
3.4 Energy Balance around Heat Exchanger= 01 ............................................................. 39
3.5 Energy Balance around Reactor: ................................................................................. 40
3.6 Energy balance on heat exchanger (E-102) ................................................................. 44
3.7 Energy balance around separator: ............................................................................... 46
3.8 Distillation energy Balance: ........................................................................................ 48
Chapter No # 4 .................................................................................................................. 51
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Equipment Design ............................................................................................................... 51
Reactor (R-101) Design....................................................................................................... 52
4.1.1 Introduction ......................................................................................................... 52
Reactor selection criteria ................................................................................................. 52
4.1.2 Difference between continuous and batch reactor ................................................. 53
4.1.3 Fixed bed catalytic reactor ................................................................................... 53
4.1.4 Types of fixed bed reactor.................................................................................... 53
4.1.5 Fixed-bed reactor configurations for gas-phase reactions ..................................... 54
4.1.6 Selection of Reactor Type .................................................................................... 55
4.1.7 Effect of variables on multi-tube fixed bed reactor ............................................... 56
4.1.7.1 Particle diameter ........................................................................................... 56
4.1.7.2 Tube diameter ............................................................................................... 56
4.1.7.3 Outside wall coefficient ................................................................................ 56
4.1.7.4 Heat of reaction and activation energy........................................................... 56
4.1.7.5 Particle thermal conductivity ......................................................................... 56
4.1.8 Designing Steps ................................................................................................... 56
4.1.9 Design Calculation .............................................................................................. 57
4.1.9.1 Weight of Catalyst ........................................................................................ 58
4.1.9.2 Volume of Reactor ........................................................................................ 60
4.1.9.3 Space Time ................................................................................................... 60
4.1.9.4 Space Velocity .............................................................................................. 60
4.1.9.5 Tube Diameter .............................................................................................. 60
4.1.9.6 Volume of Tube ............................................................................................ 60
4.1.9.7 Number of Tubes........................................................................................... 61
4.1.9.8 Diameter of Shell .......................................................................................... 61
4.1.9.9 Diameter of reactor ....................................................................................... 61
4.1.9.10 Height of Reactor ........................................................................................ 62
4.1.9.11 Pressure Drop Calculation: .......................................................................... 62
4.1.10 Cooling Water Requirement: .............................................................................. 63
SPECIFICATION SHEET .............................................................................................. 63
Design Two phase separator ................................................................................................ 65
4.2 Design Two phase separator ....................................................................................... 65
Specification sheet .............................................................................................................. 71
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Heat exchanger design (E-102)............................................................................................ 72
4.3 Heat Exchanger Design (E-102): ................................................................................ 72
4.3.1 Heat balance ........................................................................................................ 72
4.3.2 Log mean temperature difference ......................................................................... 72
4.3.3 Correctiuon factor for LMTD .............................................................................. 73
4.3.4 Surface Area ........................................................................................................ 73
4.3.5 Tube Specifications ............................................................................................. 74
4.3.6 Checking Fluid Velocity ...................................................................................... 74
4.3.7 Determinbe shell size and actual tubes cpunts ...................................................... 75
4.3.7.1 Calculate Ureq Over all Clean Cofficient ........................................................ 75
4.3.8 Calculate ho ......................................................................................................... 75
4.3.8 Estimate leakage and bypass clearances ............................................................... 76
4.3.8.1 Tube to baffle clearance ................................................................................ 76
4.3.9 Calculate the flow areas ....................................................................................... 76
4.3.10 Ideal tube bank correlations ............................................................................... 78
4.3.11 Calculate the correction factors. ......................................................................... 79
4.3.12 Baffle leakage correction factors ........................................................................ 79
4.3.13 Leakage correction factors for heat transfer and pressure drop are calculated ..... 80
4.3.14 Correction Factors for Unequal Baffle Spacing .................................................. 81
4.3.15 Laminar Flow Correction Factor ........................................................................ 81
4.3.16 Calculate the shell-side heat-transfer coefficient ................................................ 81
4.3.17 Calculate the clean overall coefficient ................................................................ 81
4.3.18 Fouling factor .................................................................................................... 81
4.3.19 Calculate the design overall coefficient .............................................................. 82
4.3.20 Tube side pressure drop ..................................................................................... 82
4.3.21 Effective no of tube rows crossed in one baffle window ..................................... 83
4.3.22 Ideal Tube Bank Pressure Drop .......................................................................... 83
4.3.22.1 Ideal Window pressure drop ........................................................................ 83
4.3.22.2 Nozzle to nozzle pressure drop .................................................................... 83
4.3.23 Pressure drop in nozzle ...................................................................................... 83
4.3.24 Total pressure drop ............................................................................................ 84
Specification sheet .......................................................................................................... 85
4.4 Shell and Tube Heat Exchanger (01)........................................................................... 86
ix
4.4 Distillation column design: ......................................................................................... 92
4.4.1 Binary Distillation: .............................................................................................. 88
4.4.2 Types of Distillation Column:-.............................................................................. 88
4.4.3 Plate column: ....................................................................................................... 89
4.4.4 Design and Analysis Factors : .............................................................................. 89
4.4.5 McCabe-Thiele’s Method: ................................................................................... 90
4.4.6 Designing steps for distillation column are following: .......................................... 90
4.4.6.2 Designing: .................................................................................................... 92
4.4.6.3 Flowrates inside Column: .............................................................................. 92
4.4.6.4 Stripping Section: ......................................................................................... 93
4.4.6.5 Height of Tower:........................................................................................... 93
4.4.6.6 Height of distillation tower:........................................................................... 93
4.4.6.7 Flooding Velocity: ........................................................................................ 94
4.4.6.8 Flooding Velocity: ........................................................................................ 94
4.4.6.9 Volumetric flow rate: (Q) .............................................................................. 95
4.4.6.10 Plate Design: ............................................................................................... 96
4.4.6.11 down comer area: ........................................................................................ 96
4.4.6.12 Net area: ..................................................................................................... 97
4.4.6.13 Active area: ................................................................................................. 97
4.4.6.14 Weir length: ................................................................................................ 97
4.4.6.15 Hole area:.................................................................................................... 97
4.4.6.16 Hole diameter: ............................................................................................ 97
4.4.6.17 Number of holes:......................................................................................... 97
4.4.6.18 Height of tower: .......................................................................................... 97
4.4.6.19 Pressure Drop Calculations: ........................................................................ 98
4.4.6.20 Pressure Drop Calculations: ........................................................................ 98
4.4.6.21 Pressure drop through holes ........................................................................ 99
Chapter # 5 ...................................................................................................................... 102
Mechanical Design ............................................................................................................ 102
5.1 Mechanical Design of Reactor .................................................................................. 103
5.1.1 Design Pressure ................................................................................................. 103
5.1.2 Heads and closures ............................................................................................ 105
5.1.3 Comparisons of Heads ....................................................................................... 106
x
5.1.4 Types of supports............................................................................................... 106
5.1.5 Weight of shell .................................................................................................. 107
5.1.6 Stress Calculations ............................................................................................. 107
5.1.7 Principle Stress .................................................................................................. 108
5.1.8 Wind Loading .................................................................................................... 109
Specification Sheet ........................................................................................................ 110
Chapter # 6 ...................................................................................................................... 111
Power Calculation ............................................................................................................. 111
6.2 Pump Calculation ..................................................................................................... 112
6.2.1 Mechanical Calculation of Pump (P-101) ....................................................... 112
6.3 Pump sizing calculation steps ................................................................................... 112
6.3.1 Pump Selection .............................................................................................. 112
6.3.2 Locate the process equipment......................................................................... 113
6.3.3 Estimation frictional pressure losses ED and ES ............................................ 113
6.3.4 Calculate Pump Work .................................................................................... 114
6.3.5 Pump Power: ................................................................................................. 114
6.3.6 Calculate electric motor horsepower & efficiency .......................................... 115
6.3.7 Net positive suction head (NPSH) .................................................................. 117
Specification Sheet P-101 .......................................................................................... 118
Chapter # 7 ...................................................................................................................... 119
Economic Analysis ........................................................................................................... 119
7.1 Pump (P-101): ...................................................................................................... 120
7.2 Reactor (R-101):-.................................................................................................. 120
7.3 Distillation Column (T-101): ................................................................................ 121
7.4 Cost of separator (V-101) ..................................................................................... 122
7.5 Cost of Heat Exchanger (E-102) ........................................................................... 122
7.6 Total Equipment Cost ........................................................................................... 123
7.6.1 Direct Cost ..................................................................................................... 123
7.6.2 Indirect Cost .................................................................................................. 123
7.6.3 Miscellaneous ................................................................................................ 124
7.6.4 Fixed Cost ..................................................................................................... 125
7.6.5 Total Production Cost .................................................................................... 125
7.6.6 Profitability Analysis ..................................................................................... 125
xi
7.6.7 Net Profit ....................................................................................................... 126
7.6.8 Rate of Return................................................................................................ 126
7.6.6 Payback Period ............................................................................................. 126
Chapter # 08 .................................................................................................................... 128
Instrumentation and Control of Major Equipment’ ............................................................ 128
8.1 Control Strategy for the Whole Plant .................................................................... 129
8.2 Establish the control objective .............................................................................. 129
8.3 Determine the control degrees of freedom............................................................. 129
8.4 Control and Instrumentation ................................................................................. 130
Chapter # 09 .................................................................................................................... 133
HAZOP study ................................................................................................................... 133
9.1 Hazard and Operation Study (HAZOP)..................................................................... 134
9.2 Hazard Communication ............................................................................................ 141
9.3 Main Hazard in Plant ........................................................................................... 141
9.4 Personal Protection Equipment ............................................................................ 142
Chapter # 10 .................................................................................................................... 147
Environmental Impact Assessment .................................................................................... 147
10.1 Environmental Impact Assessment ......................................................................... 148
10.2 Waste Treatment ................................................................................................. 148
Chapter # 11 .................................................................................................................... 150
Process simulation............................................................................................................. 150
11.1 MTO process simulation on aspen final report ........................................................ 151
Bibliography .................................................................................................................... 169
xii
Chapter # 01 Literature Survey
Chapter # 01
Literature Survey
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1.1 Project Background

Plastic is a substance that is already well known in human life. Plastic as a raw material is used
in the development of a wide range of goods, from basic to high-tech. the market for plastic in
Pakistan reached three million tons in the beginning of 2019. Synthetic plastic, which is based
on petrochemicals, is still the most commonly used plastic.” (Gogate and technology)”
One of the substances that can be turned into polyolefin or plastic is methanol. Methanol to
Olefin (MTO) is a process that transforms methanol to olefins like ethylene and propylene,
which can then be used to make polyolefin, Ethylene and propylene. The two most common
chemicals developed by the petrochemicals industry are propylene and ethylene. In 2019, the
world produced approximately 133 million metric tons of ethylene and 126 million metric tons
of propylene. The global demand for light olefins (ethylene and propylene) is expected to rise
at a rate of 5% for propylene and 4% for ethylene over the next few years. The petrochemicals
industry now produces the majority of light olefins, by either pyrolysis or other or from fluid
catalytic cracking (FCC) of naphtha. The recent sharp rise in oil prices has reignited interest in
producing light olefins from non-petroleum sources, one of which may be low-cost methanol.
A big part the technologies for making light olefins from methanol are currently ready for
commercialization.
1.1.1 The Project's Objective
Our MTO plant's main objective are to:
 Manufacture ethylene and propylene without using petroleum as a feedstock.

 To reduce Pakistan olefin imports
1.2 Project Analysis
1.2.1 Raw material & Catalyst analysis
We use Methanol as a raw material to make ethylene and propylene. Our methanol comes from
abroad; Pakistan import methanol in 2019 is 41052 tons. SAPO-34 was used as a catalyst in
Figure 1.1: comparison between SAPO-32 and ZSM-5
the Methanol-to-Olefin process. SAPO-34 has a special pore size, acidicity, and geometry that
allows for a more selective conversion of methanol to ethylene and propylene. The smaller
pore size of SAPO-34 compared to ZSM-5 prevents heavy hydrocarbons from diffusing and
2|Page
favours high selectivity for the desired light olefins. Figure 1 shows the contrast of SAPO-34
and HZSM-5 catalysts. “(Gogate and technology)”
1.2.2 Product Analysis
The MTO process produces olefin, which is made up of ethylene and propylene that can be
separated using a distillation column. Since both ethylene and propylene are intermediates,
they are the most commonly used raw materials in the production of household goods.
To make a finished product, you'll need a product. Polyethylene, ethylene glycol, styrene, and
PVC are examples of ethylene compounds that can be used in packaging, agriculture,
automotive, construction, textiles, and electronics. Polypropylene and acrylic acid are
examples of propylene derivatives that can be used in packaging, textiles, automobile, building,
and personal care products.
Figure 1.2: Block diagram of MTO
Olefins are the fundamental building blocks of the natural union. Only fossil oil and gas
reserves are used to make olefins today. The synthetic products obtained from oil refining are
known as petrochemicals. Other petroleum derivatives, such as coal or gasoline, or renewable
sources, such as corn, palm natural product, or sugar stick, may also be used to produce certain
oil-based content exacerbates. The most popular petrochemical groups are olefins (which
includes ethylene and propylene) and aromatics (counting benzene, toluene and xylene
isomers). Liquid synergist splitting of oil pieces produces olef (Placeholder1)ins and aromatics
in petroleum treatment facilities. Compound plants produce olefins. Naphtha is transformed
into a reactant. Olefins and aromatics are the building blocks of many materials, including
solvents, cleansers, and cements. Polymers and oligomers created from olefins are used in
plastics, tars, filaments, elastomers, greases, and gels. “(R.Gogate)”
Current technologies, such as methanol-to-olefin (MTO) and methanol-to-propylene (MTP),
are possible thanks to the use of renewable raw materials, such as biogas and biomass, as well
as coal, which transforms into a spotless commodity for the substance industry. Methanol is
3|Page
quickly becoming the most important structural component in the supportable substance
industry.
1.3 Introduction of Propylene
Propylene is an odorless and colorless gas. The ethylene is broken down warmly to obtain it.
It frames a touchy and combustible blend with air at low focus, while it can cause suffocation
and skin consumes at high fixations. It is used as a fuel and alkylate in the petrochemical
industry, as well as in the compound industry to make polypropylene, isopropyl liquor,
propylene oxide, and other synthetics Propylene, also known as propene or methyl ethylene, is
an inorganic compound with the formula C3H6 that occurs naturally. With just one twofold
bond, it is the second most straightforward member of the alkene class of petroleum. It's a thin
gas with a slight odour of tar.
The most popular olefins conversion technology is methanol-to-olefins/methanol-to-propene

conversion. Synthetic gas (syngas) is converted to methanol, which is then transformed into
ethylene and propene. Water is generated as a result of the cycle.” (Encyclopedia of Toxicology
(Third Edition)) 2014’’
1.3.1 Environmental safety
Propene is produced when forest fires, tobacco smoking, and engine automobile and aeroplane
fumes ignite. Some warming gases contain it as a pollutant. In national air, fixations ranged
from 0.1 to 4.8 parts per billion (ppb), in metropolitan air from 4 to 10.5 ppb, and in modern
air studies from 7 to 260 ppb. For word-related (8-hour time-weighted normal) implementation,
an edge limit estimate of 500 sections per million (ppm) was set up in the United States and
some European countries. Despite the fact that many politicians regard it as a volatile organic
compound (VOC), the United States. The Environmental Agency does not keep track of
outflows (EPA),
Propene has a low level of toxicity when inhaled. The gas's inward breath can have sedative
properties as well as obviousness at exceptionally high fixations. Humans, on the other hand,
have a much higher overall degree of combustibility (23 percent) than animals. Handling and
storage
Although propene is flammable and unstable, extra care must be exercised when treating it to
prevent fire hazards. Propene should be switched off while stacking, emptying, interfacing, or
detaching it from any devices capable of igniting it. Propane is normally stored as a liquid
under tension, but in permitted holders, it can also be safely stored as a gas at room temperature.
1.3.1.1 Overall reaction
Δ Hr 673 K = -1431 kj/kmol
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1.3.2 Industrial applications of propylene [7]
After ethylene, propene is the second most important starting material in the petrochemical
industry. It is the raw material for a wide range of products. Polypropylene producers account
for about 66 percent of total production. Movies, strands, holders, bundling, and covers and
terminations are all examples of polypropylene end uses. Propene is also used in the
manufacture of important synthetics such as propylene oxide, acrylonitrile, cumene,
butyraldehyde, and acrylic corrosive. Around 85 million tons of propene were treated around
the world in 2013. “(Encyclopedia of Toxicology (Third Edition))”
Uses of propylene in different products
21% 16%
20% 28%
15%
films (food pakaging)

rigid pakaging (crates, pails, CD and DVD boxes, corrugated boards)
consumer products (furniture and housewares toys)
technical parts (car bumper, dashboards, sevage pipes, drain pipes, electric cables )
textiles (carpets, carpet backing)
Figure 1.3: Uses of propylene over the world
1.4 Introduction of Ethylene
Ethane is a hydrocarbon with the formula C2H4 and the formula H2C=CH2 (IUPAC name).
It's a drab flammable gas with a weak "sweet and musky" odour when it's unadulterated. It is
the most user-friendly alkene (a hydrocarbon with carbon-carbon twofold bonds). Ethylene is
its gross volume (more than 150 million tons in 2016) significantly outnumbers that of any
other natural compound. Polyethylene, a commonly used resin made up of polymer chains of
ethylene units of different lengths, accounts for a significant portion of this production.
Ethylene is an important natural plant hormone that is used to regulate plant maturation in
horticulture.
Four hydrogen particles are bound to a couple of carbon iotas by a twofold bond in this
hydrocarbon. Each of the six ethylene-containing iotas is coplanar. The H-C-H point is 117.4°,
which is close to the ideal 120° for sp2-hybridized carbon. The particle is also fragile: pivoting
around the C-C bond is a low-energy step that necessitates breaking the -bond by applying heat
at 50°C. “ (Carey Franscis 2013)”
5|Page
Table-1.1: Physical, chemical and thermodynamic properties of ethylene [2]
Critical temperature 282.35 K

Critical pressure 5.0408 MPa
Critical density 214.2 kg/m3

Normal vapor density 1.26 kg/m3
Normal boiling point 169.35 K
Melting point 104 K

Molecular weight 28.054
Form Colorless
Taste Tasteless
Odor Sweet
Flash point -213 °F
Solubility 0.00M
Density 0.569 at -154.84 °F
Vapor density 0.98 (Air = 1)

Vapor pressure 5.21e+04 mmHg
Auto ignition temperature 842 °F
Corrosivity Non corrosive gas

Heat of combustion -1411.2 kJ/mol
Heat of vaporization 13.53 kJ/mol

Surface tension 0.016 N/m at -104 °C
Heat of formation 52.47(kJ/mol)
1.4.1 Industrial process
In the petrochemical industry, a few methods are used to produce ethylene. Steam breaking
(SC) is a crucial technique that involves heating hydrocarbons and steam to temperatures
between 750 and 950 degrees Celsius. This cycle converts massive hydrocarbons into smaller
ones, resulting in unsaturation. When ethane is used as a feedstock, the product is ethylene.
Rehashed pressure and refining are used to separate ethylene from the resulting mixture.
Ethylene is produced primarily in Europe and Asia by breaking naphtha, gasoil, and
6|Page
condensates with the coproduction of propylene, C4 olefins, and aromatics (pyrolysis gas). The
oxidative coupling of methane, for example, is another method for producing ethylene.
“(Encyclopedia of Toxicology (Third Edition))”
1.4.2 Industrial applications [3]
For scale requests, the following are the major mechanical responses of ethylene to remember:
1) formylation by hydro 2) Oligomerization, 3) hydration, 4) alkylation, 5) halogenation and
hydro halogenation, 6) oxidation, and 7) polymerization are the steps involved. Around 90%
of ethylene is used to deliver ethylene oxide, ethylene dichloride, ethylbenzene, and
polyethylene in the United States and Europe. Electrophilic expansion is the most common
response to ethylene.
 A wide range of businesses and applications, including, uses ethylene: Synthetic

materials: Ethylene is the starting material in a few modern blends. It is used as a
compounding center and for the production of plastics.
 Food and Beverage: To monitor the maturation of regular products, such as bananas,
an ethylene/nitrogen mix is provided in chambers. A couple of ppm of intermingling in
the conveyance place climate is used. It's also used in agriculture to speed up the
gathering process. The gas is specifically pumped into the soil in this application.
 Ethylene is used in the manufacture of distinguishing strength glass for the automotive
industry (vehicle glass).
 Ethylene is a narcotic that is used in clinical settings.
 Metal Fabrication: Ethylene is used in metal cutting, welding, and quick warm
sprinkling as an oxy-fuel product.
 Ethylene is a refrigerant that is commonly used in LNG liquefaction plants.
 Ethylene is used in the extraction of flexible and plastic materials.
1.4.3 World Wide Production of Ethylene [4]
17.065 million tons of production of ethylene in 2019

South America
2%0%
Asia North America

29% 32%
Middle east
14% Europe
23%
North America Europe Middle east Asia South America
Figure 1.4: Production of ethylene in 2019
 The majority of the increased production over the last five years is from Northeast Asia,
North America, and the Europe; within these three regions.
7|Page
 Overall demand for ethylene derivatives is now fueled primarily by the emerging world,
and is projected to further grow over the foreseeable horizon.
1.5 Shipping of the products [2]
Liquid bulk chemicals are liquid organic compounds other than oil and quasi-oil inflammables
like LPG or LNG. To date, the IMO has reported over 30,000 chemicals, of which 1400 have
been listed by the IMO's GEMSAMP and an estimated 1100 are bulk chemicals, 596 of which
have been labelled as Noxious Liquid Substances that can be shipped in bulk by sea-going
chemical vessel under the 1992 Amendment of MARPOL Annex II regulations for the Control
of Pollution of Noxious Liquids Substances. “(R.Gogate 2019)”
Bulk Chemical big haulers are vessels that transport large amounts of synthetic compounds.
Today's mass material big hauler is often equipped with a free siphon/pipe system, 70% of its
payload hold is made of top-notch treated steel, capable of conveying extremely thick and
unmistakably damaging fluid loads, as well as disturbing and idle gas frameworks. For the
exacting requirements on the ships, mass substance big haulers must go through a series of
extraordinary studies that will result in the approval of COF, NLS, or SNLSPEP, all of which
demonstrate the high limit of the mass substance transportation industry.
Specialized situation has evolved unevenly in the new homegrown mass substance
transportation. Taking the Yangtze River Delta as an example, rapid advancement in the
transportation of large synthetic freights has boosted the local economy while also posing
significant threats to local security and climate assurance. The public implementation of the
ISM code is accelerating, setting a precedent for the protection the board system to become a
mandatory requirement for all transportation organisations engaged in mass synthetic
transportation operation.
In terms of volume, the synthetic load moved by substance major haulers amounts to 130
million tonnes per year, which could be underestimated when compared to the 1.9 billion
tonnes of ocean-borne oil transportation per year. Overall, the most striking aspect of mass
compound transportation isn't its scale, but rather the variety of competitors and modes of
transportation. Aside from the massive amounts of oil transported from the Middle East or
West Africa to developed countries, compound item communities strewn across the globe, like
the EU (centred in Rotterdam), the American Bay, the Middle East, Japan, Korea, China,
Taiwan, Malaysia, Singapore, and others.
The global demand for ethylene implication was 97.6 million tonnes in 2003 and 103 million
tonnes in 2004, indicating a gross increase trend. From 2003 to 2009, China would increase its
request by 10.9 million tonnes. While the global flexibly for ethylene implication at the end of
2003 was 116.6 million tonnes, the global flexibly for ethylene implication in 2009 would be
149.1 million tonnes, depending on the contribution of new plants until 2009. It also forecasts
that the gracefully's standard annual limit will rise by 4.2 percent per year, and that as a crude
commodity, ethylene's efficiency will rise from 110.2 million in 2003 to 143.7 million in 2009.
8|Page
1.5.1 The fluid material transportation industry has its own set of
requirements. [5]
Mass synthetic transportation is critical in the coursing cycle from production to use as a
support administration to the fluid material producing and exchanging. There are three types
of mass material transportation examples currently available: street transportation, railroad
transportation, and distribution.
Street transportation is a mode of transport designed for small amounts of cargo to be
transported within a short or moderate reach separation, with either side being effectively
reachable. Uncommon big hauler vehicles are the primary mode of transportation in this mode,
which provides PTP administration on a regular basis. Because of the ease with which street
transportation can be accessed, it is often used for hazardous goods that are of low interest or
that would be handled differently by heating and squeezing. One of the disadvantages of street
transportation is its high cost; as a result, low-value mass synthetics, such as methanol or
glycol, are seldom used. “(Carey 2013)”
Since transportation is the most important factor in mass compound transportation, China's
thriving petrochemical industry must continue to push the mass synthetic distribution market
forward. Because of the perilous nature of mass substance goods, the requirements for safer
delivery, environmental insurance, and high freight efficiency are always stringent, prompting
delivery companies to search out serious expertise for armada as well as magnificent particular
purpose compound big haulers.
1.5.2 Prerequisite for Seafarers
Staff working on board synthetic big haulers should have experience in synthetic freight
acclimation, petrochemical industry training, boat moving training, firefighting readiness
training, clinical emergency treatment readiness training, and so on. They should also be well-
versed in the important details on cargo anticipation steps for shared cargoes.
Figure 1.5: Seafarers-Maritime crane operator
Responses, information on the unusual warming practice for a particular type of freight
transported mounted, information on the dangers of destructive payload, information on human
9|Page
protection initiatives, and information on clinical care for individuals polluted by toxic cargoes,
and so on.
With technological advancements, the introduction of new chemicals and materials, as well as
the demands of modern transportation systems, the potential for dangers has greatly increased.
As a result, the transportation of hazardous materials has become a major source of concern for
all those involved in ocean transportation, both in terms of protection and pollution.
To resolve these issues, new global standards have been enacted and will continue to be
enacted. The law of the sea has progressed well beyond its traditional roots, incorporating
major elements of maritime law, natural law, and maritime policy for dangerous and harmful
cargoes. In agricultural nations the instruction and preparing have not stayed up with these
advancements in the oceanic industry all in all and especially in the field of perilous substances.
These variables have caused or added to the accompanying issues in the ports of agricultural
nations including Pakistan:
 Colossal increment in amount and assortments of risky substances going through the
ports;
 Outdated guidelines and authoritative techniques;
 Lack of mindfulness with respect to port approach producers also, organizers;
 Hesitation with respect to authorities for outlining new guidelines considering
experiencing huge challenges all the while;
1.6 World production and consumption of propylene [7]
1.6.1 Consumption of propylene in 2019
In 2003, the global demand for propylene implication would be 58.8 million tonnes, rising to
78.9 million tonnes in 2009, an increase of 5% per year. Asia would expand at a rate of 6.3
WORLD CONSUMPTION OF PROPYLENE IN 2019

other Asia
23%
china
25%
china
Europe
South America
Rest of the world
North America
North America Europe
14% 18% other Asia
Rest of the world

South America…
14%
Figure 1.6: World consumption of propylene in 2019
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Percent. In terms of global propylene implication output, the cap will be 66.1 million tonnes
in 2003, 2020, According to the estimated cap derived from a speculative timetable of new
structure plants raised before the end of 2008, it will be 82.8 million tons in 2009, with a yearly
rate of 3.8 percent. From 2003 to 2009, the annual increase rate for different areas on the globe
was as follows: Asia 3.8 percent, North America 1.7 percent, and Asia's import volume in 2009
would be 3.9 million tonnes. The graph below shows propylene consumption by major regions:
With the fast-growing global demand, on-purpose propylene offices continue to be built to
supplement traditional production methods (ethylene saltines and treatment facilities).Changes
in fuel utilization, wafer feed, and new guidelines, for example, IMO 2020 are extended to alter
the propylene creation design in the medium term.
Propylene demand 2005 to 2019

110
Propylene demand, million metric tpy
120 105
100
95 99
100 90 91
80 84
75
70
80 65 68
60 64 63
60
40
20
0
200520062007200820092010201120122013201420152016201720182019
years
propylene demand, million metric tpy
Figure 1.7: Propylene in the world

Polypropylene is projected to remain the predominant source of propylene until 2024, with its
total share of the global propylene market increasing. Propylene oxide, cumene, and
acrylonitrile, for example, will continue to evolve, each with its own range of territorial
characteristics. The global economy has been harmed by vulnerabilities caused by escalating
trade conflicts between the United States and China, as well as monetary and security issues in
particular regions. Propylene demand will continue to rise in this sense, owing to the continued
economic growth of developing economies. “(trade map.com)”
1.6.2 Propylene market
The most popular propylene use is polypropylene (PP), which accounts for approximately 66
percent of global propylene use. Propylene is used to deliver acrylonitrile (ACN), propylene
oxide (PO), various alcohols, cumene, and acrylic corrosive.” (Encyclopedia of Toxicology
(Third Edition))”
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Propylene is classified into three types: polymer grade, which has a base virtue of 99.5 percent,
substance grade, which has a base immaculateness of 93-94 percent, and processing plant
grade, which has an immaculateness of around 70 percent with at least 60 percent.
1.6.3 Propylene recovery
According to US-based experts DeWitt and Co., worldwide interest in propylene recovered in
2009 as a result of a rebound in PP demand in China. The use of PP in China accounts for more
than 15% of global propylene demand. PP demand is also growing at a much faster rate than
other subsidiaries, with DeWitt forecasting annual growth rates of 5-6 percent. However,
propylene cap is also growing steadily, with 13-14 million tons/year of new limit coming on
stream in 2009 and 2010, according to DeWitt. Steam saltines account for a significant portion
of the extra flexibility, especially in China, but also in Singapore, Thailand, and India. New
processing plants focused on flexibility, such as the PetroRabigh and Reliance units in Saudi
Arabia and India, respectively, have increased the new cap. In the gracefully of propylene,
deliberate steps are also becoming more important. Several propane dehydrogenation (PDH)
plants began operations in Saudi Arabia in 2009, and new units are planned for 2010 in the
United States and Thailand. In Abu Dhabi, a massive metathesis plant will provide new
propylene supplies, and coal-based propylene production is set to begin in China in 2010.
Although there appears to be plenty of capacity to meet demand, propylene supplies have been
constrained by co-item creation from steam wafers and treatment facility tasks. Furthermore,
the new propylene cap is linked to the new PP plants, and propylene from these plants cannot
always be exchanged. Despite the fact that PP requests are relied upon to fill unequivocally in
Asia, DeWitt claims that there is a wealth of limit that will keep working rates in the low 80s.
Propylene demand in Western Europe has been hampered by both a modest economic recovery
and a drop in PP trades as a result of Middle East and Asian extensions.
1.6.4 China Propylene Supply Outlook [8]
 China propylene creation will increment to almost 40 million metric tons by 2020
 Although processing plant and steam saltine cap increases were the mainstays of
flexible production just a few years ago, coal and dealer methanol-based units, as well
as PDH, are expected to carry in a steady stream of new supplies over the next four
years.
Figure 1.8: China propylene consumption
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 Without a doubt, China's absolute intentional propylene limit increases over the next
two years would be sufficient to flexibly meet the world's entire propylene demand
growth.
Looking ahead five years, the movement of propylene limit increases, particularly from
intentionally offices, is expected to completely dominate propylene request development. The
next two years show the highest amount of new cap, but the increments are spread out over a
longer period of time to keep up with the rate of interest growth. To rebalance the market, rises
should be slowed and request growth should be accelerated. China's propylene independence
is conjecture to increment to 80%.
 China propylene creation will increment to almost 40 million metric tons by 2020
 China propylene equal interest in China will increment to around 45 million metric
tons.
 Net imports of propylene counterparts will decrease from around 10 million metric tons
in 2010 to 7 million metric tons by 2020.
 This decrease in imports (for polypropylene) will drive the worldwide market to
rebalance when different districts will grow and looking to expand send out volumes.
Figure 1.9: Top 5 Countries Adding Propylene > 79% within 2010-2020 (only China Adding 55% of
World)
America Propylene Outlook
North America is unusual in the global propylene industry in that about half of the territory is
reliant on FCC production rather than steam wafer coproduct production. Leading to projected
reductions in steam wafer demand due to the area's transition to lighter feed slates, equalisation
is likely to hold FCC and purposely units as significant wellsprings of propylene flowing
flexibly over the next ten years.
Southeast Asia Propylene Outlook
Because of the abundant supply of fluid steam wafers in Southeast Asia, propylene is primarily
obtained from steam saltines. Despite the latest steam wafer-based limits scheduled to start up
over the next five years, alternative propylene wellsprings will have more than 800,000 metric
tonnes of propylene cap in Southeast Asia. Propylene has been in short supply in the Southeast
13 | P a g e
Asian market in general. Nonetheless, the area's gracefully and demand will turn out to be more
adjusted to-long over the next five years, thanks to the start-up of the previously listed projects.
1.7 World production and consumption of Ethylene
It is expected that demand for ethylene subordinates from key end-client markets will continue
to grow. Around 45 percent of global interest in plastics pitches is driven by the bundling
industry (Polyethylene, Polystyrenes, PVC, PET). By 2025, the global bundling industry is
expected to grow at a rate of 4% per year, owing to the growing use of plastic packaging in the
food, beverage, personal care, medical care, and consumer hardware industries.
Requests from the construction industry account for nearly 20% of ethylene subsidiaries use.
China, the United States, and India are expected to boost global growth by 4.1 percent a year
by 2030. Plastics are gradually replacing traditional materials in products such as lines, wires,
and safety. As the world is getting progressively more urbanized, interest for building and
development plastics is relied upon to extend. Driven by buyer interest, in bundling,
Figure 1.10: Coal Chemical Production Chain
development and car, worldwide ethylene limit developed by 3% somewhere in the range of
2012 and 2019. In 2019, 183 million tons of ethylene was included around the world. A solid
mix of solid worldwide customer interest and less expensive feedstock’s made vigorous
conditions during 2017 and 2018, when ethylene creation limit encountered its most elevated
development pace of 4.7% and 4.1% likewise. (Carey Fransis 2014)
Between 2012 and 2018, ethane was responsible for about 60% of steady ethylene production.
Ethane-based ethylene accounted for 40% of ethylene delivered globally in 2018, up from 35%
in 2012. They are responsible for 80 percent of global ethylene production, along with naphtha.
Other feedstock groups, such as propane, butane, coal to olefins, methanol to olefins, and
methanol to propylene, share the equalization of 20%.Worldwide ethylene working rates stayed
14 | P a g e
stable in 2017 and 2018 at 90%, driven by restricted measure of ethylene limit augmentations
in comparison to the request Venture postponements and undoing’s, shifts in ethylene interest,
and feed accessibility all contribute to tight ethylene gracefully. In the coming years, the global
rate of ethylene limit production will be significantly faster than the rate of demand growth,
resulting in the possibility of an ethylene oversupply and, as a result, a decrease in working
rate. As a result, the estimated global working rate is 88 percent, which is slightly lower than
the recorded average of 89 percent.” (R.Gogate petroleum science and technology)”
1.7.1 Coal projects China [8]
State-owned, private, and unknown entities have all expressed an interest. Despite the fact that
many activities have been announced, fewer will actually be carried out due to:
 Tight government control

 High capital expense
 Water accessibility
Figure 1.11: China Coal Chemicals Projects
 North America returns as a serious provider with expanding limit

 Accelerating request development in creating locales outperform limit development
requiring expanding imports
 Assume minimal effort Middle East and North America providers develop piece of
the pie Logistics foundation venture must keep movement to help expanding trade
patterns
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1.7.2 Ethylene global demand: [3]
Indeed, global interest in ethylene has grown in lockstep with global GDP growth. Regardless,
the relationship between ethylene demand growth and financial growth is becoming less clear.
The increasing impact of the innovation and administrations sector on GDP growth, as well as
the correspondingly lower effect of assembling, is eroding the ethylene interest to GDP
flexibility. Furthermore, there has been a strong push toward sustainability and reusing, so
some ethylene demand has been replaced by reused or popular materials (paper, glass, and so
on). This is resulting in lower products to GDP growth, especially in developed countries. In
2019, progressing exchange pressures between the United States and China have brought about
a general lull in subsidiaries request and a move in worldwide exchange streams. Costs of
Figure 1.12: Ethylene demand elasticity vs GDP growth

feedstock’s were unpredictable in 2019 in the midst of assents on Iranian raw petroleum,
assaults on Saudi oil creation offices, the up and coming 2020 usage of another International
Maritime Organization (IMO) fuel guideline, and in general length in worldwide LPG flexibly,
all of which impact value seriousness and wafer feed slates. The 2019-2024 figure period
ventures ethylene request development at a normal pace of 1.2 occasions GDP.
The effect of foundation and port offices, feedstock seriousness, monetary growth, and demand
on global limit expansion has been lopsided across global districts. In the previous decade, Asia
and the Middle East were driving new ethylene limit expansions, and Asia, especially China,
will continue to do so in the coming decade. Because of an ethane feedstock advantage, the US
has invested heavily in new wafer projects recently, with about 7 million metric tonnes (mt) of
new ethylene production facilities planned for 2018-19. In order to come online in 2020, an
additional 3.5 million mt must be added to the cap. Beginning around 2010, the rise of cheaper
coal to olefins (CTO) and methanol to olefins (MTO) technologies to deliver light olefins
coincided with the peaking of unrefined petroleum and naphtha prices. As a result, in the years
since, CTO and MTO have surpassed new limits in China, while enthusiasm for traditional
steam saltine projects has waned due to more fragile mission financial aspects.
In any case, the tide is increasingly turning against MTO and CTO advances due to the traction
of comparatively low raw petroleum and naphtha prices since the breakdown toward the end
of 2014. The corporation also understands that both CTO and MTO technologies face unique
obstacles. For environmental concerns, CTO advancements are being studied more in China,
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while MTO advances are uncompetitive due to high methanol feedstock costs. Several new
MTO and CTO ventures in China were ultimately delayed or scrapped. Then, due to both
natural and financial favourable circumstances, steam saltine projects are regaining
prominence. Most new saltine technologies and speculations in China and South Korea
consider the use of both naphtha and LPG as feedstocks. In China, a few gas wafers are also in
the production and planning stages, despite the high cost of feedstock. The financial advantage
from breaking LPG compared to naphtha is expected to continue for the next few years,
according to IHS Markit, who predicts that the duration in the global LPG market will continue
for the next few years, while naphtha and gas oil gracefully are expected to fix due to the
implementation of the latest IMO guideline. With limited production outperforming demand,
increased fares of serious ethylene and subsidiaries from incorporated structures in the United
States, and a global economic slowdown anticipated in the coming few years, it is critical for
Asian saltines to maintain cost seriousness. Production and consumption data of Olefins in
Pakistan. “(Encyclopedia of Toxicology (Third Edition))”
1.7.3 Consumption of propylene
According to the United Nations COMTRADE knowledge base on global exchange, Pakistan
imported US$116.01 thousand worth of Polymers of propylene or various olefins, tidy
structures from Qatar in 2019. Imports of polymers of propylene or other olefins, demure
structures, from Pakistan - information, registered diagrams, and measurements - were updated
in October of 2020.
1.7.4 Pakistan Balance of Trade
Since 2003, Pakistan has had a predictable import/export deficit, largely due to high energy
imports. China has replaced the United States as Pakistan's most important trade partner since
2012. The highest import/export imbalances have recently occurred in China, India, the United
Arab Emirates, Saudi Arabia, Kuwait, and Malaysia. In trade with the United States,
Afghanistan, Germany, and the United Kingdom, Pakistan has deficits.
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1.8 Pakistan propylene import and export data [7]
Table-1.2: Pakistan propylene import data in over the world from 2010 to 2019
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019
Exporters Imported Imported Imported Imported Imported Imported Imported Imported Imported Imported
quantity, quantity, quantity, quantity, quantity, quantity, quantity, quantity, quantity, quantity,
Tons Tons Tons Tons Tons Tons Tons Tons Tons Tons
World 47,024 59,013 65,515 80,297 67,126 50,313 30,664 59,893 60,958 49,409
Singapore 900 50 17,889 4,167 18,147
United Arab
44,190 64,866 38,252 36,428 21,836 3,700 40,525 13,937
Emirates
Malaysia 1,319 1,499 8,468 6,583
Thailand 4,959 3,284 5,678
Turkey 3,503 3,510 4,165
Italy 2,120 6,421 3,405 825
China 435 469 346 402 415 74
Europe 5,499
Indonesia 4,866 818 1,359
Taipei,
2,206
Chinese
Netherlands 1,000 2,414
Portugal 4,656
Qatar 42,157 55,014 21,325 15,431 6,086 1,544
Saudi
3,999 28,354
Arabia
Sweden 4,968
United
3,736
Kingdom
United
States of 2,011
America
Table-1.3: Pakistan propylene export data over the world
Importers 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019
Exported Exported Exported Exported
Exported Exported Exported Exported Exported Exported
quantity, quantity, quantity, quantity,
quantity, quantity, quantity, quantity, quantity, quantity,
Tons Tons Tons
World 97 1 1
Bangladesh 97
China 1
Hong Kong,
1
China
Reference: “trademap.org/Index.aspx”
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1.10 Market Assessment of Olefins [8]
The most popular modern uses for ethylene. Changes in ethylene oxide, which is a precursor
to ethylene glycol; ethylbenzene, which is a precursor to styrene; different forms of
polyethylene; and ethylene dichloride, which is a precursor to vinyl chloride, clockwise from
upper right.
1.10.1 Size of Olefins market
The worldwide olefin market was esteemed at $200.8 billion of every 2017. Asia-Pacific was
the biggest geographic locale in the market in 2017, representing 39% offer on the lookout.
China was the biggest nation in the olefins market in 2017, representing 17.6% offer on the
lookout.
1.10.2 Ethylene market patterns, improvements and possibilities: [5]
Ethylene is found in a variety of downstream uses, such as polyethylene, ethylene oxide,

ethylene dichloride, and ethyl benzene, to name a few.
China, driven by demand from ethylene downstream businesses, will display high utilization
growth rates and imports will increase in the Asia Pacific district, which has the highest
ethylene production cap.A ton of ethylene ventures are in progress in the
Figure 1.14: Global ethylene demand by application
As a rule, the global ethylene market will continue to grow steadily, with business sectors in
the Middle East and Africa, as well as Asia and the Pacific, rising at higher-than-average rates.
Ethylene (ET) 2020 World Market Outlook and Forecast up to 2029 awards admittance to the
remarkable information on the inspected market. Having utilized a huge assortment of essential
and auxiliary sources,
1.10.3 Olefins Market Segmentation [7]
The olefins producing market incorporates, however isn't restricted to, the accompanying:
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The ethylene market includes the production and sale of ethylene (CH2=CH2). With two
carbons, ethylene is the simplest Olefin. The majority of ethylene is generated by steam
breaking naphtha, gas oil, and petroleum gas. Polyethylene, vinyl chloride, ethylene oxide,
glycol, and other subsidiary industrial compounds are all delivered by ethylene. Cleansers,
thickeners, solvents, and plastics are all made of synthetic chemicals like ethylene oxide.
Figure 1.15: Annual import data of Ethylene in Pakistan
The propylene market includes the production and sale of propylene (CH2=CH-CH3).
Propylene is made up of three carbon atoms connected by a twofold bond. Propylene is made
primarily by steam splitting naphtha, gas oil, and flammable gas.
Propylene is mostly used to transport polypropylene, acrylonitrile, acrylic corrosive, and other
Ethylene Demand in Pakistan

90,000
80,297
80,000
65,515 67,126
70,000
59,013 59,893 60,958
60,000
50,313 49,409
47,024
50,000
TONS
40,000
30,664
30,000
20,000
10,000
0
2010 2011 2012 2013 2014 2015 2016

2017 2018 2019
Figure 1.16: Ethylene demand in Pakistan
industrial materials. Acrylic corrosive, for example, is used as a commoner with acrylamide to
create anionic polyacrylamide and hydroxyacrylates for use in mechanical covering details.
1.11 Project motivation:
 If one of these two chemicals is imported into Pakistan and a plant is built there, the
transportation and import costs will be eliminated. Pakistan will reap significant
benefits in the future. In Pakistan, we want to design a plant that produces olefins from
methanol.
20 | P a g e
 In future of Pakistan, there will be install coal to syngas or syngas to methanol plant.
Therefore, we will buy our raw material from our country and produce the requirement
of propylene and ethylene in the Pakistan.
 It is not done in Pakistan, either officially or privately. So, we will begin by stating that
it is necessary to emphasize the importance of it and that it will be officially recognized
in Pakistan. As a result, it is essential to produce olefins from methanol at this time.
Pakistan has no plans to make it as normal, but it must consider the possibility.
 In china and Ethylene and Propylene have been traditionally produced from Petroleum
based feedstock via steam cracking and catalytic cracking. Therefore, it is the point to
avail a motivation that we need to make and need to think about it.
 As overall review provides us an analysis Methanol to olefins technology based on like
molecular sieves. Therefore, it is necessarily to think about the production of olefins
from methanol. It will be good and may be a new beginning for the World.
 As we have some facts and data on the production of methanol from olefins. As this
data and facts is very helpful for us to make as possible the production of olefins from
methanol, and it make favorable for us and make possible a new beginning as the
production of olefins from methanol.
 And the main thing it will be a new story and may be a great one to take a new start for
all the rest of World and I think at that time it is necessarily to make as possible and to
take a new start and make a new motivation to produce olefins from methanol.
 As methanol can first have obtained from coal and natural gas and methanol is then
converted to ethylene and propylene, which are used to make many plastic materials.
As the question of olefins from methanol is concerned, it will be a new thinking and a
new rest.
 MTG and MTP processes have provided a rich tableau for scientist research and
pursuits. Motivation for us we will first provide information and discovery of these
processes. Then how to make the opposite means MTP to OTM and it will be useful
for the whole.
21 | P a g e
Chapter # 2 Process Selection
Chapter # 2
Process description
22 | P a g e
Chapter 02 Process Selection
2.1 PROCESS SYNTHESIS
2.1.1 Black Box
The general process to get product by indirect liquefaction process for free-to-liquid (XTL)
conversion can be seen on the Figure below:
Feed Feed to Syngas to Syncrude Product

Syngas Syncrude to Product
The following is an explanation of Figure 1. Natural gas is not the only feedstock or raw
material that can be converted in the first step; coal, biomass, waste, oil shale, and oil sands are
all possibilities. The raw material constrains technology selection for the next stage, feed-to-
syngas, but not for the steps after that. If the feedstock is coal, the feed-to-syngas conversion
technology is gasification; if the feedstock is natural gas, the feed-to-syngas conversion
technology is reforming. This is the most energy-intensive and costly phase in the indirect
liquefaction process.
Sync rude can be generated after the raw material has been converted to syngas and the syngas
has been cleaned and conditioned using any combination of technologies. Fischer- Tropsch
(FT), syngas-to-methanol, and syngas-to-oxygenates are some of the syngas-to-syncrude
technologies. Syncrude-to-product conversion is the next step, which is divided into three
levels: upgrading (result intermediate product), partial refining (result intermediate and final
product), and stand-alone refining (result final product). Fuels or chemicals may be the final
product. As shown in Figure 2, our plant's target is to turn methanol into ethylene and
propylene. As a result, we will only cover ethylene and propylene in this article.
Figure 2.1: Production methods
23 | P a g e
2.1.1.1 Coal to Syngas
The gasification of coal is one method that can produce power, liquid fuels, chemicals, and
hydrogen. Specifically, hydrogen is produced by first reacting coal with oxygen and steam
under high pressures and temperatures to form synthesis gas, a mixture consisting primarily
of carbon monoxide and hydrogen.
2.1.1.1.1 Process description
Coal is first heated in a closed reaction chamber where it undergoes a pyrolysis process at
temperatures above 400°C. ... The dominant reactions consist of partial oxidation of char,
which produces a syngas with high fractions of H2 and CO. The process takes place at
temperatures between 800°C and 1800°C.
2.1.1.2 Syngas to Methanol
Methanol is actually produced from syngas, usually obtained by means of steam reforming of
natural gas. The syngas-to-methanol reaction is conventionally performed in a fixed-bed
tubular reactor operating at 60–100 bar and 250–280 ◦C over a Cu–ZnO-based catalyst.
2.1.2 Alternative Processes
Lurgi, Haldor Topsoe, UOP/Hydro, and ExxonMobil are the MTO technologies that are widely
used around the world. The following is an overview of the technologies:
2.1.2.1 Lurgi
The MTP process developed by Lurgi is based on an effective combination of the best reactor
method and a highly selective and stable zeolite-based catalyst. It has the highest propylene
selectivity, the lowest coking propensity, the lowest propane yield, and the least by-product
formation. As a result, compared to on-spec ethylene/propylene separation, the purification
scheme is simplified, requiring only a smaller cold box system. Figure 2.2 depicts the
simplified process diagram.” (Carey Preliminary Design of Methanol to Oleﬁn Plant 2017)”
Figure 2.2: Lurgi MTP process
24 | P a g e
2.1.2.2 Haldor Topsoe
Haldor Topsoe created this technology with the aim of reducing capital and energy costs by
combining methanol synthesis and the MT phase into a single loop, rather than isolating
Figure 2.3: Haldor Topsoe MTO Process
methanol as an intermediate. This method uses a changed catalyst and condition to ensure that
the device pressure is balanced and that no additional compression steps are taken. This method
creates a single recycle loop that connects the gasoline synthesis step to the MeOH/DME
synthesis step. In this step, the olefin is mostly in the gasoline range. “(Encyclopedia of
Toxicology (Third Edition))”
2.1.2.3 UOP/Hydro
A fixed bed reactor is used in the MTO process. The MTO reactor's catalyst operation and
product composition will remain stable. The UOP/Hydro MTO process has a wide range of
versatility for adjusting the propylene stock ratio by modifying the operation severity. The
graphical method is seen in Figure 2.4.
Figure 2.4: UOP/Hydro MTO Process
25 | P a g e
2.1.2.4 Exxon/Mobil
In addition to the MTG (Methanol to Gasoline) process, Mobil produced a number of other
zeolite-based processes for converting methanol to hydrocarbons. MTO synthesis can be
optimized because light olefins are intermediates in the MTG phase. Higher reaction
temperatures (5000C), lower pressures, and lower catalyst (acidity) activity (Keil, 1999) favor
light olefin growth.” (Carey Preliminary Design of Methanol to Oleﬁn Plant)”
Figure 2.5: ExxonMobil Process
2.2 Process Selection
Process selection is done to decide which process will be used to make polypropylene from
methanol in our factory. The phases of process selection include determining a parameter to
evaluate some alternative processes, determining a process, and determining a process.
Each scoring parameter has a weight and rank, and scoring is done based on the scoring
parameters, with the process with the highest score being chosen for production in our plant.
There are four technologies used in the MTO process that have been used by several companies
around the world. Lurgi Mega Methanol, Haldor Topsoe, UOP/Hydro Methanol Synthesis, and
Exxon Mobil are among the companies involved. These parameters will be used to rate the
MTO method in order to determine which is the most feasible to construct.
1. Suitability of the operating conditions. Temperature and pressure for reactors that are
used, whether they are sensible or not.
2. Process Yield is the second factor to consider. The amount of propylene needed to meet
demand.
3. Capabilities The plant's payback time is determined by its capacities. There is also a
factor to consider, whether or not the plant is viable to construct.
4. Hands-on experience The technology is widely used, built, and safe, according to field
experience.
26 | P a g e
5. Manufacturing is number five. Even if the plant has a long payback period, the long
term and difficulty of producing a technology affects the plant value.
After mention the criteria with their scoring percentage that will be used to evaluate some
qualify concept, now arrange the “concept scoring” matrix with value of scoring the process
condition in Table 1 based on parameters in Table 2.2
Table-2.1: Methanol to olefins different processes comparison
Haldor Topsoe
Parameter Lurgi MTP UOP/Hydro ExxonMobil
Two Step
Operating T 250 – 7000C 200 – 2500C 350 – 5250C 350 – 5000C
Condition P 10 - 40 bar 50 – 60 bar 30 – 50 bar 40 – 80 bar
Yield 54% 46% 26 – 32% 16 – 18%
Capacities ~2500 MTPD ~7000 MTPD ~2000 MTPD ~5000 MTPD
Field Experience Common More Common Common Rare
Manufacturing 3 4 3 3
conversion 80% 91% 99% 81%
2.3 Process Description
We then synthesise the process based on the results of the selection process. We use Lurgi's
method with a few changes to the heat exchanger network. Methanol from the storage tank is
vaporised, superheated, and fed to the MTO reactor using the reactor product as the overall
process summary. Since the reactor's output has a high temperature. The reaction within the
reactor, as well as the catalyst needed, contribute to the high temperature. The catalyst has a
high activity and selectivity, and it achieves a near-thermodynamic equilibrium. The reaction
is exothermic, and the equilibrium of the reaction is almost independent of the operating
pressure. In the MTP reactor the MeOH converted to olefins on zeolite-based catalyst. The
reaction is describe by the following summary below:
Δ Hr 673 K = -1431 kj/kmol
about 95% of the carbon from the fresh feed reacts to olefins with conversion of 99%
As previously mentioned, high selectivity towards propylene necessitates a fixed bed operating
temperature of around 450oC and an operating pressure of 40bar. Water is one of the MTO's
side products. Another hydrocarbon may be overlooked because it is so thin. Before entering
the separation process, the intermediate reaction product from each catalyst bed is cooled. After
27 | P a g e
that, the water is separated to be used as drinking water, while the hydrocarbon vapour fluid is
fed into distillation column to separate ethylene or propylene.
2.3.1 Block Flow Diagram
The block flow diagram as previous explanation can be seen on Figure 7 below:
Heating Methanol to Cooling

Methanol
olefins
Ethylene
Distillation Water
separation
Propylene
Figure-2.6: Block Flow diagram
28 | P a g e
F-101 P-101 E-101 R-101 V-101 T-101 D-101 D-102
Feed Pump Heat Packed Bed Separator Distillation Drum Drum

Tank Exchanger Reactor Column
8
D-101
5 V-101 Drum
T=40°C Ethylene
E-102
P=39bar
T=400°C T=-32°C
11
P=39.1bar 4 P=18.6 bar
6
C2H4=5723.9 kg/hr D=6009 kg/hr
C3H6=8585 kg/hr yAD=0.857
T=39°C yBD=0.142
H2O=18396 kg/hr
P=19bar
Unreacted=330 kg/hr
H2O=18398 kg
Unreacted = 330
R-101 kg/hr 7 T-101
T=40°C
P=19bar
F-101 F=14551 kg/hr
xAf=0.4023
xBf=0.5976
T=42°C
P=18.6 bar
T=25°C 1 10 W=8299 kg/hr
P=1bar xAw=0.068
F=33035 kg/hr xBw=0.931 Propylene
3 Drum
T=25°C E-101 T=400°C D-102

P=40bar P=39.7
P-101 F=33035kg/hr F=33035kg/hr 9
Figure 1.7: Process flow diagram of MTO process
29 | P a g e
2.4 Plant Capacity Selection
Import of propylene per year in Pakistan

80000
70000 68000
60297 60958
59893
60000 57126
Import per year (Tons)
49515 50313 49409

50000
39013
40000
30024 30664
30000
19124
20000
10000
Years
Figure 2.8: Growth rate of propylene
• According to Persistent Market Research, capacity can be chosen based on capital

annual growth rate for the projected period 2020-2030.
• Plant capacity is 68,000 Ton/years
• Plant capacity in 8585 kg/hr
60,000 tons 1000 kg 1 year 1 day
year 1 ton 330days 24 hr
30 | P a g e
2.5 Production Methods Comparison:
Table 2.2: MTO & MTP Comparison
MTO MTP
Definition Order-Oriented Plan-Oriented
Advantage Zero inventory Littele inventory as buffer
Disadvantage Stock -out risk channel owner More sophistication SC

has excess power coordination Affects the
performance of whole SC
Product in application Computer and peripheral Consumer electronic
Typical company Dell,gateway Philip
Marketing environment Volatile Less volatile
Preferred inventory Just in time(JIT) Safety stock policy

strategy
Orientaion Production Market demand
Value of indivisual part of Each Each component contains

product component(e.g,CPU,RAM,etc.) insignificant value for
contains individual value and sale;the value is operative
easy for sale after assembly process
Degree of modularity High Medium
Uncertainity of sale Less uncertainity More uncertainity
Lead time of delivery of Shorter Longer

raw materials
Literature studying on Numerous Few
31 | P a g e
Chapter 03 Material Balance
Chapter # 03
Material Balance
32 | P a g e
Capacity Selection:
Production of propylene Plant is 68000 ton/year
68,000 tons 1 year 1 day 1000 Kg
year 330 days 24 hours 1 ton
Propylene = 8585 Kg/hr
3.1 Material Balance on Reactor:
Reaction:
Δ Hr 673 K = -1431 kj/kmol
For Methanol:
8585 Kg of C3H6 1 Kmol C3H6 5 Kmol CH3OH 32KgCH3OH
hr 42 Kg C3H6 1Kmol C3H6 1Kmol CH3OH
Total Methanol Consumed = 32704.76 Kg/hr
Reactor Conversion = 99 %
Total amount of methanol feed:
= 32704.76 /0.99 Kg/hr

= 33035.11 Kg/hr
Unreacted amount = 33035.11 – 32704.76 Kg/hr

= 330.35 kg/hr
33 | P a g e
For Ethylene:
32704.76 Kg 1 Kmol CH3OH 1Kmol C2H4 28kg C2H4
CH3OH
Hr 32Kg CH3OH 5 Kmol CH3OH 1 kmol C2H4
Amount of Ethylene Produce = 5723.33 Kg/hr
For water:
32704.76 Kg 1 Kmol CH3OH 5 Kmol H2O 18 Kg H2O
CH3OH
Hr 32 Kg CH3OH 5 Kmol CH3OH 1Kmol H2O
Amount of water produced = 18396.42 Kg/hr
3.1.1 Overall Material Balance:
3 4
Reactor
CH3OH =33035.11Kg/hr C2H4 = 5723.33 Kg/hr

C3H6 = 8585 Kg/hr
H2O =18396.42 kg/hr
Unreacted = 330.35 Kg/hr
Total = 33035.11 Kg/hr
Compositions:
8585
Propylene = × 100 = 25.9 %
33035.11
5723.33
Ethylene = × 100 = 17.3 %
33035.11
18396.42
Water = × 100 = 55.6 %
33035.11
34 | P a g e
330.35
Unreacted = × 100 = 0.99 %
33035.11
Components Inlet Outlet
Flowrate wt% Flowrate wt%
CH3OH 33035.11 100
C3H6 8585 25.9 %
C2H4 5723.33 17.3 %
H2O 18396.42 55.6 %

Unreacted 330.35 0.99%
Total 33035.11 100% 33035.11 100%
35 | P a g e
3.2 Material Balance around Separator:
C2H4 = 5723.33 Kg/hr

C3H6 = 8585 Kg/hr
C3H6 = 8585 Kg/hr Separator Total = 14308.33Kg/hr
C2H4 = 5723.33 Kg/hr
H2O = 18396.42 Kg/hr
Unreacted = 330.35 Kg/hr H2O = 18396.42Kg/hr
Total = 33035.1 Kg/hr Unreacted = 330.35
Total = 18726.77 kg/hr
Components Inlet 5 Outlet 7 (kg/hr) Outlet 6 (kg/hr)

(kg/hr)
Ethylene 5723.33 5723.33
Propylene 8585 8585
Water 18396.42 18396.42
Unreacted 330.35 330.35
Total 33035.1 14308.33 18726.77
36 | P a g e
3.3 Material Balance around Distillation:
D= 6009.1 Kg/hr
F= 14308.33 Kg/hr yethyleneD = 0.857
YpropyleneD = 0.142
XethyleneF = 0.3999
XpropyleneF = 0.6000
Distillation
W= 8299.23 kg/hr
XethyleneW = 0.068
XpropyleneW = 0.931
A = ethylene
B = propylene
F=D+W
For Component A:
XAF = yAD + XAW
XAF = 0..3999 × 14308.33

XAF = 5721.9 Kg/hr
90 % Ethylene at D:
yAD = 0.90 × 5721.90

yAD = 5149.71 Kg/hr
10 % Ethylene at W:
XAW = 5721.90 – 5149.71
XAW = 572.08 Kg/hr
For component B
XBF = yBD + XBW
XBF = 0.6000 × 14308.33

XBF = 8584.98 Kg/hr
37 | P a g e
10 % Propylene at D:
YBD = 0.1 × 8584.98

YBD = 859.49 Kg/hr
90 % Propylene at W:
XBW = 8584.98 – 858.49
XBW = 7727.15 Kg/hr
Composition %
Ethylene 39.99%
Propylene 60.01%
Components Inlet Outlet
Stream 7 (kg/hr) Stream 8 (kg/hr) Stream 9 (kg/hr)
Ethylene 5723.33 5149.71 572.08
Propylene 8585 859.49 7727.15
Total 14308.33 14308.33
38 | P a g e
Energy Balance
Energy balance accounts for energy being transferred to or from the each equipment and it are
done here by taking into account the law of conservation of energy that is defined as bellow:
[Energy going into the system]-[Energy going out of the system] +[Energy generation within
the system]-[Energy consumption within the system]=[Energy accumulation in the system]
The value of Cp can be calculated by the following equation;
Cp = a + bT + cT2 + dT3
3.4 Energy Balance around Heat Exchanger= 01
Tin = 25 °c or 298 k
Tout = 400 °c or 673 k

T1=420°c
Tavg = 485.5 k
Tin = 25°c Tout=400°c
T2 = 420°c
Component flowrate Cp (kj/kg.K) at 485.5 k
CH3OH 33035 kg/hr 2.8151
For methanol: -
Q = mCpΔT
Q = 33035.11*2.81513*(673-298) k
Q = 3.48 × 107 kj/hr
Steam required -
T = 400 oc
P = 40 bar
39 | P a g e
λ = 1705.71 kj/kg
m = Q/λ
m = 3.48 × 107 /1705.71

m = 20445.6 kg/hr
3.5 Energy Balance around Reactor:
Tin = 400 oc Tout = 400 oc
p = 39.7 bar Reactor p = 39.1 bar
CH3OH = 33035.11 kg/hr unreacted = 330.33kg/hr

CH3OH = 100 percent C2H4 = 5723.33 kg/hr
C3H6 = 8585 kg/hr

H2O = 18396.42 kg/hr

Inlet temp = 400 °C or 673 K
Outlet temp = 400 °C or 673 K
Tref = 25 oc or 298 k
For reactor inlet:

Methanol:
Q = mCpΔT
Q= 33035.11 *2.24966*(673k-298k)
(https://www.tlv.com/global/TI/calculator/steam-table-pressure.html)
Q = 2.78 × 107 kJ/hr
For reactor outlet:-

For ethylene:
Q = mCpΔT
Q = 5723.33*2.76815*(673k-298k)
Qethylene = 5.94 × 106 kJ/hr
For propylene:
Q = mCpΔT
40 | P a g e
Q = 8585*2.2422*(673-298)
Qpropylene = 7.21 × 106 KJ/hr
For water:
Q = mCpΔT
Q = 18396.4*2.2488*(673-298)
Qwater = 1.55 × 107 kJ/hr
For unreacted:
Q = mcpΔT
Q = 330.35*2.2496*(673-298)
Qunreacted = 2.78 × 105 KJ/hr

Qtotal = Qethylene + Qpropylene + Qwater + Qunreacted
Qout total = (5.94 × 106 + 7.21 × 106 + 1.55 × 107 + 2.78 × 105) KJ/hr
Qout total = 5.67 × 107 KJ/hr
Components at Flow rate (kg/hr) Cp(kj/kg.k) at 400 Q (kj/hr)

outlet °C or 673 k
C2H4 5723.3 2.7681 5.94 × 106

C3H6 8585 2.2422 7.21 × 106
H2o 18396.42 2.2488 1.55 × 107
Unreacted 330.35 2.2496 2.78 × 105
Qout total 5.67 × 107
The value of cp for heat of reaction can be calculated by following equation;

Hr = a(T-Tref) + b/2(T2-T2ref) + c/3(T3-T3ref) + d/4(T4-T4ref)
41 | P a g e
Heat of reaction
Component Heat of formation (kJ/kmol)
CH3OH -239
C2H4 52.283
C3H6 20.41
H2O -285.8
ΔH 298 = ∑ Hf (product) - ∑ Hf (reactant)
ΔH 298 = [Hf(C2H4) + Hf(C3H6) + 5Hf(H2O) – 5Hf(CH3OH)

ΔH 298 = 52.283 + 20.41+5(-285.8) – 5(-239)
ΔH 298 = -157.30 kj/kmol …………(A)
For Δ Hr 673 K
298 673
∆𝐻𝑟673 = 𝛥𝐻𝑟 298 + ∫673 𝑛𝐶𝑝 𝑑𝑇reactant + ∫298 𝑛𝐶𝑝 𝑑𝑇product
298 298 3.6223 ∗ 102
∫673 𝑛𝐶𝑝 𝑑𝑇Reactant=𝑥5 ∫503 [1.0580 ∗ 105 ∗ (𝑇 − 𝑇𝑟𝑒𝑓) − 2
∗ ( 𝑇 2 − 𝑇𝑟𝑒𝑓 2 ) +
9.3790∗10−1
∗ (𝑇 3 − 𝑇𝑟𝑒𝑓 3 )] 𝑑𝑇
3
=5[-44259499.3 + 87023872.16]
298
∫673 𝑛𝐶𝑝 𝑑𝑇reactant = -2138 kj/kmol …………. (B)
673 673 673 673
∫298 𝑛𝐶𝑝 𝑑𝑇product = ∫298 𝑛𝐶𝑝 𝑑𝑇ethylene + ∫298 𝑛𝐶𝑝 𝑑𝑇propylene + ∫298 𝑛𝐶𝑝 𝑑𝑇water
For Ethylene:
673 673 0.9479 ∗ 10−5
∫298 𝑛𝐶𝑝 𝑑𝑇Ethylene= 𝑥 ∫298 [0.3338 ∗ 10−5 ∗ (𝑇 − 𝑇𝑟𝑒𝑓) + ∗ ( 𝑇2 −
2
1.5960∗10−3 0.5510 ∗ 10−5
𝑇𝑟𝑒𝑓 2 ) + ∗ (𝑇 3 − 𝑇𝑟𝑒𝑓 3 ) + ∗ (𝑇 4 − 𝑇𝑟𝑒𝑓 4 )] 𝑑𝑇
3 4
673
∫298 𝑛𝐶𝑝 𝑑𝑇ethylene = 1.7270 + 148086 - 271723.6
= -419.8113 …………. (1)

For Propylene:
673 673 1.5200 ∗ 10−5
∫298 𝑛𝐶𝑝 𝑑𝑇Propylene= 𝑥 ∫298 [0.4339 ∗ 10−5 ∗ (𝑇 − 𝑇𝑟𝑒𝑓) + ∗ ( 𝑇2 −
2
1.4250∗10−3 0.7860 ∗ 10−5
3 4
673
∫298 𝑛𝐶𝑝 𝑑𝑇propylene = 0.00162 + 2.2767 + 132219.8 - 387623.0
42 | P a g e
= -519.8350 …………. (2)

For Water:
673 673 0.2679 ∗ 10−5
∫298 𝑛𝐶𝑝 𝑑𝑇Water= 𝑥 ∫298 5 ∗ [0.3336 ∗ 10−5 ∗ (𝑇 − 𝑇𝑟𝑒𝑓) + ∗ ( 𝑇2 −
2
2.6105∗10−3 0.0890 ∗ 10−5
3 4
673
∫298 𝑛𝐶𝑝 𝑑𝑇water = 0.00125 + 0.48774 + 316849.4 + 43890.0
= 1803.695 …………. (3)
For Δ Hr 673 K
298 673
∆𝐻𝑟673 = 𝛥𝐻𝑟 298 + ∫673 𝑛𝐶𝑝 𝑑𝑇reactant + ∫298 𝑛𝐶𝑝 𝑑𝑇product
673
∫298 𝑛𝐶𝑝 𝑑𝑇product = (-419.8103 - 519.8350 + 1803.695) kj/kmol
673
∫298 𝑛𝐶𝑝 𝑑𝑇product= 864 KJ/kmol
Δ Hr 673 K = (-157.30 -2138 + 864) kj/kmol

Δ Hr 673 K = -1431 kj/kmol
For 99 % conversion
Δ Hr 673 K= 0.99*-1431*298
Δ Hr 673 K = -422173 kj/kmol

This reaction is exothermic:
Heat is generated in this reactor so cooling water is required to cool the reactor.
Heat to be removed
= input-output - Δ Hr 673 K
= (2.78 × 107 - 5.67 × 107 + 422173) kj/kmol
Q= 2.91 × 107 kj/hr
Cooling Water required

Q=mcpΔT
Cp=2.248 ΔT= 375k
m=Q/cpΔT
43 | P a g e
m= 2.91 × 107 /2.248*375

m=19234.5 kg/hr
3.6 Energy balance on heat exchanger (E-102)
Tin = 400 °C
Tout = 40 °C
Tavg = 220 °C or 493 k
Component Flowrate Cp at
493 K kg/hr (kj/kg.k)
C2H4 5723.33 2.316
C3H6 8585 2.405
H2O 18396.4 2.497
Cold medium:
For ethylene
Q = mcp∆T
Q = 5723.33 * 2.316 * 633 k

Qethylene = 8.39 × 106 kj/hr
For propylene
Q = mcp∆T
44 | P a g e
Q = 8585 * 2.405 * 633 k

Qpropylene = 1.30 × 107 kj/hr
For water
Q = mcp∆T
Q = 18396.4 * 2.497 * 633 k

Qwater = 2.90 × 107 kj/hr
∑ Qtotal = Qethylene + Qpropylene + Qwater

∑ Qtotal = 5.0 × 107 kj/hr
Cooling water required

Q = mcp∆T
m = Q/cp ∆T
m = 5.0 × 107 /4.18*20
m = 82137.2 kg/hr
45 | P a g e
3.7 Energy balance around separator:
T1 = 40 °C
P = 19 bar
Tin=40°C Separator
T2 = 39 °C
P = 19 bar
Energy at Inlet:
For ethylene:
Tref = 298k
Ts = 313k
Using Q = mcpΔT
Q = 5723.33 Kg/hr × 1.7544 × (313-298) k

Qethylene = 1.5 × 105 KJ/hr
For propylene:
Tref = 298k
Ts = 313k
Using Q = mcpΔT
Q = 8585 Kg/hr × 2.0721 × (313-298) k

Q = 2.6 × 105 kj/hr
For water:
Q = mCpΔT
Q = 18396.4*2.2488*(313-298)
For unreacted:
Q = mcpΔT
46 | P a g e
Q = 330.35*0.7238*(313-298)
ΣQ inlet = 1.0 × 106 KJ/hr
Energy at outlet (7):

For ethylene:
Tref = 298k
Ts = 313k
Using Q = mcpΔT
Q = 5723.33 Kg/hr × 1.7544 × (313-298) k

For propylene:
Tref = 298k
Ts = 313k
Using Q = mcpΔT
Q = 8585 Kg/hr × 2.0721 × (313-298) k

Q = 2.6 × 105 kj/hr
Σ Qinlet = 4.1 × 105 KJ/hr

Energy at outlet (8):
For water:
Q = mCpΔT
Q = 18396.4*2.2488*(312-298)
For unreacted:
Q = mcpΔT
Q = 330.35*0.7238*(312-298)
47 | P a g e
ΣQ total = 5.7 × 105 KJ/hr
Energy balance
ΣQ total = ΣQ inlet - ΣQ outlet
ΣQ total = 1.6 × 105 Kj/hr
3.8 Distillation energy Balance:
Tdew = -32 °C
8 P = 9 bar
Tin = 40 °C
7
P = 19 bar
Tbubble = 42°C
P = 9 bar
9
For Intlet: (7)
Total flow rate = 14308.33 Kg/hr
For ethylene:
Tref = 298k
Ts = 313k
Using Q = mcpΔT
Q = 5723.33 Kg/hr × 1.7544 × (313-298) k

For propylene:
Tref = 298k
Ts = 313k
Using Q = mcpΔT
Q = 8585 Kg/hr × 2.0721 × (313-298) k

Q = 2.6 × 105 kj/hr
48 | P a g e
Σ Qinlet = 4.1 × 105 KJ/hr
For Outlet: (8)

Ethylene
C2H4 = 6009.1 Kg/hr
Tref = 298K
(dew point) Ts = 241.15K
Q = mcpΔT
= 6009.1 * 1.5085 * (298-241) K
ΔQ, = 5.1 × 105 KJ/hr
Propylene
C3H6 = 859.49 Kg/hr
Tref = 298K
(dew Point Temp) Ts = 241.15K
Cp = 1.7946 KJ/Kg.K
Q2 = mcpΔT
= 859.4 * 1.7946 * (298-241)

Q2 = 8.7 × 104 KJ/hr
ΣQ = Q1 + Q2
= 5.9 × 105 KJ/hr
Condenser Duty
Q = 5.9 × 105 kj/hr
λ = 2014.23 kj/kg
Coolant flow rate

m = 292.9 kg/hr
For Outlet: (9)

Ethylene:
C2H4 = 572.08 Kg/hr
Tref = 298 K
(bubble Point Temperature) Ts = 315K
49 | P a g e
Cp = 1.6020 KJ/Kg.k
Q = mcpΔT
= 572.08 * 1.6020 * (315-298) k

Q = 1.5 × 104 KJ/hr
Propylene:
C3H6 = 8299.2 Kg/hr
Tref = 298K
(Dew Point Temp) Ts = 315K
Cp = 1.6835 KJ/Kg.k
Q2 = 8299.2 * 1.6835 * (315-298) k
= 2.3 × 105 KJ/hr

ΣQ = Q1 + Q2 = 2.5 × 105 KJ/hr
Reboiler duty
Q = 2.5 × 105 kj/hr
λ = 2014.23 kj/kg
steam flow rate

m = 124.1 kg/hr
50 | P a g e
Chapter 04 Equipment Design
Chapter No 4
Equipment Design
Reactor (R-101) Design
4.1.1 Introduction
The most common kind of reactor used in the chemical industry is heterogeneous catalytic
reactors. There is no question that reactors of this kind play a critical economic role in modern
technical society, whether determined by the wholesale value of the products generated,
processing capabilities, or total investment in the reactors and related peripheral equipment.
Heterogeneous catalytic reactors are commercially important types of heterogeneous catalytic
reactor.
The types of reactors used in manufacturing for heterogeneous catalytic reactions can be divided
into a few groups. The relative motion of the catalyst particles is one basic method of
classification. We consider the following:
1. Reactors wherein the rigid catalyst particles are fixed in relation to each other (fixed bed, trickle
bed, and moving bed reactors).
2. Reactors in which ions are suspended in a solvent and move about continuously (fluidized bed
and slurry reactors).
Reactor selection criteria
1. Heat exchange
2. Catalyst Distribution
3. Hold-up Time
4. Availability
5. Energy utilization
6. Economics
7. conversion
8. Yield
52 | P a g e
4.1.2 Difference between continuous and batch reactor
Continuous Reactor Batch Reactor
1. It is used for activities with a short 1. It is used in operations with a long

residence period. residence period.
2. It has a low cost of operation. 2. It has a high running cost.
3. It takes time for production variance to 3. During each batch, output can easily be
reach a stable state. varied.
4. Continuous flow reactors are simpler 4. Batch reactors are bigger than
than batch reactors but still producing continuous reactors, but they produce
the same amount of energy. the same amount of material.
4.1.3 Fixed bed catalytic reactor
The workhorses of the process industries have been aptly defined as fixed-bed catalytic
reactors. They are usually the first option for producing large quantities of product at a low cost,
particularly in gas-phase reactions. Many catalysed gaseous reactions will benefit from long
catalyst life (1-10 years), and as the time between catalyst changes rises, annualised replacement
costs drop sharply, owing to lower shutdown costs. Fixed-bed reactors now dominate the scene
of large-scale chemical component manufacturing, which is unsurprising. A fixed bed reactor is
made up of a cylindrical tube filled with catalyst pellets in its most simple shape. Reactants are
converted into compounds when they pass into the catalyst bed. Packed bed reactors are another
name for fixed bed reactors. In most cases, the catalyst that makes up the fixed bed can be used
in one of the following configurations:
1) A single, spacious bed.
2) A vertical stack of trays supports a number of horizontal beds.
3) A single shell with several parallel lined tubes.
4) Several beds, each with its own shell.
4.1.4 Types of fixed bed reactor
Fixed-bed reactors fall into one of two major categories:
 Adiabatic
 Non-adiabatic.
53 | P a g e
A variety of reactor configurations has developed to meet the basic needs of various reactions
and environments. Table and accompanying diagrams summaries some of the most common ones
used for gas-phase reactions. The table can be used to make an initial decision about a reaction
system by comparing it to the known systems mentioned.
4.1.5 Fixed-bed reactor configurations for gas-phase reactions
Classification Use Typical Applications
Non-equilibrium limited Mild hydrogenation

Single adiabatic bed moderately exothermic or
endothermic
When a low AP is needed
Radial flow and helpful in situations where Styrene from
things are changing ethylbenzene
is high in moles
SO2 oxidation
High conversion, equilibrium Catalytic reforming
Adiabatic beds in series
with intermediate cooling limited reactions Ammonia synthesis
or heating
Hydrocracking Styrene
from ethylbenzene
Many hydrogenations
Reactions that are highly Ethylene oxidation to

Multi-tabular endothermic or exothermic and ethylene oxide,
require precise temperature formaldehyde
non-adiabatic regulation ensure a high level of
selectivity by methanol oxidation,
phthalic anhydride
production
Direct-fired Highly endothermic, Steam reforming
non-adiabatic high temperature reactions
54 | P a g e
4.1.6 Selection of Reactor Type
After examining various configurations of fixed bed reactors, we have determined that the multi
tube fixed bed reactor is the best fit for our system. Since the oxidation of acetaldehyde is a
strongly exothermic reaction, cooling is required; otherwise, the temperature of the reactor will
rise, affecting the catalyst operation and selectivity, and, as a result, the accumulation of by-
products will increase, resulting in a direct loss of output.
The required temperature for our reaction is 673.15K, and if we use an adiabatic reactor, the
temperature of the reactor will be increased abruptly, affecting our ideal product. The best reactor
for this case is a multi-tube fixed bed reactor.
Construction and operation of multi-tube fixed bed reactor

It may not be feasible to use a single large-diameter tube filled with catalyst due to the need to
remove or add heat. In this case, the reactor could be made up of several tubes encased in a single
body, as seen in Fig. The energy exchange with the environment is accomplished by circulating,
or perhaps boiling, a fluid between the tubes. To avoid high temperatures inside the reaction
mixture if the heat effect is significant, each catalyst tube must be short (tubes as small as 1.0-
2.0in. diameter have been used). A major issue in the design of such reactors is determining how
wide the tube diameter should be, and therefore, how many tubes are needed, to achieve a given
output.
The rate of heat transfer to the fluid covering the tubes is around the same all the way down the
tube length, but the majority of the reaction takes place near the entrance, which is a downside of
this form of heating.
Figure 4.1: Fixed bed reactor
55 | P a g e
4.1.7 Effect of variables on multi-tube fixed bed reactor
4.1.7.1 Particle diameter
In the normal physical range, the average heat transfer coefficient decreases as particle size
decreases. With a reduction in particle size, redial gradients increase dramatically. Smaller
catalysts, on the other hand, can boost rate or selectivity in some cases by making the inner surface
of the catalyst more visible.
4.1.7.2 Tube diameter
The radial profile is reduced by reducing tube diameter. Heat transfer area per unit volume is
inversely proportional to tube width, and a difference in this area affects reaction temperature.
4.1.7.3 Outside wall coefficient
It is worthwhile to improve to the point that this resistance is minimal. Because of their high heat
transfer coefficient, boiling liquids are favorable.
4.1.7.4 Heat of reaction and activation energy
Since measured temperature is sensitive to all of these, especially the value of activation energy,
precise values should be used. This must be deliberately assessed over the spectrum of concerns,
but measured outcomes can be collected depending on various activation energies over the likely
range of precision for the data so that final equipment sizing can be achieved with a sense of
uncertainties.
4.1.7.5 Particle thermal conductivity
One of the mechanisms of radial heat transfer in a bed, conduction through solid packing, which
must logically be dependent on the bed's thermal conductivity, can be reasoned to be dependent
on the solid's thermal conductivity. However, the proportionally cannot be direct since it only
involves one or many processes. At lower Reynolds numbers, the biggest difference will be seen.
The conductivities of most catalyst carriers are mild, but others, such as carbides, have high
conductivities.
4.1.8 Designing Steps
 Determining Weight of Catalyst

 Determining volume of reactor
 Determining Space time
 Space velocity
 Number of Tubes
 Tube diameter
 Diameter of shell
 Shell Height
 Diameter of reactor
 Height of reactor
 Area of reactor
56 | P a g e
4.1.9 Design Calculation
T=400 oC
pressure drop P=39.1 bar
unreacted = 330.33kg/hr
C3H4 = 5723.33 kg/hr
C3H6 = 8585 kg/hr
4 H2O = 18396.42 kg/hr
Reactor (R-101)
3
T=400 oC
P=39.7 bar
CH3OH = 33035.11 kg/hr
Operating Temp = 400°C
Operating Pressure = 40 bar

Design Equation for PBR
𝑊 𝑋𝐴
= ∫0 𝑑𝑥/−𝑟𝐴
𝐹𝐴𝑜
Primary Reaction
5CH3OH C2H4 + C3H6 + 5H2O
Rate Equation for Particular Reaction

-rA = KCA n
As, our system is constant density system so,
𝜀=0
As, the reaction is elementary i.e
57 | P a g e
(Order of Reaction) n = 1
K = k0e(-E/RT)
E = 11600 J/mol
k0 = 2.255×109 s-1
K = 2.255 × 109 e (-11600/8.314×673)
K = 2.23 s-1
Composition Flowrate Flow rate Composition

Kg/hr Kg/s
CH3OH 33035 9.17 1
Total 33035 9.17 1.00
𝑚 9.17
V0 = =
𝜌 792
V0 = 0.0115 m3/s
9.17
FA0 = = 0.286 kmol/s or 286 mol/s
32
𝐹𝐴0 0.286
CA0 = = = 24.86 kmol/m3
𝑉0 0.0115
CA = CA0 (1 – XA) = 24.86 (1 – 0.99)
CA = 0.2486 kmol/m3
-rA = KCAn
-rA = 2.23 × 0.2486
-rA = 0.554 Kmol/m3.s

1
− = 1.805 m3.s/kmol
𝑟𝐴
4.1.9.1 Weight of Catalyst
(Nikle oxide catalyst on Alumina support of size 2mm of granules shape is used)
Porosity of granules = 0.4
Using of following Equation

𝑊 𝑋𝑎 𝑑𝑥
= ∫0
𝐹𝐴0 −𝑟𝐴
By applying Simpson’s quadrant formula
58 | P a g e
𝑋𝑎 ℎ
∫𝑋0 𝑓 (𝑥 )𝑑𝑥 = 3
(𝑓0 + 4f1 + 2f1 + 4f2 + 4f3 + f4)
Table 4.1: Conversion & Inverse of Rate Law
XA -rA -1/rA
0 55.43 0.0180
0.247 41.72 0.0239
0.495 27.98 0.0357
0.742 14.30 0.0699
0.99 0.554 0.8050
Graph between XA and -1/rA

2
1.8
1.6
1.4
1.2
-1/rA
1
0.8
0.6
0.4
0.2
0
0 0.2 0.4 0.6 0.8 1 1.2
XA
Figure 4.2: Graph between conversion and rate law
0.99−0
h= = 0.0825
4×3
= 0.0825(0.0180 + 4(0.0239) + 2(0.0357) + 4(0.0699) + 0.8050)
Volume = 18.72 ≈ 18 m3
Weight of catalyst = 510 × 18 = 9549kg

59 | P a g e
4.1.9.2 Volume of Reactor
Volume of catalyst = 18 m3
Porosity = 0.4
18
Volume of Reactor = = 31.2m3
1−0.4
4.1.9.3 Space Time
𝑣
τ =
𝑉0
31.2
=
0.0115
= 2713s or 45min
4.1.9.4 Space Velocity
1
𝜏
1
=
45
= 0.02min-1
Length of Tubes
Length of tube = 20ft = 6.098m
4.1.9.5 Tube Diameter
As, we know that to prevent deviation from plug flow assumption Dt/Dp > 15
Dt = dia of tube
Dp = dia of particle
Let, inside dia of tube = 2.205in = 55.95mm
55.98
Dt/Dp = = 28( which is satisfactory)
2
4.1.9.6 Volume of Tube

𝜋
Volume of one tube = 4 × Dt2 × Lt
3.14 (55.98)2
= × × 6.098
4 (1000)
= 0.785 × 0.00313 × 6.098

= 0.0150m3
60 | P a g e
4.1.9.7 Number of Tubes
As, total volume = 18m3

So, number of tubes
𝑡𝑜𝑡𝑎𝑙 𝑣𝑜𝑙𝑢𝑚𝑒
=
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒
18𝑚3
=
0.0150
= 1248 tubes
4.1.9.8 Diameter of Shell
To calculate shell dia

𝜋
[𝐷𝑠−𝑘1)^2 +𝑘2]−𝑃𝑡(𝐷𝑠−𝑘1)(𝑛𝑘3+𝑘4)
4
NT =
1.223 (𝑃𝑡)^2
Where
NT = Number of tubes = 1248
Ds = Shell dia =?
Pt = pitch – 1.2 of tube dia – 2.6in
For this pitch

K1 = 1.08 K2 = -0.9
K3 = 0.69 K4 = -0.8
n = (1 tube pass)
𝜋
[(𝐷𝑠−1.08)2 4 −0.9]−2.6(𝐷𝑠−1.08)(0.69−0.8)
1248 =
1.223(2.6)^2
Ds = 114.64in = 2.912m
Shell Height
Length of tube = 6.098
Leaving 20% spacing above & below

So, height of shell = 6.098 × 1.4 = 8.53m
4.1.9.9 Diameter of reactor
L/D = 4
61 | P a g e
L = 4D
𝜋𝐷2×𝐿
Volume of reactor = 4
D = 2m
L = 4(2)
L = 8m
4.1.9.10 Height of Reactor
H = L = 8m
15% allowance = 1.15

H = 9m
Area of reactor
A = (πD2/4)
A = 3.14m2
4.1.9.11 Pressure Drop Calculation:
𝛥𝑃 150µ(1− 𝜀 )2 𝑢𝑜 1.75(1− 𝜀 )𝜌𝑢𝑜2

𝐿
= 𝜀3 𝑑𝑝2
+
𝜀3 𝑑𝑝
𝜀 = Porosity =0.4
L = 6.096m
Viscosity µ = 1.7 ×10-5 kg/m.s
0.0115
Superficial velocity = = 0.036 m/s
3.14
(Feed density) ρ = 792 kg/m3
u0 = G = mass velocity = ρu = 792×0.036

= 2.85 kg/m2s
Dp = 2mm = 0.002m
𝛥𝑃 150(1.7 ×10−5 )(1− 0.4)2 ( 2.85) 1.75(1− 0.4)(792)(2.85)2
8.53
=
(0.4)3 ×(0.002)2
+ (0.4)3 × (0.002)
ΔP = 665 gm/cm2
= 6650 kg/m2
= 0.6 bar
62 | P a g e
4.1.10 Cooling Water Requirement:
Q = ṁ×Cp×∆T
m= 2.91 × 105 /2.248*375
m=345 kg/hr
SPECIFICATION SHEET
63 | P a g e
Identification
Item Reactor R-101
Type Packed Bed Multi Tubular Reactor
Function
5CH3OH → C2H4 + C3H6 + 5H2O
Operating Pressure 40 bar
Operating Temperature 673 K
Space Time 45 min
Volume of Reactor(Vr) 31.2 m3
Volume of Catalyst(Vc) 18 m3
Weight of Catalyst 9549 kg
Number of Tubes 1258
Diameter of Reactor(D) 2.1 m
Length of Reactor(L) 8m
Pressure Drop(ΔP) 0.6 bar
64 | P a g e
Design Two phase separator
4.2 Design Two phase separator
Separator separate on 3 basic principles

 Momentum
 Gravity
 Colescor
C2H4 = 5723.33 Kg/hr

C3H6 = 8585 Kg/hr
Total = 14308.33Kg/hr
T = 40 oC 7
P = 39 bar
C3H6 = 8585 Kg/hr
C2H4 = 5723.33 Kg/hr
H2O = 18396.42 Kg/hr
5
Unreacted = 330.35 Kg/hr
Total = 33035.1 Kg/hr SEPARATOR
6
H2O = 18396.42Kg/hr
Unreacted = 330.35
Molecular weight of ethylene = 28.05 g/mol

Molecular weight of propylene = 42.08 g/mol
Inlet pressure = 39.5 bar
Inlet temperature = 40 C
Outlet pressure =2 bar
Outlet temperature=37 C
Density of gas
Pv = nRT
Pv = (m/Mw)RT
65 | P a g e
p.Mw = m/vRT
p.Mw = ρRT
ρ = p.Mw/zRT (1)
R = 10.73 ft3 psia/R lbmol
Absolute pressure = gauge pressure + atmospheric pressure

= 500 + 14.7
= 514.7 psia
Replace all values in eq 1

ρ = 514.7 psi *(2.019) lb/0.9 (1073) ft3.psi/R.lb mol (19) bar
ρ = 0.050 lb/ft3
Specific gravity = density of given liquid /density of water
Density of liquid = specific gravity * density of water
Specfic gravity of ethylene = 0.9740
Specific gravity of propylene = 0.516
Replace in eq 2
Density of propylene = 0.516*1000
= 516 kg/m3 = 31.84 lb/ft3
Density of ethylene = 0.9740*1000
= 974 kg/m3 = 60.10 lb/ft3
Volumetric flowrate of liquid

Flowrate = 18726.77 kg/hr 4.02459 ft3/sec
Mass flowrate of gas

Mass flowrate of gas = volumetric flowrate of gas *density of gas
For propylene
= 5723 kg/hr *1.74kg/m3
=9958.0
For ethylene
=8500 kg/hr * 1.18kg/m3
66 | P a g e
= 10030
Total = 10030 + 9958.0
= 19988
Mass flowrate of liquid
water
Mass flowrate of liquid = volumetric flowrate of liquid*density of liquid
= 4.02459ft3/sec*1000kg/m3
= 1839800
For velocity
V = k (density of liquid-density of gas/density of gas)
Density of gas=0.050 kg/m3
Density of liquid = 0.516 kg/m3
For k values we take from table values 0.12
Replace all values
v = 0.12√ ( 0.005-0.516/0.005)
v = 6.132
Area of gas = volumetric flowrate of gas/velocity

= 199880 /(6.132ft/s)
= 32596.21
33.69 = pi*r
r = √ (33.6/x)
r = 3.27 ft
D = 2.0
=2*3.27
=6.54 ft
D = (6.64 ft)(12inch/1ft)
D= 78.48 in
Total dia is 78.48 in
L(HH) – L(H) = 1 min
Height = vol/area
67 | P a g e
= 4.02459*60 /1623.93
=1623.93 ft
=L(H)-L(L)-2min
=4.02459 -*2*60/1623.93
=0.29739 ft
=(L)(L)-(L)(LL)-1min
=4.02459*60/1623.93
=0.1486 ft
Total height = 0.0023+0.007+0.0023
= 0.0116 ft
Feed nozzle
Lm = M(l)l– M(g)/V(l) – V(g)
= 1839800-9958.0 /0.006498-9958.0
= 183.756
Pm*vm2=2100
Vm2 =2100/183.756
= 130.6037
Area = volumetric flowrate of liquid – volumetric flowrate of gas/velocity
= 4.02459- 19988/130.6037
= 153.01ft2
0.542 = pi*r2
r = 0.4153
d = 2*r
= 2*0.4153
= 0.8306 ft * 12inch/1 ft
Feed nozzle dia = 9.9672 inch
Gas nozzle
Density(g)*V2(g) = 4500
Velocity2(g) = 4500/0.05 lb/ft
= 90000 inch
68 | P a g e
Area
Area = volumetric flowrate of gas/velocity
= 9958.0/130.6037
= 76.2459 ft2
r= 0.35/pi
r= 0.33
D = 2*0.33
=0.66ft*12inch/ft
=8 inch
Velocity should not exceed at 1 m/s

Im/s = 6.132 ft
Area = volumetric flowrate of liquid/velocity
Area = 4.02459/6.132
= 0.65632 ft2
This is a liquid nozzle area
Mesh pod diameter
V = k √ density of liq – density of gas
V = 0.25√ (0.050- 0.051)
V =- 0.000000025
Area = volumetric flowrate of gas/velocity
= 19988/0.000025
= 7995200
Pi*r2 = 16.16
r= 2.26
D = 2 * 2.26
D = 4.52*12 m
D= 54.24 inch
Mesh height
Mesh height = mesh nozzle dia- gas nozzle dia/2
=54.24-90000/2
= 44972.88 m
69 | P a g e
Vessel height = Mesh height – liquid settling height – vessel diameter+feed nozzle dia +6
=23 +( 0.5688*12) + 98.48+10
=138.3056
L /D = 2.5
194/78.48 = 2.5
Vt2 = 4/3 * Dp*g(density of liquid – density of gas/density of gas)
C=1
= 4/3(200 * 28*10^-6)*9.8*(0.050-0.051/0.051)
= 0.9456 m
70 | P a g e
Specification sheet
identification
Items Gas liquid separator
Item no S-101
No required 1
Type vertical
Operation continuous
Function
Separation of liquid and vapors
Design data
Length of separator 138.3 m
Dia of separator 78.48 m
Pressure 37.5 bar
Temperature 3C
L/D ratio 2.5
71 | P a g e
Heat exchanger design (E-102)
4.3 Heat Exchanger Design (E-102):
A shell-and-tube exchanger consists of a cylindrical shell containing a bundle of tubes. The

Tubular Exchanger Manufacturers Association has developed guidelines for the construction of
most shell-and-tube exchangers (TEMA). For more than 70 years, these standards have included
manufacturing procedures and construction guidance to ensure that machinery built and
fabricated by various organizations performs equally and predictably. While the ASME Boiler
and Pressure Vessel code normally dictates the mechanical specification, the TEMA
specifications help to standardize exchanger thermal efficiency.
Ta=400oC =752F Tb=Tout =40 oC =104F
ta= 30oC =86 tb=50 oC =122 F
△𝑇2−△𝑇1
(ΔTlm)cf = 𝑇
𝑙𝑛( 2 )
𝑇1
(ΔTlm)cf = 86 F
4.3.1 Heat balance
∑ Qtotal = 5.0 × 107 kj/hr =47390856Btu/hr
4.3.2 Log mean temperature difference
{400 → 40
ΔT = 120oC −20
72 | P a g e
{ 50 ← 30
4.3.3 Correctiuon factor for LMTD

𝑇𝑎−𝑇𝑏
R= 𝑡𝑏−𝑡𝑎
𝑡𝑏−𝑡𝑎
P = 𝑇𝑎−𝑡𝑎
752−104
R= = 612
122−86
122−86
P = 752−104 = 0.055
Figure 4.3: Relation between F and P
From above graph;

F = 0.95
So 1–2 exchanger’s type is used
4.3.4 Surface Area
Place the process stream on the shell side and utility fluid (cooling water) on the tube side.
Assume overall heat transfer coefficient =𝑈𝑑 = 50𝐵𝑡𝑢⁄𝑓𝑡 2 ֯ 𝐹 ℎ𝑟
73 | P a g e
𝑄
𝐴=
𝑈𝑑 𝐹(𝛥𝑇𝑙𝑚 )𝑐𝑓
𝐴 = ((47390856btu/hr)/50*0.95*86)
=11601.2𝑓𝑡 2
4.3.5 Tube Specifications
Assume
Outside diameter of tube = OD = ¾ in = 0.0625 ft
Length of tube = L = 20 ft
BWG = 16
Assume 1 in. square pitch, With 2 tube passes, 3/4 in. OD and 1 in. square pitch,
𝐴
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑇𝑢𝑏𝑒𝑠 =
3.14 ∗ 𝐷𝑜 𝐿
1278
𝑛𝑡 =
3.14 ∗ 0.0625 ∗ 20
𝑛𝑡 = 325 𝑇𝑢𝑏𝑒𝑠
No of tubes Passes
𝑛
4 ṁ (( 𝑝⁄𝑛𝑡 )
𝑅𝑒 =
𝜋 𝐷𝑖 µ
4 ∗ 82137.2(2⁄325)
𝑅𝑒 =
𝜋 ∗ 0.04125 ∗ 2.15
𝑅𝑒 = 0.351240
4.3.6 Checking Fluid Velocity

𝑛
ṁ (( 𝑝⁄𝑛𝑡 )
𝜌 𝜋 𝐷𝑖 2 /4
82137.2(2⁄325)
𝑣=
62.428 ∗ 3.14 ∗ 0.0487 2 /4
𝑣 = 212.3 𝑓𝑡⁄𝑠𝑒𝑐
74 | P a g e
4.3.7 Determinbe shell size and actual tubes cpunts
From tube count table for 3⁄4 𝑖𝑛 tubes on 1 in square pitch table (C-3) with 2tubes passes and S
head.
𝑛𝑡 = 332 𝑡𝑢𝑏𝑒𝑠 from Appendix C-3
And Shell ID 𝑑𝑠 = 23.25 𝑖𝑛 = 1.77 𝑓𝑡
4.3.7.1 Calculate Ureq Over all Clean Cofficient
𝑄
𝑈𝑟𝑒𝑞 =
𝑛𝑡 𝜋 𝐿 𝐷𝑜 𝐹(𝛥𝑇𝑙𝑚 )𝑐𝑓
8990970.45
𝑈𝑟𝑒𝑞 =
332 ∗ 𝜋 ∗ 20 ∗ 0.0625 0.95 ∗ 86
𝑈𝑟𝑒𝑞 = 84.45 𝐵𝑡𝑢⁄𝑓𝑡 2 ֯ 𝐹 ℎ𝑟
4.3.8 Calculate ho
B = 0.3 ds
B = 0.3 (1.77)
= 0.5 ft = 6.9 in
PT= 1 inch
C’ = 0.290 in = 0.02 ft
de= 0.95 in = 0.08 ft
𝑑𝑠 𝐶 ′ 𝐵
𝑎𝑠 =
144 𝑃𝑇
23.25 ∗ 0.25 ∗ 6.9
𝑎𝑠 =
144 ∗ 1
𝑎𝑠 = 0.3 𝑓𝑡 2
ṁ
𝐺=
𝑎𝑠
148289.23
𝐺= = 494297.23 𝑙𝑏𝑚⁄ℎ𝑓𝑡 2
0.3
0.95
𝐺= = 0.080 𝑓𝑡
12
75 | P a g e
4.3.8 Estimate leakage and bypass clearances
4.3.8.1 Tube to baffle clearance
δtb= 0.4 mm = 0.015748 in

Estimate the shell-to-baffle clearance:
δsb= 0.8 + 0.002 Ds= 0.8 + 0.002 * 23.25 * 25.4

δsb= 1.9811 mm
Adding the safety factor (for heat transfer) of 0.75 mm gives:

δsb= 2.7311 mm
Shell to-bundle diametral clearance is obtained from Figure 6.10(Process Heat Transfer.
Principles, Applications and Rules of Thumb,2nded and Searth)with Ds = 590 mm. Reading the
graph for split ring and packed floating heads gives:
Ds- Dotl= 37 mm = 1.5 in
The outer tube limit and central tube limit diameters follow from this value:
Dotl= Ds – 1.5
Dotl= 23.25 – 1.5

= 22 in
Dctl= Dotl - Do
Dctl= 22 – 0.75 = 21.25 in
4.3.9 Calculate the flow areas
(i) Cross-flow area

The cross-flow area is calculated
𝐷𝑜𝑡𝑙 − 𝐷𝑜
𝑆𝑚 = 𝐵 [𝐷𝑠 − 𝐷𝑜 + (𝑃𝑇 − 𝐷𝑜 )]
𝑃𝑡𝑒𝑓𝑓
22 − 0.75
𝑆𝑚 = 6.9 [23.25 − 22 + (1 − 0.75)]
1
𝑆𝑚 = 45.3 𝑖𝑛 2 = 0.314 𝑓𝑡 2
(ii) Tube-to-baffle leakage area Equation (6.25) is first used to calculate the value of angle
ϴctl
𝐷𝑠 (1 − 2𝐵𝑐 )
𝛳𝑐𝑡𝑙 = 2𝑐𝑜𝑠 −1 ⌊ ⌋
𝐷𝑐𝑡𝑙
76 | P a g e
23.25 (1 − 2(0.2)
𝛳𝑐𝑡𝑙 = 2𝑐𝑜𝑠 −1 ⌊ ⌋
21.25
𝛳𝑐𝑡𝑙 = 97.9 ֯ = 1.7 𝑟𝑎𝑑

Next, the fraction of tubes in cross flow is calculated
1
𝐹𝑐 = 1 + (𝑠𝑖𝑛 𝛳𝑐𝑡𝑙 − 𝛳𝑐𝑡𝑙 )
𝜋
1
𝐹𝑐 = 1 + (𝑠𝑖𝑛(1.7) − 1.7)
𝜋
𝐹𝑐 = 0.468
The tube-to-baffle leakage area
𝑆𝑡𝑏 = 0.5 ∗ 𝜋 ∗ 𝐷𝑜 𝛿𝑡𝑏 𝑛𝑡 (1 + 𝐹𝑐 )
𝑆𝑡𝑏 = 0.5 ∗ 𝜋 ∗ 0.75 ∗ 0.015748 ∗ 332 ∗ (1 + 0.47)
𝑆𝑡𝑏 = 9.05 𝑖𝑛2 = 0.0068 𝑓𝑡 2
(ii) Shell-to-baffle leakage area is first used to calculate the value of angle 𝛳𝑑𝑠
𝛳𝑑𝑠 = 2 𝑐𝑜𝑠 −1 (1 − 2(𝐵𝑐 ))
𝛳𝑑𝑠 = 2 𝑐𝑜𝑠 −1 (1 − 2(0.2))
𝛳𝑑𝑠 = 106 ֯ = 1.85 𝑟𝑎𝑑

shell-to-baffle leakage area
𝑆𝑠𝑏 = 𝐷𝑠 𝛿𝑠𝑏 (𝜋 − 0.5𝑑𝑠 )
𝑆𝑠𝑏 = 23.25 ∗ 0.009952 ∗ (𝜋 − 0.5(1.85))
𝑆𝑠𝑏 = 5.12 𝑖𝑛2 = 0.0356 𝑓𝑡 2

(iii) Shell-to-bundle bypass flow area
The bypass flow area:
𝑆𝑠𝑏 = 𝐵(𝐷𝑜 − 𝐷𝑜𝑡𝑙 )
𝑆𝑠𝑏 = 6.9 ∗ (23.25 − 22)
𝑆𝑠𝑏 = 8.63 𝑖𝑛2 = 0.059 𝑓𝑡 2

(iv) Window-flow area
The fraction of tubes in one baffle window is calculated
77 | P a g e
𝐹𝑤 = 0.5 (1 − 𝐹𝑐 )
𝐹𝑤 = 0.5 (1 − 0.46)
𝐹𝑤 = 0.27
Window-flow area is calculated
1 2 1
𝑆𝑤 = (𝐷𝑠 (𝛳𝑑𝑠 − 𝑠𝑖𝑛𝛳𝑑𝑠 ) − 𝑛𝑡 𝐹𝑤 𝜋𝐷𝑜2 )
8 4
1 1 3
𝑆𝑤 = ((23.25)2 ∗ (1.85 − 𝑠𝑖𝑛 1.85) − ∗ 332 ∗ 0.27 ∗ 3.14 ∗ ( )2 )
8 4 4
𝑆𝑤 = 83.22 𝑖𝑛2 = 0.57 𝑓𝑡 2
4.3.10 Ideal tube bank correlations

ṁ
𝐺=
𝑎𝑠
148289.06
𝐺=
0.314
𝐺 = 472258.15 𝑙𝑏⁄ℎ𝑓𝑡 2
𝐷𝐺
𝑅𝑒 =
𝜇
0.0625 ∗ 472258.15
𝑅𝑒 =
2.15
𝑅𝑒 = 13728.4
𝑃𝑇 1
= = 0.33
𝐷𝑜 0.75
From Figure below 𝐽 = 0.008and𝑓 = 0.1.

The ideal tube bank heat transfer coefficient:
78 | P a g e
Fig 4.4: Ideal tube bank correlation for square pitch

The ideal tube bank heat transfer coefficient :
−2⁄
ℎ𝑖𝑑𝑒𝑎𝑙 = 𝐽 𝐶𝑝 𝐺 Ф𝑃𝑟 3
−2⁄
ℎ𝑖𝑑𝑒𝑎𝑙 = 0.008 ∗ 1.004 ∗ 472258.15 ∗ 1 ∗ 5.9 3
ℎ𝑖𝑑𝑒𝑎𝑙 = 1161.7 𝐵𝑡𝑢⁄ℎ𝑓𝑡 2 𝐹
4.3.11 Calculate the correction factors.
(i) Correction factor for baffle window flow
𝐽𝐶 = 0.55 + 0.72 𝐹𝐶
𝐽𝐶 = 0.55 + 0.72(0.468)
𝐽𝐶 = 0.89
4.3.12 Baffle leakage correction factors
Area ratios rs and rl are calculated

𝑆𝑠𝑏
𝑟𝑠 =
𝑆𝑠𝑏 + 𝑆𝑡𝑏
79 | P a g e
0.0356
𝑟𝑠 =
0.0356 + 0.068
𝑟𝑠 = 0.34
𝑆𝑠𝑏 + 𝑆𝑡𝑏
𝑟𝑙 =
𝑆𝑚
0.068 + 0.0356
𝑟𝑙 =
0.314
𝑟𝑙 = 0.32
𝑝 = 0.8 − 0.5(1 + 𝑟𝑠 )
𝑝 = 0.8 − 0.5(1 + 0.34)
𝑝 = 0.599
4.3.13 Leakage correction factors for heat transfer and pressure drop are
calculated
𝐽𝐿 = 0.44 (1 − 𝑟𝑠 ) + [1 − 0.44(1 − 𝑟𝑠 ) 𝑒𝑥𝑝(−2.2𝑟𝑙 )]
𝐽𝐿 = 0.44 (1 − 0.34) + [1 − 0.44(1 − 0.34) 𝑒𝑥𝑝(−2.2 ∗ 0.32)]
𝐽𝐿 = 1.5
𝑅𝐿 = 𝑒𝑥𝑝[−1.33(1 + 𝑟𝑠 )(𝑟𝑙 𝑝 )]
𝑅𝐿 = 𝑒𝑥𝑝[−1.33(1 + 0.34) (0.320.599 )]
𝑅𝐿 = 0.4
(i) Bundle bypass correction factors
correction factors for the bundle bypass flow
𝑆
𝐽𝐵 = 𝑒𝑥𝑝 [−𝐶𝐽 ( 𝑏⁄𝑆 ) (1 − 3√2 𝑟𝑠𝑠 )]
𝑚
𝑁𝑠𝑠
𝑟𝑠𝑠 = = 0.1
𝑁𝑐
Where
CJ =1.35 for Re < 100

And 1.25 for Re => 100
𝐽𝐵 = 𝑒𝑥𝑝 [−1.25(0.059⁄0.314)(1 − 3√2 ∗ 0.1)]
𝐽𝐵 = 0.36
80 | P a g e
𝑆
𝑅𝐿 = 𝑒𝑥𝑝 [−𝐶𝑅 ( 𝑏⁄𝑆 ) (1 − 3√2 𝑟𝑠𝑠 )]
𝑚
Where
CR = 4.5 for Re < 100
and 3.7 for Re => 100
𝑅𝐿 = 0.64
4.3.14 Correction Factors for Unequal Baffle Spacing
𝐵𝑖𝑛 = 𝐵𝑜𝑢𝑡 = 𝐵
For JS and RS is equal to 1.
4.3.15 Laminar Flow Correction Factor
As , Re> 100 ,
So, JR=1
4.3.16 Calculate the shell-side heat-transfer coefficient
hO = hideal (JC JL JB JR JS)

hO = 1161.7 (0.8*1.5*0.36*1*1)
hO = 558.3 𝐵𝑡𝑢⁄ℎ𝑓𝑡 2 ֯𝐹
4.3.17 Calculate the clean overall coefficient

𝐷𝑂 𝐷𝑂 𝑙𝑛𝐷𝑂 ⁄𝐷𝑖 1 -1
𝑈𝐶 = [ + + ]
ℎ𝑖 𝐷𝑖 2𝑘 ℎ𝑂
0.75 0.75 𝑙𝑛(0.75⁄0.584) 1

𝑈𝐶 = [ + + ]-1
4680.06 ∗ 0.584 2∗26 558.3
𝑈𝐶 = 176 𝐵𝑡𝑢⁄ℎ𝑓𝑡 2 ֯𝐹
So UC >Ureq,Countinue
4.3.18 Fouling factor
RDi = 0.001 – 0.002
81 | P a g e
(from Table 3.3, Process Heat Transfer. Principles, Applications and Rules of Thumb by Robrt
W. Searth)
𝑅𝐷𝑖∗𝐷𝑜
RD = + RDo
𝐷𝑖
0.001∗0.75
= + 0.002
0.584
= 0.00956 hft2oF/BTU
4.3.19 Calculate the design overall coefficient

1
UD = (𝑈2 + RD) -1
1
= (176.62 + 0.00450) -1
= 92.21 BTU/hft2oF
Exchanger is thermally workable
𝑈2 176
Over surface = -1 = –1
𝑈𝑟𝑒𝑞 49
= 35.9 %
𝑈𝐷 50
Over design = 𝑈𝑟𝑒𝑞 -1 = 49 – 1
= 2%
4.3.20 Tube side pressure drop
Friction factor
f = 0.4137 (Re) – 0.2585
= 0.4137 (11188.07) – 0.2585
f = 0.037
ղ𝑝
𝑚 ( 𝑛𝑡 )
G=
𝜋∗𝐷𝑖2∗ /4
2
148289(332)
= 0.048752
𝜋∗( )
4
G = 490080.6 lbm/h ft 2
No of tubes rows crossed

𝐷𝑠(1−2𝐵𝑐)
Nc =
𝑃𝑡
82 | P a g e
1−210.2
= 23.25( )
1
= 13.95
4.3.21 Effective no of tube rows crossed in one baffle window

0.8 𝐵𝑐 𝐷𝑆
𝑁𝑐𝑤 =
𝑃
0.8 ∗ 0.2 ∗ 23.25
𝑁𝑐𝑤 =
1
𝑁𝑐𝑤 = 3.72
4.3.22 Ideal Tube Bank Pressure Drop

2 𝑓𝑖𝑑𝑒𝑎𝑙 ∗ 𝑁𝑐 ∗ 𝐺^2
ΔPideal =
𝑔𝑐 ∗ 𝛿 ∗ Ф
2∗0.03∗13.95∗(490080.6)^2
=
4.17∗108 ∗ 62.4 ∗1
= 7.7 lbf/ft2
= 0.05 Psi
4.3.22.1 Ideal Window pressure drop
2+0.6 𝑁𝑐𝑤
ΔPwideal =
2 𝑔𝑐 𝑝 𝑆𝑚 𝑆𝑤
= 19.88 lbf/ft2
= 0.13 Psi
4.3.22.2 Nozzle to nozzle pressure drop
ΔPf= [(𝑛𝑏 − 1 )𝛥𝑃𝑖𝑑𝑒𝑎𝑙 𝑅𝑏 + 𝑛𝑤 𝛥𝑃𝑖𝑑𝑒𝑎𝑙 𝑅𝑏 + 2 𝛥𝑃𝑖𝑑𝑒𝑎𝑙 (1 + 𝑁𝐶𝑊 ⁄𝑁𝐶 )𝑅𝑏 𝑅𝑆 ]
ΔPf= [(45 − 1 ) ∗ 7.7 ∗ 0.89 + 42 ∗ 7.7 ∗ 0.89 + 2 ∗ 7.7 ∗ (1 + 3.72⁄13.95)0.89 ∗ 1]
ΔPf= 8.29 𝑙𝑏𝑓 ⁄ 𝑓𝑡 2 = 0.06 psi
4.3.23 Pressure drop in nozzle

𝑚
𝐺𝑛 = 2
𝜋 𝐷 ⁄4
148289.23
𝐺𝑛 =
(6.026)2
𝜋∗ ∗ 12
4
83 | P a g e
𝑙𝑏
𝐺𝑛 = 748727.8
ℎ 𝑓𝑡 2
𝑁𝑠 𝐺𝑛2
𝛥𝑃𝑛 = 2 × 10−13
𝑠
1 ∗ 748727.82
𝛥𝑃𝑛 = 2 × 10−13
1.14
𝛥𝑃𝑛 = 0.09 𝑙𝑏⁄𝑓𝑡 2 = 0.0006 𝑝𝑠𝑖
4.3.24 Total pressure drop
𝛥𝑃𝑂 = 𝛥𝑃𝑛 + 𝛥𝑃𝑓
𝛥𝑃𝑂 = 0.06 + 0.0006
𝛥𝑃𝑂 = 0.006 𝑝𝑠𝑖
84 | P a g e
Specification sheet
Identification
Item Heat Exchanger(02)

Type Shell and Tube Heat Exchanger
Function
To decrease temperature in order to increase conversion
Heat Duty 5.0 × 107
Actual Syrface Area 0.1963
AC Calculated 653.2884
UD Calculated 763.0946
Friction Factor 0.002834682
Fluid Allocation Shell Side Tube Side
Fluid Name Feed Water
Temperature (In/Out) 400 oC to 40oC 30 oC to 50oC
Pressure 1 bar 1 bar
Viscosity 0.0006 1.8588E-05
Thermal Conductivity 0.26 0.561
Pressure Drop 0.006psi 0.7784385
OD: 0.75
BWG : 16
Pitch : 1 in triangular
number of Tubes: 325
TEMA type: AES
85 | P a g e
Specification sheet (E-101)
Identification
Item Heat Exchanger(01)

Type Shell and Tube Heat Exchanger
Function
To increases temperature in order to increase conversion
Heat Duty 32984035.79
Actual Syrface Area 0.1963
AC Calculated 653.2884
UD Calculated 763.0946
Friction Factor 0.002834682
Fluid Allocation Shell Side Tube Side
Fluid Name Feed Water
Temperature (In/Out) 25C to 400C 420 to 420C
Pressure 1 bar 1 bar
Viscosity 0.0006 1.8588E-05
Thermal Conductivity 0.26 0.561
Pressure Drop 4.6318365 0.7784385
OD: 0.75
BWG : 16
Pitch : 1 in triangular
number of Tubes: 211
TEMA type: AES
86 | P a g e
Distillation Column (T-101) Design

4.4 Distillation column design:
“The application and elimination of heat separates a liquid or vapour mixture of two or more
substances into its constituent fractions of desired purity.”
It's possible that the column would be trayed or packed. The rectification (or refining) portion is
located above the feed, and the striping section is located below the feed. The reboiler at the
bottom of the column receives heat, which is then expelled by the condenser at the end. The feed
reaches the column through an intermediate layer.
Distillation (fractionation) is the process of separating a feed mixture of two or more ingredients
into two or more products, such as an overhead distillate and a bottoms product, whose
compositions vary from the feed. The feed is usually a liquid or a vapor–liquid mixture. Although
the bottom component is nearly always a liquid, the distillate may be either a liquid or a vapour.
The division necessitates:
(1) In a trayed or filled column, a second phase must be created such that both liquid and vapour
are present and may make contact when moving in opposite directions.
(2) Elements have varying volatilities, causing them to partition between phases to varying
degrees.
(3) By gravity or mechanical means, the two processes may be separated.
Figure 4.7: Distillation column
87 | P a g e
4.4.1 Binary Distillation:
Binary distillation is a separation method used in the chemical process industry to purify mixtures
into their two distinct components. The phases of the mixture of components are segregated
during this step. The lighter species is vaporised and passes into the distillate to exit the column.
This portion is more unpredictable and is often the separation's preferred species. The heavy
species is left in a liquid state and leaves through the bottoms of the column.
4.4.2 Types of Distillation Column:-
Types of distillation column are following as:-

 Simple distillation
 Steam distillation
 Vacuum distillation
 Fractional distillation Here we use Vacuum distillation
Vacuum distillation
For extracting mixtures of liquids with very high boiling points, vacuum distillation is suitable.
Heating these compounds to high temperatures is an inefficient way of boiling them. As a result,
the strain in the environment is reduced.
Since the strain is reduced, the part will boil at lower temperatures. When the component's vapour
pressure equals the surrounding pressure, it is converted to a vapour.
Choice between Plate and Packed Column:-
Comparison between Plate and Packed column are following as:-
88 | P a g e
4.4.3 Plate column:
The plate column was chosen for the following reasons:

Only by costing each design will a decision between a plate and a packed column for a specific
application be taken with total certainty. However, this is not necessarily worthwhile or
appropriate, and the decision should normally be taken based on experience by weighing the key
benefits and drawbacks of each form, which are described below:
1. Plate columns, as opposed to stacked columns, can be built to accommodate a broader
range of liquid and gas flow speeds.
2. Packed columns are ineffective at handling very low liquid concentrations.
3. A plate's performance can be predicted with greater accuracy than the comparable term
for packing (HETP or HTU).
4. Plate columns are more reliable than packed columns in terms of construction. There is
still some doubt that a packed column will sustain good liquid distribution under all
operating conditions, particularly in large columns.
5. In a plate column, it is easier to provide cooling; coils should be mounted on the plates.
6. It is less difficult to plan for the removal of side-streams from plate columns.
7. Whether the liquid fouls or contains solids, washing in a plate column is easier;
manways should be mounted on the plates.
8. Packed columns are better at dealing with foaming structures.
4.4.4 Design and Analysis Factors :
Factors that influence the design or analysis of a binary distillation

operation include:
1. Feed flow rate, composition, temperature, pressure, and phase condition
2. Desired degree of component separation
3. Operating pressure (which must be below the critical pressure of the mixture)
4. Pressure drop, particularly for vacuum operation
5. Minimum reflux ratio and actual reflux ratio
6. Minimum number of equilibrium stages and actual number of equilibrium stages (stage
efficiency)
7. Type of condenser (total, partial, or mixed)
8. Degrees of liquid reflux subcooling
9. Type of reboiler (partial or total)
10. Type of trays or packing
11. Column height
12. Feed-entry stage
13. Column diameter
14. Column internals, and materials of construction
15. Heat lability and chemical reactivity of feed components
89 | P a g e
4.4.5 McCabe-Thiele’s Method:
The graphical scheme developed by McCabe and Thiele is one of the most popular methods for
calculating the architecture parameters of the column. This is the most straightforward approach
for determining the number of equilibrium stages in a distillation operation. It should be noted,
though, that it is only applicable to systems with two parts. As a result, we normally skip the
feature index for the light component, writing x = x1 (light component) and x2 = 1x (dark
component) (heavy component). McCabe-approach, Thiele's on the other hand, necessitates
certain additional assumptions. It is believed, in fact, that:
(1) the molar overflow is constant,
(2) the molal heats of vaporization of the components are roughly the same and
(3) heat effects are negligible
Under these circumstances, McCabe-approach Thiele's helps one to calculate the theoretical
number of stages needed for binary mixture separation and, as a result, the number of trays
required for distillation column construction.
The vapor-liquid equilibrium data for a portion of the binary mixture of composition xf is plotted
first in McCabe-system. Thiele's The x-axis and y-axis, respectively, are used to plot the
compositions of liquid and vapour.
The operation line for the rectification area of the column (the portion of the column above the
feed tray) will be plotted next.
The next step in McCabe-graphical Thiele's approach is to figure out how many steps there are
in the distillation process. This is a series of related steps that result in a set of "corner" parts that
are linked to the levels.
4.4.6 Designing steps for distillation column are following:
 Calculation of number of plates

 Calculation of Physical properties
 Estimation of column diameter
 Estimation of liquid flow pattern
 Provisional plate design
 Check weeping
 Checking of plate pressure drop
 Checking down corner liquid back up
 Checking entrainment
 Trial layout perforated area
 Tray column specification sheet
4.4.6.1 Choice of Plate type:
The bubble cover, sieve tray, ballast or valve trays, and counter flow trays are the four primary
tray forms.
Since sieve trays are lighter in weight and less costly, I chose them.
90 | P a g e
1. It is simpler and less expensive to instal.
2. As compared to bubble cap trays, the pressure drop is minimal.
3. In general, peak performance is high.
4. Since cleaning is easy, maintenance costs are minimised.
Figure 4.8: Distillation Column
91 | P a g e
4.4.6.2 Designing:
Determination of the column diameter:
Mecab theile Method

1
45 line
0.9
0.8
equilibrium curve
0.7
y-composition
0.6 q line
0.5
0.4 top section
0.3
0.2 bottom section
0.1
Top 1 a
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
X- Composition top 1 b
Figure 4.9: Mecab theile method
Assume column efficiency 80%,take reboiler as equivalent to one stage:
By this Diagram:
Theoratical Stages = 14
=14-1=13
Real stages/Theoretical stage = 13/0.8 = 16 stages
4.4.6.3 Flowrates inside Column:
Rectifying Section:
𝐿𝑛
R= 𝐷
Ln = D × R
92 | P a g e
= 200.98 × 2.0625
= 415.023 Kmol/hr
Vn = Ln =D
= 415.023 = 200.98
Vn = 616.0037 Kmol /hr
4.4.6.4 Stripping Section:
F = 408.005 Kmol/hr
q = 0.75
L/ = Ln = 415.023 Kmol/hr
V = F + Vn = 408.005 + 616.0037
V = 1024.0087 Kmol/hr
4.4.6.5 Height of Tower:
Number of theoretical Stages = 14
Reboiler = 1
Ns = No of theoretical stages = 14 -1
= 13
𝑁𝑜 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑎𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠
NR = Actual stage = ∈
13
= 0.80 = 16
4.4.6.6 Height of distillation tower:
Height of distillation tower = 2.3 × 16
= 36.8 ft
93 | P a g e
4.4.6.7 Flooding Velocity:
𝐿𝑛 𝜌𝑣
FLV = 𝑉𝑛 √𝜌𝐿
415.023 1.53
= 616.0037 √2.48
FLV = 0.5291
Taking spacing 0.60 between trays :
Kf = 0.07
4.4.6.8 Flooding Velocity:
𝜌𝐿− 𝜌𝑣
Ut = Kf √ 𝜌𝑣
2.48− 1.53
= 0.07 √ 1.53
Ut = 0.055 m/s
Flooding velocity in stripping section :
𝜌𝑣
FLV = L/ / v √𝜌𝐿
415.023 1.53
= √
1024.0083 2.48
FLV = 0.318
Taking plate spaces = 0.60
Kf = 0.069
𝜌𝐿− 𝜌𝑣
Ut = Kf √ 𝜌𝑣
2.48− 1.53
= 0.069 √
1.53
Ut = 0.054 m/s
94 | P a g e
Molecular weight of top and bottom product:
Molecular weight of top product = (28 × 0.857) + (42.08 × 0.142)
= 29.971 Kg/mol
Molecular weight of bottom product = (28 × 0.068) + (42.08 × 0.931)
= 41.08 Kg/mol
4.4.6.9 Volumetric flow rate: (Q)
For Rectifying Section :

𝑉𝑛 ∗29.98
Q = 1.8 ∗ 3600
616.0037 ∗ 29.97
= 1.8 ∗ 3600
Q = 2.849 m3/s
For Stripping Section:

𝑉∗ 41.08
Qv = 1.53 ∗ 3600
1024.0087 ∗ 41.08
= 1.53 ∗ 3600
Qv = 7.63 m3/s
Down-comer area as 12% of total:

Down-comer area = Ad = 0.12 AT
AN = AT – Ad = 0.88 AT
𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟𝑠

Net area = 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑛𝑒𝑡 𝑎𝑟𝑒𝑎
Rectifying Section:
An = Qv / Un
2.849
= 1.438
95 | P a g e
= 1.9798 m2
𝐴𝑛
AT = 0.88
1.9798
= 0.88
AT = 2.25 m2
4𝐴
D=√
𝛱
4 ∗ 2.25
=√ 3.14
D = 1.69 m
Stripping Section:
An = Qv /Un
7.63
= 1.702
= 4.48 m2
𝐴𝑛
AT = 0.88
4.48
AT = 0.88
AT = 5.09 m2
4𝐴
D = √𝛱
4 ∗ 5.09
=√ 3.14
D = 2.54 m
Average Dia by taking mean of top and bottom section:

A = 2.115 m
4.4.6.10 Plate Design:
Column diameter = 2.115 m
Ac = Column Area = 𝛱 D2 /4
= 3.512 m2
4.4.6.11 down comer area:
Ad = Down comer area

96 | P a g e
= 0.12 × Ac
= 0.12 × 3.512
= 0.42 m2
4.4.6.12 Net area:
Net area = An = Ac – Ad
= 3.512 – 0.42
= 3.092 m2
4.4.6.13 Active area:
Active area = Ac – 2d
= 3.512 – 2 (0.42)
Active area = 2.672 m2
4.4.6.14 Weir length:
Weir length = 0.77 × Column diameter
= 0.77 × 2.115 m
= 1.62855 m
4.4.6.15 Hole area:
Hole area = 0.07 × 2.672 ( 7 % of active area)

= 0.1870 m2
4.4.6.16 Hole diameter:
Hole diameter = 5 mm
Area = 1.30 * 10-4 m2 of one hole
4.4.6.17 Number of holes:
Number of holes = 0.1870 / 1.308 × 10-4

= 1430 m2
Height of column = 16 trays
4.4.6.18 Height of tower:
Height of tower = 2.3 × 16

97 | P a g e
= 36.8 ft = 11.21 m
Which is allowable range ( 5 to 20m)
4.4.6.19 Pressure Drop Calculations:
4 ∗ 𝑐𝑜𝑙𝑢𝑚𝑛 𝑎𝑟𝑒𝑎 1
𝐶𝑜𝑙𝑢𝑚𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐷𝑐 = ( )2
𝜋
So,
𝑏𝑢𝑏𝑏𝑙𝑖𝑛𝑔 𝑎𝑟𝑒𝑎
𝑐𝑜𝑙𝑢𝑚 𝑎𝑟𝑒𝑎 =
0.7
And
𝑣𝑎𝑝𝑜𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
𝐵𝑢𝑏𝑏𝑙𝑖𝑛𝑔 𝐴𝑟𝑒𝑎 =
𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝐵𝑢𝑏𝑏𝑙𝑖𝑛𝑔 𝐴𝑟𝑒𝑎 = 𝑐𝑜𝑙𝑢𝑚𝑛 𝑎𝑟𝑒𝑎 ∗ 0.7

= 1.855 m2
If the bubbling area is 0.7 of the total column area,

Then,
𝑏𝑢𝑏𝑏𝑙𝑖𝑛𝑔 𝑎𝑟𝑒𝑎
0.7
1.855
0.7
= 2.65 m2
4 ∗ 𝑐𝑜𝑙𝑢𝑚𝑛 𝑎𝑟𝑒𝑎 1
𝜋
4 ∗ 2.65 1
𝜋
= 1.83 m
4.4.6.20 Pressure Drop Calculations:
The plate area of one unit of three holes on triangular ¾ in. pitch is
1 3 3
∗ ( √3/2)
2 4 4
= 9√3/64 in2
The hole area in this section (half a hole) is
98 | P a g e
1 𝜋 1 2
∗ ∗( )
2 4 4
𝜋
= in2
128
Thus the hole area is

𝜋
= ∗9√3/64
128
= 0.1008
As
𝑏𝑢𝑏𝑏𝑙𝑖𝑔 𝑎𝑟𝑒𝑎 1.855
𝑉𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ ℎ𝑜𝑙𝑒𝑠 = 𝑢𝑜 = =
ℎ𝑜𝑙𝑒 𝑎𝑟𝑒𝑎 0.1008
= 18.4 m/s
4.4.6.21 Pressure drop through holes
𝑢𝑜2 𝜌𝑣
ℎ𝑑 = 51 ∗ ( 2
)∗( )
𝐶𝑜 2𝑔𝜌𝑖
Co2 = 0.73
51 ∗ (18.14)2 ∗ (1.53)
ℎ𝑑 =
0.732 ∗ 2 ∗ 9.8 ∗ 2.48
= 991.24 mm
Head of liquid on plate
Weir length = hw = 2*16.2855 = 32.5 mm
Height of the liquid above weir

𝐷𝑐 2.115
𝐿𝑤 = 1.62 ∗ ( ) = 1.62 ∗ ( )
2 2
= 1.713 m
Liquid flowrate
𝐷∗𝑅 600.9 ∗ 2.0625
𝑞𝑙 = =
𝜌𝑖 24.8 ∗ 60
= 0.83 m3/min
As,
𝑞𝑙 2 8.3 2⁄
ℎ𝑜𝑤 = 43.4( ) ⁄3 = 43.4( ) 3
𝑙𝑤 1.84
= 118.48 mm
99 | P a g e
As,
ℎ𝑙 = 𝛽(ℎ𝑤 + ℎ𝑜𝑤 )
𝛽 = 0.6
ℎ𝑙 = 0.6(32.5 + 11.848)
=26.6 mm
As,
ℎ𝑡 = ℎ𝑙 + ℎ𝑑 = 26.6 + 991.24
=1017.8 mm
Forth Height
let hf.1 = 10 mm
𝑍𝑐 = 𝛽 (ℎ𝑤 + ℎ𝑜𝑤 ) + ℎ𝑑 + ℎ𝑓.1
=138.58 mm
And,
𝑍𝑐 138.58
𝑍= =
0.5 0.5
= 326 mm
Pressure drop at Distillation column = 0.45 bar
100 | P a g e
Specification Sheet of Distillation Column:

Identification
Item Ethylene and Propylene Distillation Column
No.required 1
Tray type Sieve tray
Function
Separation of Ethylene from Propylene
Operation Continuous Tray thickness 5 mm
Operating pressure 18 bar Hole diameter 5 mm
Number of trays 16 Weir height 45 mm
Reflux ratio 2.0625 Weir length 1.62855 m
Tray spacing 0.60 Active area 2.672 m2
Height of column 11.21 m % flooding 37.33
Diameter of column 2.115 m Pressure Drop 0.45 bar
101 | P a g e
Chapter 05 Mechanical Design
Chapter # 5
Mechanical Design
Mechanical Design
5.1 Mechanical Design of Reactor Ethylene 5723.33 Kg/hr
Propylene 8585 Kg/hr
Water 18396.42 kg/hr
T 400OC
P 39.5 bar
Methanol 33035.11Kg/h
3
T 400OC
P 40 bar
3
5.1.1 Design Pressure 3
Operating pressure = 40 bar

Design pressure = 5-10 % of operating pressure
Design pressure= 40+1*4 = 44 bar

Design pressure= 44 bar
Design Temperature
Operating temperature = 400oC
Design temperature = 5-10 % of operating temperature
Design temperature = 440℃

Minimum practical wall thickness
A thinner wall thickness is needed to ensure that any part of the vessel is sturdy enough to support
its own weight as well as any unintended loads. According to general standards, a vessel's wall
thickness must not be less than the values mentioned below, which provide a 2 mm corrosion
allowance.
Table 5.1: Vessel wall thickness
Since the diameter of the vessel is 2.9 m, so from the above table the thickness of shell is 12
mm.
Thickness of the reactor shell =
Pi= 44 bar or 4.4= N/mm2

J =1 (for no joints in the head)
f= stress factor =75 N/mm2
Stainless Steel Stress factor =105 N/mm2
Di = 2900 mm
4.4∗2900
e=
2∗1∗75−4.4
e=87.6 mm
104 | P a g e
5.1.2 Heads and closures
Heads of various shapes close the ends of a cylindrical vessel. The principal types used are:
1. Flat plates and formed flat heads;

2. Hemispherical heads
3. Ellipsoidal heads
4. Tori spherical heads
Figure 5.1: Hemispherical heads
Figure 34: Hemispherical heads
Figure 5.2: Ellipsoidal heads
Figure 5.3: Tori spherical heads
Domed heads belong to hemispherical, ellipsoidal, and tori spherical heads as a group. Huge
diameters are fabricated from formed parts, which are formed by pressing or spinning. Dished
ends are a term used to describe Tori spherical heads.
105 | P a g e
5.1.3 Comparisons of Heads
Flat Head Tori spherical heads Ellipsoidal heads Hemispherical heads
Applicable to low Used up to operating Above 15 bar Used for very high
pressure pressure of 15 bar ellipsoidal head is pressures
used
Cheapest from all Above 10 bar their Economical with in Capital cost is high
types cost should be pressure limits
compared with that of
an equivalent
ellipsoidal head
Thickness of Head
Hemispherical heads
Examining equations 13.7 and 13.9, it can be found that for equivalent stress in the cylindrical
portion and hemispherical head of a vessel, the head just has to be half the thickness of the
cylinder. Discontinuity pressures would be generated at the head and cylinder junction
because the dilation of the two components would be different. For no discrepancy in dilation
between the two components (equal diametrical strain), it can be seen that the ratio of
hemispherical head thickness to cylinder thickness should be 7/17 for steels (Poisson's ratio D
0.3). However, the tension in the head will be greater than in the cylindrical portion, and the
optimal thickness ratio is usually 0.6; see Brownell and Young (1959) for more details.
Hemispherical head thickness / cylinder thickness = 0.60

Hemispherical head thickness = 0.60 * cylinder thickness
= 0.60 * 87.6
= 52.56 mm
5.1.4 Types of supports
• Saddle supports ( for horizontal vessels)

• Brackets supports ( for vertical vessels )
• Skirt support (for vertical vessels, particularly where the length is high and effect of wind
is prominent).
For the desired reactor, I used “Bracket Supports”
106 | P a g e
Figure 5.4: Brackets supports
5.1.5 Weight of shell
Wv = 240 * Cv *Dm*(Hv+0.8*Dm)*t .
W= Total weight of shell
Cv = A factor to account for the weight of nozzles, manways, internal supports, etc.; which
can be taken as = 1.08 for vessels with only a few internal fittings,
Dm = Mean diameter = (Di+t) = 2.9+0.0876
Dm = 2.987 m
Hv = height of vessel = 9 m
t = thickness of shell = 0.0876 m
Wv = 240×1.08×2.987×(9+0.8×2.987)×0.0876
Wv = 772 N
5.1.6 Stress Calculations
Longitudinal stress:
4.4×2900
ϬL = 4×87.6
= 36.4 N/mm2
Circumferential
Stress:
Ϭh = (4.4* 2900)/ 2*87.6
Ϭh = 72.8 N/mm2
107 | P a g e
Dead weight stress:
Ϭw = 772/ 3.14*(2900+87.6)* 87.6

Ϭw = 0.000939 N/mm2
5.1.7 Principle Stress
For Longitudinal Stress:
σz = Total longitudinal stress = σL + σw
σz = 36.4 N/mm2
σh =72.8 N/mm2
σL =36.4 N/mm2
t= Torsional shear stress is very small and is usually

neglected σ1 = 72.82 N/mm²
For Circumferential, (hoop) Stress
σ2 =
½ [σh + σz - √(σh − σz)² + 4t²
Total Longitudinal Stress
σz = σ L + σ w
t= Torsional shear stress is very small and is usually

neglected
σ2 = 36.3 N/mm²
For Radial Stress:
σ3 = 0.5 P
σ3 = 0.5 (4.4)
σ3 = 2.2 N/mm2
108 | P a g e
Allowable Stress Intensity:

The numerical greater of the following is the overall stress strength taken at some stage for
design purposes:
σ1 – σ2
σ1- σ2 = [72.8 – 36.3]
σ1- σ2 = 36.5 N/mm²
σ1- σ3
σ1- σ3 = [72.8 – 2.2 ]
σ1- σ3 = 70.6 N/mm²
σ2- σ3
σ2- σ3 = [36.3-2.2]
σ2- σ3 = 34.1 N/mm²
The maximum stress intensity is σ1- σ3 = 70.6 N/mm2
The maximum stress is less than design stress which is 75 N/mm² .So Carbon steel is best choice.
σ1- σ3 < f
70.6 N/mm² < 75 N/mm²
5.1.8 Wind Loading
Fw = Pw * Deff .
Take dynamics wind pressure as 1030 N/m2]
Deff = The outer diameter of the column plus an allowance for thermal insulation
and additions like pipes and ladders equals the effective column diameter. A caged
ladder can be applied to the equation with a 0.4 m allowance.
Deff = 2.9 + (0.0876) *2
Deff = 3.07
Fw = 1030*3.07
Fw= 3162 N/m
109 | P a g e
Specification Sheet
SPECIFICATION SHEET
Identification
Item Reactor R-101
Type Packed Bed Multi Tubular Reactor
Function
To react the starting materials to create the products
Design Pressure 40 bar
Design Temperature 400 oC
Thickness of the reactor shell 87.6 mm
Weight of shell 772 N
Diameter of shell 2.9 m
Length of shell 7.46 m
Types of supports Brackets supports
Heads and closures Hemispherical heads
Thickness of Head 52.56 mm
110 | P a g e
Chapter 06 Power Calculations
Chapter # 6
Power Calculation
Pump calculation (P-101)

6.2 Pump Calculation
6.2.1 Mechanical Calculation of Pump (P-101)
Temperature 25 °C
Pressure 40 bar
Phase Liquid
Flow rate 33035 kg/hr
Temperature 25 °C
Pressure 1 bar
Phase Liquid
Flow rate 33035 kg/hr
6.3 Pump sizing calculation steps

Pump sizing steps are as follows
 Select the pump type
 Locate the process equipment
 Estimate z2 and z1.
 Estimate Frictional pressure losses ES and ED
 Calculate Pump Work.
 Calculate Pump estimate its Efficiency & shaft horsepower.
 Calculate electric-motor horsepower & estimate its Efficiency.
 Select a standard electric motor horsepower.
6.3.1 Pump Selection

Pump type is selected from Silla, H. (2003). Chemical process engineering: Design and
economics. New York: M. Dekker.
112 | P a g e
Capacity = 33035 kg/hr
Capacity = 196.73 gpm
Sp. Gravity = 1000 kg/m3
P = 10197.16 kg/m2
𝑃(𝑔)
Head =
𝑆𝑝.𝑔𝑟𝑎𝑣𝑖𝑡𝑦 ×0.4367
Head = 23.35 ft
Hence, the Pump Selected is Centrifugal Pump.
6.3.2 Locate the process equipment
Locate the process equipment according to the rule of
thumb listed in figure 6.1
As we need to pump the liquid in to the heat exchanger
so our process equipment is heat exchanger.
Estimation of Z1 and Z2 Figure 6.1: Rules-of-Thumb for Locating Process

Equipment
Z1=0
Z2= 4ft
6.3.3 Estimation frictional pressure losses ED and ES

The friction pressure loss term is split into two parts, one for the suction side of the pump, E S
s
and, the other for the discharge side of the pump, E D

D
ES & ED is equal to 0.35 from figure 6.2
113 | P a g e
Figure 6.2: Approximate Frictional Pressure Drop across Process Equipment
6.3.4 Calculate Pump Work
𝑔 𝑃1−𝑃2
W = 𝑔𝑐 (𝑧1 − 𝑧2) + − (𝐸𝑠 + 𝐸𝑑)
𝑥
P1=0.98atm
P2=39.4 atm
(0.98−39.4)∗101325 (0.35+0.35)
W= 32.4 (0-4) + − *101325
1000 1000
𝑁.𝑚
W= -4093
𝑘𝑔
6.3.5 Pump Power:
Pump power is calculated as,
𝑚𝑊
P= (5.49)
𝜂
Pump efficiency = 45% (from table 6.1)
33035∗4093
P=
0.45
P = 3.0*108 J/hr.
P = 140 hp.
114 | P a g e
Table 6.1: Pump Characteristics
6.3.6 Calculate electric motor horsepower & efficiency

Based on horsepower the selected motor is squirrel cage Induction motor having power rangeof 1
to 5,000 hp.
Efficiency of motor is selected to be = 0.94 (from table 6.2)
The power of motor is calculated as
𝑃𝑝
PE = (8.6) by McCabe Smith
𝜂
140
PE =
0.94
PE = 148.93 hp.
115 | P a g e
Table 6.2: Characteristics of Compressor and Pump Drivers
Table 1: Characteristics of Compressor and Pump Drivers

Select
a
standard electric motor horsepower
As seen in Table 5.10, the scale of electric motors is uniform according to horsepower. If the
measured horsepower is less than the normal horsepower, the next standard horsepower is chosen.
Hence the selected motor is of 150 hp. (from table)
116 | P a g e
Table 6.3: Standard Electric-Motor Sizes
6.3.7 Net positive suction head (NPSH)
Absolute pressure at the surface of reservoir = Pa = 0.465 atm =47.13 KPa
Pv = Vapor pressure of solution= 3.17 KPa
Hfs= Friction in suction line = 0
Z1=0
1 47.13−3.17
NPSH = ( -0)-0
9.8 1000
= 4.48 m
117 | P a g e
Specification Sheet P-101
Specification Sheet P-101
Total Mass flow rate 33035 kg/hr
z2 24.4 ft
Work -6205.9 N-m/kg
Pump Power 106 hp
Electric-motor Power 116.4 hp
118 | P a g e
Chapter 07 Cost Estimation
Chapter # 7
Economic Analysis
119 | P a g e
7.1 Pump (P-101):
Centrifugal pump
Inlet pressure = 1 bar
Outlet pressure = 40 bar

Pump work = -6205.9 j/kg
Capacity = 12.41 L/s
Cost constants, a = 3300 & b = 48

Equipment exponents, n = 1.2
Cost of pump in 2004 = a+bSn
Cost of pump in 2004 = $4,103

Cost index in 2004 = 478.6
Cost index in 2020 = 1086.3
𝑐𝑜𝑠𝑡 𝑖𝑛 2004∗𝑐𝑜𝑠𝑡 𝑖𝑛 2020
Cost of pump in 2020 = 𝑐𝑜𝑠𝑡 𝑖𝑛 2004
1086.3
Cost of pump in 2020 = 4103 * 478.6
Cost of pump in 2020 = $9312
7.2 Reactor (R-101):-
Height = 9m
Diameter = 2m
Material Factor = S.S = 2

Pressure Factor = 30-40 bar = 1.6
Bare cost = 25*1000
Cost of Fermenter in 2004 = $25*1000

Cost of Fermenter in 2004 = $25,000
Purchased Cost = Bare Cost from Fig *Material Factor*Pressure Factor

Purchased Cost = 25,000*2*1.6
Purchased Cost = $80,000

Cost Index in 2004 = 444.2
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Cost of Fermenter in 2020 = Ce* (Cost Index in 2020/Cost Index in 2004)

Total Cost in 2020 = 80,000*(593.6/444.2) = $ 106906
10 % cost of cooling system = $ 10690
Total Cost of Reactor = $106906+$10690 = $117596
7.3 Distillation Column (T-101):
Material of Construction = Stainless Steel
Height of Column = 11.21 m.
Diameter of column = 2.115 m.
Form Appendix:
Bare cost= 40,000 $
Material factor = C.S = 2
Pressure factor = 1-5 bar = 1

Cost of vessel = 40,000 * 2* 1
Cost of vessel in 2004= Ce = 80,000 $
Plate diameter = 2.115 m
Plate material = Stainless Steel
Plate type = Sieve plate
From Appendix:
Material Factor = 1.7
Cost from Figure = 400 $
Installed Cost = Cost form fig * Material factor
Installed Cost = 400* 1.7
Installed Cost = 680 $
No of Plates = 16
Cost of Plate in 2004 = Installed Cost * No of Plates
= 680 * 16
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= 10880 $
Total Cost CE = Cost of Plate in 2004 + Cost of Vessel in 2004
= 10880 + 80,000
= 90880 $
2004 Cost Index = 541.2
2020 Cost Index = 613.5
Equipment Cost in 2020 = Total Cost * 2020 cost index / 2004 cost index
= 90880 * 613.5 / 541.2
= 13020.8427 $
7.4 Cost of separator (V-101)
Bare Module Cost Factor (FBM) = 4.07

Cost in 2004 = Cp o = $ 7000
Bare Module Cost Factor (FBM) = 4.07
Bare Module Equipment Cost (CBM) = Cp o × FBM
= $ 28490
Cost Index in 2020= 757.5
𝐶𝑜𝑠𝑡 𝑖𝑛 2020 = 𝐶𝐵𝑀 ( 𝑖𝑛 2020/ 𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2004)
Purchase cost of equipment in 2019 = $ 41367

7.5 Cost of Heat Exchanger (E-102)
Shell and Tube Heat Exchanger

Area = 664.6924972 ft2
Material of Construction=Carbon Steel

From Appendix F Figure F-5
Exchanger cost in 2005= $ 60,000

Pressure Factor1-10=1
Type factor U-tube=0.85

Equipment Cost in 2004= $ 60,000 *Pressure factor *type factor
Equipment cost in 2004= $ 51,000
2004 Cost Index=509.2
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2021 cost Index=616.1

Cost of reaction in 2021= (Equipment cost in 2004*(Cost index in 2021)/cost index in 2004
Equipment Cost in 2021=$ 61,706
7.6 Total Equipment Cost
Total Equipment Cost = $ 302982.0
7.6.1 Direct Cost
Table 7.1: Direct cost

Items Range % Cost ($)
Purchased
--- 100% 302982.0
Equipment
Installation 25-55% of purchased equipment cost 25% 75,745.0

Instrument and
6-30% of purchased equipment cost 6% 18,142.92
Control
Piping 40-80% of purchased equipment cost 40% 12,0952.8

Electricity 10-15% of purchased equipment cost 10% 30,238.2
Building 15% of purchased equipment cost 15% 45,357.3
Land 4-8% of purchased equipment cost 4% 12,095.2
Service facility 30-80% of purchased equipment cost 30% 90,714.6
Yard Improvement 10-20% of purchase equipment cost 10% 30,238.2
Insulation cost 8-9% of purchased equipment cost 8% 24,190.56
Total --- --- $750,655.000
7.6.2 Indirect Cost
Table 7.2: Indirect cost

Items Range % Cost ($)
Engg. & supervision 8% of total direct cost 8% 60,052.40
Contractor fee 2-8% of direct plant cost 2% 15,013.10
Construction Expenses 10% of Total direct plant cost 10% 75,065.5
123 | P a g e
Contingences Direct plant cost 5% 37,532.75
Total --- --- $187662.7
7.6.3 Fixed Capital Investment

FCI = Direct Cost + Indirect cost
= $93, 8317.75
Working Capital Investment
WCI is 15% of FCI = $14, 0747.66
Total Capital Investment = $10, 79065.16
Variable Cost
Utility Cost
Water (Cooling)
Flow rate = 793135.1 T/Y
Cost of Water = 0.01 $/T
Cost of Total water = 7931 $/Y
Steam
Total flow rate of steam = 20445 kg/hr.
= 197421 T/Y
Price of steam = 0.02 $/kg
= 20 $/T
Total price of Steam = 27, 63894.0 $/Y
Total Cost of Utility = (27, 63894.0 + 7931) $/Y
Total Cost of Utility = 27, 71825.0 $/Y
Raw Material
Methanol = 873.9 T/D
Cost of 1 ton methanol = 430 $/T
Cost of Total methanol = 37, 5777 $/D
= 12, 400, 6410 $/Y
Cost of Total methanol = 1.2 hundred million $/Y
7.6.3 Miscellaneous
Materials Cost
Maintenance cost = 7% of FCI
Maintenance cost = 65,682.2 $/Y
Miscellaneous material = 10% of maintenance cost
Miscellaneous cost = 6568 $/Y
Variable cost = Raw Materials Cost + Utilities cost + Miscellaneous cost
Variable cost = 12, 678, 4803.0 $/Y
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7.6.4 Fixed Cost
Table 7.3: Fixed cost

Maintenance 10% of FCI 93831.77
Operating Cost of Labor 1% of TPC 0.01(TPC)
Laboratory Cost 1.5% of TPC 0.015(TPC)
Supervision Cost 2% of TPC 0.02(TPC)
Plant Overheads 5% of TPC 0.05(TPC)
Capital Charges 12% of FCI 11, 2598.1
Insurance 5% of FCI 46,915.88
Local Taxes 2% of FCI 18, 766.3
Royalties 5% of FCI 46, 915.88
Fixed Cost - 31, 9027.6 +
0.095(TPC)
7.6.5 Total Production Cost
TPC = Variable Cost + Fixed Cost

TPC = 12, 678, 4803.0 + 31, 9027.6 + 0.095TPC
TPC - 0.095TPC = 10, 710, 3830.6
12,710,3830.6
TPC = = 11, 900, 4255.6 $/Y
0.095
Total Production Rate = 138161 T/Y
$
𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝐶𝑜𝑠𝑡( )
𝑌
Production Cost ($/T) = 𝑇
𝑇𝑜𝑡𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 ( )
𝑌
$
11,900,4255.6 ( )
𝑌
= 𝑇
138161( )
𝑌
Production Cost = 861.34 ($/T)
Below this We Can’t sale our product
Selling Price:
Cost of Propylene in USA = 1015 $/T
Cost of Propylene in Pakistan = 154,873 PKR/T
Selling price = 1015
$/T
7.6.6 Profitability Analysis
Production cost = 861.3 $/T
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Selling price = 1015 $/T

Profit = Selling price – production cost
= 1015 – 861.3
Profit = 153.65 $/T
Total production per year = 138161 T/Y
Profit per year = 21221529.6 $/Y
Total Income
Selling price of Methanol = 1015 $/T
Total production per year = 13, 8161 T/Y.
Total income = 13, 8161 * 1015 = 14, 506, 9050 $/Y
Gross Profit
Gross profit = Total income – Total production cost
= 14, 506, 9050 – 11, 900, 4255.6
Gross profit = 26, 064794 $/Y
7.6.7 Net Profit
Assume that the fixed capital investment depreciate by straight-line method for 20 years.
Assuming 5% selvage value at the end of plant life.
𝑉 − 𝑉𝑆⁄
Depreciation = D = 𝑁
V = FCI = $93, 8317.75
Salvage value = VS = 0.05(FCI) = $ 46, 915.8
Number of years = N = 20 years.
Depreciation = D = $44570
Net profit before taxation = Gross profit – Depreciation
= 26, 064794 – 44570
= 26, 020224 $/Y
Taxes = 30% of net profit before taxation Taxes = 25, 298, 8.0$/Y
Net profit = Net profit before taxation – Taxes
= 26, 020, 224 -25, 298, 8.0 $/Y
= 72, 141, 5.0 $/Y
7.6.8 Rate of Return
Rate of return = (Net Profit⁄Total Capital Investment) * 100

Rate of return = (72, 141,5.0/10, 79065.16) × 100
ROR = 66.85%
7.6.6 Payback Period
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Payback period = 1⁄Rate of return

Payback period = 1.49Y
127 | P a g e
Chapter 08 Instrumentations and Control
Chapter # 08
Instrumentation and Control of Major Equipment’
128 | P a g e
8.1 Control Strategy for the Whole Plant
The overall process goals should guide the design of a plant-wide control system. This technique is
used to help our plants achieve their goals. The steps in the design process for our plant-wide control
are as follows.
8.2 Establish the control objective
This phase is used to establish the goal. The following are the control objectives for our plant:
 Maintain ethylene production rates in order to meet our capacity.

 Maintain the plant's highest conversion rate.
 Maintain consistency in the final product's composition.
8.3 Determine the control degrees of freedom
As shown in five figure above about PID for our plant has some freedom or manipulated variables
which the actuator is valves controlling the manipulated variables. The control system will be reached
after this stage.
Create an energy management device.
Control loops are placed in this step to keep exothermic and endothermic reactors at the desired
temperature. Temperature controls are often placed to ensure that disruption is eliminated from the
process through the utility stream rather than being recycled by the heat-integrated process device.
Decide on a production rate.

The rate of ethylene product production is controlled to achieve a capacity of 82898.88 tons per year.
Maintain production quality while addressing protection, environmental, and operational

concerns
The product quality is regulated by keeping the reactor, distillation process, absorber, and stripper in
good working order. The operating conditions are carefully monitored in order to achieve the most
effective process possible.
Monitor vapour and liquid inventory by adjusting the flow rate in each recycle loop.
This move will ensure that the process is as efficient as possible. Since the liquid inventories in the
flash vessel and separator do not self-regulate, they must be monitored. Since the liquid product valve
from the equipment regulates the material flow rate, inventory management must be in the opposite
direction of the process flow.
Make sure the components are in order.
129 | P a g e
This move is unnecessary due to all of the above-mentioned controllers.
Control each process unit separately.

This phase is used to monitor the process of each unit in order to achieve our plant's goal.
8.4 Control and Instrumentation
The instrument control selection is based on the equipment's parameter urgency. Temperature, for
example, is a regulating parameter in a methanol to olefin reactor since it determines the olefin
conversion, which is critical for subsequent processing, such as ethylene and propylene
polymerization. We use three types of instrument control in this plant:
 Transmitter, b. receiver, and c. controller. The transmitter, which is located on the field near
the equipment, is used to denote the most recent state of the equipment.
 Controlling the indicators. The indicator controller receives an electrical signal from the
transmitter and determines if the controller or final part can make a decision.
 Final Element Controller The controller, or final part, is used to carry out the decision that has
been given. The DCS (Distributed Control System) software is used to control this control
system from a computer in the control room.
Electricity transports the transmitted signal to the indicator controller. The energy impulses come
from a power generator, and if the power goes out, the data from the transmitter or indicator cannot
be accessed. An air compressor supplies the pressurized power, and the system is still operated
whether the plant is shut down or tripped in an emergency. The signal is transmitted pneumatically
from the indicator controller to the device. Here on Table, you can see a list of each plant's instrument
control.
130 | P a g e
Table 8.1: instrument control
Process Controlled Controlling

Sensor Controller Alarm Function To Maintain Procedure
Equipment Parameter Parameter
The flow of the water utility flow as the
Flow of water Temperature To maintain the inter-stage cooler inside the reactor. If the
High
Temperature utility as the Thermocouple indicator to reactor operation temperature is higher, flow of the water
and low
MTO cooling controller in 4350C utility will increased and if lower will
Reactor medium decreased
Pressure To maintain the The flow of product will be increased if
Pressure High
Pressure Product pressure indicator to pressure inside the
gauge and low
controller the reactor pressure is higher and decreased if lower
To maintain the
level of the
The flow of bottom product will increased
Water Bottom Mechanical Level indicator High water separator in
Level if the level is higher and decreased if the
Separator product float to controller and low 50%
level lower
flow volume with
deviation 5%
The flow of the refrigerant as the
To maintain
Refrigerant Temperature separator cooling system. If the
Water High temperature of
Temperature flowas the Thermocouple indicator to temperature is
Separator and low the separator
cooling controller higher, flow of the refrigerant will
around 50C
medium increased and if lower will decreased
Adjusting the feed rate if the outlet
Flow indicator
Pump Flow Outlet flow Flowmeter Low flowrate doesn’t meet the required
tocontroller
condition
Temperature Adjusting the flow if the outlet

Heat Outlet fluid
Temperature Thermocouple indicator to Low temperature doesn’t meet the required
Exchanger flow
controller condition
Pressure The flow of product will be increased if

Top product High To maintain
Pressure Pressure gauge indicator the pressure is higher and decreased if
outlet and low the pressure at
to lower
10 atm
controller
Distillation
Column
131 | P a g e
To maintain the
level of the The flow of bottom product will
Bottom Mechanical Level indicator High water separator increased
Level
product flow float tocontroller and low in 50% if the level is higher and decreased if the
volume level lower
with
deviation
5%
To maintain the when detection unspecific temperature at
Temperature
Distillation High distillation inlet, temperature indicator will be sent a
Temperature Steam flow Thermocouple indicator to
Column and low temperature at signal to control valve cooling water to
controller
cryogenic more or little open
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Chapter 09 HAZOP Study
Chapter # 09
HAZOP study
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9.1 Hazard and Operation Study (HAZOP)
A Hazard and Operability Study (HAZOP) is a formal, systematic evaluation of a process or project
that has occurred or is currently in the planning stages, with the aim of identifying and evaluating
issues that may pose a risk to individual workers, equipment operation, or process performance.
HAZOP is the process of identifying anomalies / deviations in the operation of an industrialized
installation, as well as the resulting negative effects on protection, operability, and the environment.
Rigid questioning, accompanied by a set of standard "guidewords" applied to the planned template,
generates potential deviations.
HAZOP is completed during the planning stage of a new build and prior to modifying or installing
new equipment. HAZOP is a term that refers to a comprehensive study of a critical installation's
configuration, consequences, and potential deviations, as well as the possibility of hazard
occurrence. The following are the objectives after completing HAZOP:
1. Identify process-related safety, danger, and organisational issues that pose an immediate
threat to workers' safety and operations.
2. Determine the magnitude of the problem impact that has been found.
3. Determine the engineering and operational protections and review them.
4. If necessary, suggest additional engineering and procedural protections.
HAZOP is carried out by a team of experts from various backgrounds, headed by a qualified safety
professional or training advisor.
1. Obtaining all process lineation for each plant process
2. Sub-processes are broken down into smaller and smaller sub-processes. Nodes in the upper-
ends of each sub-process are provided to explain the breakdown of sub-processes. There is
no set rule for restricting the distance between processes.
3. Using systematic questions to look for all possible sources of variance in each operation. (To
make the review process simpler, the HAZOP model for query is created using keywords.)
4. Each negative effect induced by each of the previously described deviations is scored.
5. Determination of corrective measures for any deviations that occur.
The use of two classes of keywords in the HAZOP protocol appears to be systematic in emphasizing
questions.
 The Most Important Keywords
All terms relating to a process' state or parameter, such as flow, strain, temperature, viscosity,
corrosion, erosion, level, density, relief, composition, addition, and reaction
134 | P a g e
 Supplementary Keywords
When all terms are combined with primary keywords, the likelihood of variance that may
occur is shown, such as no, more, less, reverse, and as well as. Table shows the HAZOP analysis
for methanol-based olefin processing.
135 | P a g e
Table 9.1: HAZOP analysis

Equipment/
Equipment
Operation Parameter Guideword Possible Causes Consequences Action Required Safeguards
Code
Unit
Temperature
The stream controlling and
Production does not
Low temperature is monitoring the
run well
too small performance of
heat exchangers Temperature
Pipes - Temperature
Temperature Control
Production does not
The stream controlling by
run well and labours
High temperature is install the
are possible to get
too high insulator outside
injured
of pipes
Pressure drop in
The reaction does Pressure
pipe before
not go well since the controlling by Pressure
MTO Reactor R - 101 A/B Pressure Low entering
optimum condition install the safety Control
methanol
is not maintained valve
sythesis reactor
136 | P a g e
Equipment/
Equipment Possible Action
Operation Parameter Guideword Consequences Safeguards
Code Causes Required
Unit
Pressure drop
Pressure
in pipe after
Explosion possibility controlling by Pressure
Pressure High entering
due to excess pressure install the safety Control
methanol
valve
synthesis
reactor
The reaction does not

MTO Reactor R - 101 The cooling
go well since the
Low water stream is
optimum condition is
too high Temperature
not maintained
controlling by Temperature
Temperature
install the safety Control
valve
The cooling
Explosion possibility
High water stream is
due to excess pressure
too low
137 | P a g e

Equipment/
Equipment Possible
Operation Parameter Guideword Consequences Action Required Safeguards
Code Causes
Unit
The water
Low stream outlet Level controlling by
is too high Mechanical
install the safety
Level Floating
The water valve inwater outlet
Control
High stream stream
outlet is too Separation
Water
V-101 low process doesn't
Separator
work well
The cooling
Low water stream Temperature
is too high controlling by install Temperature
Temperature
The cooling the safety valve in Control
High water stream cooler stream
is too low
138 | P a g e
Equipment/
Equipment Possible
Code Causes
Unit
The cold Heat exchanger
E-101 Low stream is to duty will be
Temperature
low excessive
Heat controlling by Temperature
E-102 Temperature
Exchanger The cold Heat exchanger install the input and Control
High stream is too duty will be output valve
low overloaded
The liquid
level inside Liquid will carry
Low Level Control
the column is out with the vapor Level and pressure
Distillation too high controlling by
V-102 Pressure
Column The liquid install the output
level inside Fire and/or valve Pressure
High
the column is explosion Control
too low
139 | P a g e
Equipment/
Equipment Possible
Code Causes
Unit
The ethylene The condenser will
outlet stream have high pressure due
Low
flowrate is to to no liquid inside the
Level controlling
high column
by install the safety Level
Condenser V-103 Level
valve in condenser Control
The ethylene
Fire and/or explosion outlet stream
outlet stream
High due to leakage on the
flowrate is to
condenser column
low
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Chapter#09 Instrumentations and Control
9.2 Hazard Communication
Below is the hazard communication sign summary for harmful materials inour plant:
Table 9.6: Hazard communication
Hazard Communication
No. Material
Sign
1 Methanol
2 Propylene
3 Ethylene
4 Methane
5 Ethane
6 Propane
7 Nitrogen
9.3 Main Hazard in Plant
Methanol and ethylene produced by the facility, as well as hydrogen, carbon monoxide,
and carbon dioxide, are among the chemicals used in the plant, none of which pose a major
occupational or environmental threat. Such possible occupational emergencies include
explosions, flooding, and power outages.
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Natural or fabricated disasters and medical emergencies. The hazard of each chemical such as:
 Methanol is a highly flammable liquid. In the event of skin touch, it is slightly

dangerous (sensitizer). The drug may harm Blood, kidneys, liver, brain, peripheral
nervous system, upper respiratory tract, skin, central nervous system (CNS), and optic
nerve.
 Ethylene is a flammable and explosive gas. You can feel dizzy, lightheaded, or pass out
if you are exposed to the gas. Ethylene in liquid form can induce frostbite. Suffocation
can be caused by ethylene. In a confined space, excessive concentrations in the air can
reduce the amount of oxygen available. The health consequences of Ethylene
contamination are much less severe than the chance of fire and explosion.
 Propylene gas is extremely flammable and poses a serious fire danger. Over the flash
point, vapour/air mixtures are explosive. The vapour has a higher density than air.
Vapours or gases will ignite at a distance and then flash back. Flow or agitation can
cause electrostatic discharges, which can result in combustion or explosion.
9.4 Personal Protection Equipment
To ensure workers safety in the plant, equipment (PPE) that should be wore by
labourer, such as such as several personal protections:
Table 9.7: PPE
Equipment Function Picture

Eye Protection
Employees can come into contact with a variety of hazards that endanger their eyes and faces.
If workers are exposed to eye or face dangers such as flying particles, molten metal, liquid
substances, acids or caustic liquids, chemical gases or vapours, or potentially contaminated
objects, OSHA allows employers to have adequate eye or face protection.
material or light radiation that may be toxic.
Face shield that fully covers the eyes, eye
sockets, and the facial region directly
around the eyes and provides impact, mud,
Google
and splash protection.
Figure 9.1: Google

(Source: sksafetyproduct.com)
Face Protection
These clear plastic sheets cover the entire breadth of the employee's head, from the brows to below
the chin. Face masks, when used in conjunction with helmets or protective spectacles, can provide
extra impact protection.
142 | P a g e
Face masks guard against irritating dust
and possible splashes or sprays of toxic
Face shield substances, but they are ineffective against
impact risks.
Figure 9.2: Face Shield
Head Protection
Any protection policy must provide measures to protect staff from possible head trauma. A head
injury can leave an employee permanently disabled or even kill them. One of the simplest ways
to shield an employee's head from injuries is to wear a protective helmet or hardhat.
Employees can be protected from contact

Safety Helmet and intrusion risks, as well as electrical
shock and burn hazards, by wearing hard
hats... Figure 9.3: Safety Helmet
Table 9.8: PPE (cont’)

Foot and Leg Protection
Protective boots should be used by employees who are at risk of foot or leg trauma from
dropping or moving devices, as well as smashing or penetrating items. Employees who deal
around hot liquids, corrosive or toxic objects, or both, must wear safety clothing that covers
exposed body parts, such as their legs and feet. Non-conductive boots should be worn if an
employee's feet can be vulnerable to electrical hazards. In the other hand,
Static electricity exposure at work, on the other hand, can necessitate the use of conductive
footwear.
Impact-resistant toes and heat-resistant soles
shield the feet from hot work surfaces such
as those used in the roofing, pavement, and
hot metal industries. Some protective shoes
have metal insoles that guard against
puncture wounds. Electrically conductive
safety shoes are intended to avoid the build-
Safety shoes up of static energy in environments with the
potential for volatile atmospheres, whereas
nonconductive safety shoes are designed to
shield employees from occupational
electrical hazards..
Figure 9.4: Safety Shoes
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Hand and Arm Protection
Potential hazards include skin absorption of harmful substances, chemical or thermal burns,
electrical dangers, bruises, abrasions, cuts, punctures, fractures and amputations. Protective
equipment includes gloves, finger guards and arm coverings or elbow-length gloves.
Chemical-resistant gloves are constructed
from a variety of materials, including
Chemical and
rubber and plastic. The stronger the
Liquid
chemical tolerance, the thicker the glove
Resistant
material, however heavy gloves will hinder Figure 9.5: Chemical
Gloves Resistant Gloves
grip and flexibility, putting your life at
risk.
Table 9.9: PPE (cont')

Body Protector
Employees who are exposed to the risk of physical harm in some way that cannot be avoided by
engineering, operating practices, or institutional controls must wear adequate body protection when
doing their duties..
Some contaminants and physical risks are

covered by wearing a coverall. Check with
the garment manufacturer whether
Coverall
chemical or physical risks are present to
ensure that the substance chosen can have
protection against the particular danger.
Figure 9.6: Coverall
Apron protects the body from exposure to

Apron hazardous welding, against dry heat and
flames.
Figure 9.7: Apron for Welding
144 | P a g e
Cotton uniform protects the body from
Cotton uniform
exposure to hazardous electrostatic.
Figure 9.8: Cotton Uniform

forElectrostatic
Ear Protector
It can be difficult to determine whether or not workers need hearing safety. The shorter the
exposure period until hearing aid is needed, the louder the noise.
The ear plug protects the ears from too harsh

and distracting noises. Ear plugs may be
Ear Plug removable or reusable and must be installed
by a specialist. Recyclable
Figure 9.9: Ear Plug
Table 9.10: PPE (cont')

Where a perfect seal around the ear is needed,
earmuffs are used. Glasses, facial hair, long
hair, or facial gestures such as chewing can
Earmuffs reduce earmuffs’ defensive importance.
Figure 9.10: Earmuffs
Respiratory Protector
Respiratory safety equipment is particularly helpful in an emergency, such as when an employee
must assist another employee who has been injured, or when an employee must flee from
unexpected ambient air composition changes that threaten his life, or when an employee must repair
machinery or equipment that contains extremely high levels of pollutants.
Dust Masker Prevent inhalation of dust
Figure 9.11: Dust Masker
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Breathing Prevent inhalation of harmful inert and
Apparatus general gases
Figure 9.12: Breathing
Apparatus
Prevent inhalation of harmful chemical

Cartridge
gases
Figure 9.13: Cartridge
Fall Protector
Falls are one of the most frequent causes of serious accidents and fatalities at work. Employers
must set up the work environment so that workers do not slip off of elevated work tables, benches,
or down gaps in the floor or walls. Fall defence must be given at four feet in general industry
workplaces, five feet in shipyards, six feet in manufacturing, and eight feet in long shoring
operations, according to OSHA. In addition, regardless of the fall distance, OSHA demands that
fall safety be given while operating over hazardous equipment and machinery.
Prevent a fall from a high place or protect

Safety Belt from impact due to accidents while driving
in the plant.
Figure 9.14: Safety Belt
Prevent falling objects from high places

Safety Net
which is under construction
Figure 9.15: Safety Net
146 | P a g e
Chapter # 10
Environmental Impact Assessment
147 | P a g e
Chapter # 10 Environmental Impact Assessment
10.1 Environmental Impact Assessment
Every industry have waste from the process. Waste from the plant must be managed because it
can damaged the environment. To manage the waste of our plant, we have to identify it first.
Waste from our plant can be seen below:
 Waste Water
 Methanol
 Ethylene
 Propylene
 House Hold Waste
 Sludge
All of these wastes can be directly discarded, recycled, or used again to main process. We have
grouped all of the waste based on the type or phase. There are liquid waste, gas waste, and solid
waste.
1. Liquid Waste
Liquid waste of methanol to olefin plant is including waste water from production and
utility process and house hold waste from domestic water. Waste water from production and
utility process comes from dehydration reaction of methanol and utility activity in order to
cooling the process. For house hold waste water or domestic water comes from the activity in the
pantry and sanitation.
2. Gas waste
Gas waste of methanol to olefin plant is including ethylene, propylene, and methanol
that cannot be separated from water and carbon dioxide that produced from combustion reaction
in boiler. Ethylene, propylene, and methanol will be recovered in the stripping tower in the waste
water treatment unit and returned to the process. Meanwhile, CO2 from the boiler will going to
gas waste treatment to reduce the cointain of CO2
3. Solid Waste
Solid waste of methanol to olefin plant is sludges that produced from utility activities
and house hold activities. Sludges will separated from waste water in the air flotation unit and it
will burned in the incinerator.
10.2 Waste Treatment
Wastewater treatment process is used to reduce the emission gas (ethylene and propylene),
methanol, COD, and BOD in wastewater. Waste Water Treatment Unit is one of the alternative
processes that could be used for the efficient use of raw materials and minimize the amount of
waste that will be formed. Waste minimization is done by the recovery of gases, which still
contains ethylene and propylene.
Water treatment results that have met the required specifications to be cooling agent will
transferred to the utility plant. Then, wastewater from utility plant met wastewater from
148 | P a g e
Chapter # 10 Environmental Impact Assessment
household in the equalization tank. Wastewater from equalization tank will moved to the
neutralization tank. The function of neutralization tank is to reduce pH of caustic wastewater with
acid injection.
Sludge’s that produced from coagulation and flocculation tank transferred to air flotation unit to
separate sludge’s from wastewater. Then, sludge is burned in the incinerator at temperature
800oC – 900oC and wastewater transferred to aeration unit to reduce BOD and COD contain of
wastewater. If the specification met the regulation by government, wastewater transferred to final
check basin and go to the sea. This processing can reduce the volume of wastewater discharged
and minimize the amount of raw material production, which can also reduce production costs.
149 | P a g e
Chapter # 11 Process Simulation
Chapter # 11
Process simulation
150 | P a g e
11.1 MTO process simulation on aspen final report
++++++++++++++++++++++++++++++++++++++++
++++++++++++++++++++++++++++++++++++++++
++ ++
++ ASPEN PLUS CALCULATION REPORT ++
++ ++
++++++++++++++++++++++++++++++++++++++++
++++++++++++++++++++++++++++++++++++++++
ASPEN PLUS IS A TRADEMARK OF HOTLINE:

ASPEN TECHNOLOGY, INC. U.S.A. 888/996-7100
781/221-6400 EUROPE (44) 1189-226555
PLATFORM: WINDOWS MAY 20, 2021

VERSION: 36.0 Build 249 THURSDAY
INSTALLATION: 10:16:01 P.M.
151 | P a g e
ASPEN PLUS PLAT: WINDOWS VER: 36.0 05/20/2021 PAGE I
ASPEN PLUS (R) IS A PROPRIETARY PRODUCT OF ASPEN TECHNOLOGY, INC. (ASPENTECH), AND
MAY BE USED ONLY UNDER AGREEMENT WITH ASPENTECH. RESTRICTED RIGHTS LEGEND: USE,
REPRODUCTION, OR DISCLOSURE BY THE U.S. GOVERNMENT IS SUBJECT TO RESTRICTIONS SET
FORTH IN (i) FAR 52.227-14, Alt. III, (ii) FAR 52.227-19, (iii) DFARS 252.227-7013(c)(1)(ii), or (iv) THE
ACCOMPANYING LICENSE AGREEMENT, AS APPLICABLE. FOR PURPOSES OF THE FAR, THIS
SOFTWARE SHALL BE DEEMED TO BE "UNPUBLISHED" AND LICENSED WITH DISCLOSURE
PROHIBITIONS. CONTRACTOR/SUBCONTRACTOR: ASPEN TECHNOLOGY, INC. 20 CROSBY
DRIVE,BEDFORD, MA 01730.
TABLE OF CONTENTS
RUN CONTROL SECTION.................................... 1
RUN CONTROL INFORMATION........................... 1
FLOWSHEET SECTION...................................... 2
FLOWSHEET CONNECTIVITY BY STREAMS................. 2
FLOWSHEET CONNECTIVITY BY BLOCKS.................. 2
COMPUTATIONAL SEQUENCE............................ 2
OVERALL FLOWSHEET BALANCE......................... 2
PHYSICAL PROPERTIES SECTION............................ 3
COMPONENTS........................................ 3
U-O-S BLOCK SECTION.................................... 4
BLOCK: E-101 MODEL: HEATER.................... 4
BLOCK: E-102 MODEL: HEATER.................... 5
BLOCK: P-101 MODEL: PUMP...................... 6
BLOCK: REACTOR MODEL: RSTOIC.................... 6
BLOCK: S-101 MODEL: FLASH2.................... 8
BLOCK: T-101 MODEL: DSTWU..................... 9
STREAM SECTION......................................... 11
1 10 11 2 3....................................... 11
4 5 6 8........................................... 12
PROBLEM STATUS SECTION................................. 13

BLOCK STATUS...................................... 13
152 | P a g e
ASPEN PLUS PLAT: WINDOWS VER: 36.0 05/20/2021 PAGE 1
RUN CONTROL SECTION
RUN CONTROL INFORMATION

-----------------------
THIS COPY OF ASPEN PLUS LICENSED TO #
TYPE OF RUN: EDIT
INPUT FILE NAME: _3320lrx.inm
INPUT PROBLEM DATA FILE NAME : _3320lrx

OUTPUT PROBLEM DATA FILE NAME: _0919vuq
LOCATED IN:
PDF SIZE USED FOR INPUT TRANSLATION:

NUMBER OF FILE RECORDS (PSIZE) = 0
NUMBER OF IN-CORE RECORDS = 256
PSIZE NEEDED FOR SIMULATION = 1
CALLING PROGRAM NAME: apmain

LOCATED IN: C:\Program Files (x86)\AspenTech\Aspen Plus V10.0\Engine\\xeq
SIMULATION REQUESTED FOR ENTIRE FLOWSHEET
153 | P a g e
FLOWSHEET SECTION
FLOWSHEET CONNECTIVITY BY STREAMS
---------------------------------
STREAM SOURCE DEST STREAM SOURCE DEST

1 ---- P-101 2 P-101 E-101
3 E-101 REACTOR 4 REACTOR E-102
6 S-101 T-101 8 S-101 ----
10 T-101 ---- 11 T-101 ----
5 E-102 S-101
FLOWSHEET CONNECTIVITY BY BLOCKS

--------------------------------
BLOCK INLETS OUTLETS

P-101 1 2
E-101 2 3
REACTOR 3 4
S-101 5 68
T-101 6 10 11
E-102 4 5
COMPUTATIONAL SEQUENCE
----------------------
SEQUENCE USED WAS:

P-101 E-101 REACTOR E-102 S-101 T-101
OVERALL FLOWSHEET BALANCE

-------------------------
*** MASS AND ENERGY BALANCE ***

IN OUT GENERATION RELATIVE DIFF.
CONVENTIONAL COMPONENTS
(KMOL/HR )
ETHYLENE 0.00000 204.001 204.135 0.656563E-03
PROPENE 0.00000 204.013 204.135 0.598284E-03
WATER 0.00000 1021.19 1020.68 -0.502461E-03
METHANOL 1030.99 10.2989 -1020.68 0.105948E-04
TOTAL BALANCE
MOLE(KMOL/HR ) 1030.99 1439.50 408.270 -0.171022E-03
MASS(KG/HR ) 33035.0 33035.0 -0.440500E-15
ENTHALPY(CAL/SEC ) -0.165050E+08 -0.189522E+08 0.129124
*** CO2 EQUIVALENT SUMMARY ***

FEED STREAMS CO2E 0.00000 KG/HR
PRODUCT STREAMS CO2E 0.00000 KG/HR
NET STREAMS CO2E PRODUCTION 0.00000 KG/HR
UTILITIES CO2E PRODUCTION 0.00000 KG/HR
TOTAL CO2E PRODUCTION 0.00000 KG/HR
154 | P a g e
PHYSICAL PROPERTIES SECTION
COMPONENTS
----------
ID TYPE ALIAS NAME

ETHYLENE C C2H4 ETHYLENE
PROPENE C C3H6-2 PROPYLENE
WATER C H2O WATER
METHANOL C CH4O METHANOL
155 | P a g e
U-O-S BLOCK SECTION
BLOCK: E-101 MODEL: HEATER

------------------------------
INLET STREAM: 2
OUTLET STREAM: 3
PROPERTY OPTION SET: PENG-ROB STANDARD PR EQUATION OF STATE

IN OUT RELATIVE DIFF.
TOTAL BALANCE
MOLE(KMOL/HR ) 1030.99 1030.99 0.00000
MASS(KG/HR ) 33035.0 33035.0 0.00000
ENTHALPY(CAL/SEC ) -0.164930E+08 -0.123624E+08 -0.250443

*** INPUT DATA ***

TWO PHASE TP FLASH
SPECIFIED TEMPERATURE C 400.000
SPECIFIED PRESSURE BAR 40.0000
MAXIMUM NO. ITERATIONS 30
CONVERGENCE TOLERANCE 0.000100000
*** RESULTS ***

OUTLET TEMPERATURE C 400.00
OUTLET PRESSURE BAR 40.000
HEAT DUTY CAL/SEC 0.41306E+07
OUTLET VAPOR FRACTION 1.0000
V-L PHASE EQUILIBRIUM :
COMP F(I) X(I) Y(I) K(I)

METHANOL 1.0000 1.0000 1.0000 MISSING
156 | P a g e
U-O-S BLOCK SECTION
BLOCK: E-102 MODEL: HEATER

------------------------------
INLET STREAM: 4
OUTLET STREAM: 5

TOTAL BALANCE
MOLE(KMOL/HR ) 1439.26 1439.50 -0.171022E-03
MASS(KG/HR ) 33035.0 33035.0 0.00000

*** INPUT DATA ***

TWO PHASE TP FLASH
SPECIFIED TEMPERATURE CHANGE C 40.0000
*** RESULTS ***

HEAT DUTY CAL/SEC 0.30371E+06
OUTLET VAPOR FRACTION 1.0000
PRESSURE-DROP CORRELATION PARAMETER 34643.

ETHYLENE 0.14183 0.14183 0.14183 MISSING
PROPENE 0.14183 0.14183 0.14183 MISSING
WATER 0.70917 0.70917 0.70917 MISSING
METHANOL 0.71633E-02 0.71633E-02 0.71633E-02 MISSING
157 | P a g e
U-O-S BLOCK SECTION
BLOCK: P-101 MODEL: PUMP

----------------------------
INLET STREAM: 1
OUTLET STREAM: 2

TOTAL BALANCE
MOLE(KMOL/HR ) 1030.99 1030.99 0.00000
MASS(KG/HR ) 33035.0 33035.0 0.00000
ENTHALPY(CAL/SEC ) -0.165050E+08 -0.164930E+08 -0.725716E-03

*** INPUT DATA ***

PRESSURE CHANGE BAR 39.0000
PUMP EFFICIENCY 0.90000
DRIVER EFFICIENCY 1.00000
FLASH SPECIFICATIONS:
LIQUID PHASE CALCULATION
NO FLASH PERFORMED
MAXIMUM NUMBER OF ITERATIONS 30
TOLERANCE 0.000100000
*** RESULTS ***

VOLUMETRIC FLOW RATE L/MIN 694.374
PRESSURE CHANGE BAR 39.0000
NPSH AVAILABLE M-KGF/KG 10.7932
FLUID POWER KW 45.1343
BRAKE POWER KW 50.1492
ELECTRICITY KW 50.1492
PUMP EFFICIENCY USED 0.90000
NET WORK REQUIRED KW 50.1492
HEAD DEVELOPED M-KGF/KG 501.550
BLOCK: REACTOR MODEL: RSTOIC

------------------------------
INLET STREAM: 3
OUTLET STREAM: 4
158 | P a g e
U-O-S BLOCK SECTION
BLOCK: REACTOR MODEL: RSTOIC (CONTINUED)

IN OUT GENERATION RELATIVE DIFF.
TOTAL BALANCE
MOLE(KMOL/HR ) 1030.99 1439.26 408.270 0.00000
MASS(KG/HR ) 33035.0 33035.0 0.00000

*** INPUT DATA ***

STOICHIOMETRY MATRIX:
REACTION # 1:
SUBSTREAM MIXED :
ETHYLENE 1.00 PROPENE 1.00 WATER 5.00 METHANOL -5.00
REACTION CONVERSION SPECS: NUMBER= 1

REACTION # 1:
SUBSTREAM:MIXED KEY COMP:METHANOL CONV FRAC: 0.9900
SELECTIVITY SPECIFICATIONS:
NUMBER COMPONENT SUBSTREAM REF COMP REF SUBS

(PRODUCT) (REACTANT)
1 ETHYLENE MIXED METHANOL MIXED
2 PROPENE MIXED METHANOL MIXED
3 WATER MIXED METHANOL MIXED
TWO PHASE TP FLASH

SIMULTANEOUS REACTIONS
GENERATE COMBUSTION REACTIONS FOR FEED SPECIES NO
159 | P a g e
U-O-S BLOCK SECTION
BLOCK: REACTOR MODEL: RSTOIC (CONTINUED)
*** RESULTS ***

HEAT DUTY CAL/SEC -0.15799E+07
VAPOR FRACTION 1.0000
REACTION EXTENTS:
REACTION REACTION
NUMBER EXTENT
KMOL/HR
1 204.14
SELECTIVITY RESULTS:
NUMBER COMPONENT SUBSTREAM REF COMP REF SUBS SELECTIVITY

(PRODUCT) (REACTANT)
1 ETHYLENE MIXED METHANOL MIXED 1.0000
2 PROPENE MIXED METHANOL MIXED 1.0000
3 WATER MIXED METHANOL MIXED 1.0000

ETHYLENE 0.14183 0.85081E-01 0.14183 9.2527
PROPENE 0.14183 0.10440 0.14183 7.5401
WATER 0.70917 0.80290 0.70917 4.9024
METHANOL 0.71633E-02 0.76166E-02 0.71633E-02 5.2200
BLOCK: S-101 MODEL: FLASH2

------------------------------
INLET STREAM: 5
OUTLET VAPOR STREAM: 6
OUTLET LIQUID STREAM: 8

160 | P a g e
U-O-S BLOCK SECTION
BLOCK: S-101 MODEL: FLASH2 (CONTINUED)

TOTAL BALANCE
MOLE(KMOL/HR ) 1439.50 1439.50 0.00000
MASS(KG/HR ) 33035.0 33035.0 -0.220250E-15
ENTHALPY(CAL/SEC ) -0.186693E+08 -0.186693E+08 0.199541E-15

*** INPUT DATA ***

TWO PHASE TP FLASH
*** RESULTS ***

HEAT DUTY CAL/SEC -0.42694E-08
VAPOR FRACTION 0.28468

ETHYLENE 0.14172 0.41845E-04 0.49770 11894.
PROPENE 0.14172 0.97745E-05 0.49781 50930.
WATER 0.70940 0.99034 0.35031E-02 0.35373E-02
METHANOL 0.71545E-02 0.96085E-02 0.98831E-03 0.10286
BLOCK: T-101 MODEL: DSTWU

-----------------------------
INLET STREAM: 6
CONDENSER OUTLET: 10
REBOILER OUTLET: 11

161 | P a g e
U-O-S BLOCK SECTION
BLOCK: T-101 MODEL: DSTWU (CONTINUED)

TOTAL BALANCE
MOLE(KMOL/HR ) 409.802 409.802 0.00000
MASS(KG/HR ) 14345.2 14345.2 -0.126801E-15
ENTHALPY(CAL/SEC ) 866636. 583798. 0.326364

*** INPUT DATA ***

HEAVY KEY COMPONENT PROPENE
RECOVERY FOR HEAVY KEY 0.100000
LIGHT KEY COMPONENT ETHYLENE
RECOVERY FOR LIGHT KEY 0.90000
TOP STAGE PRESSURE (BAR ) 19.0000
BOTTOM STAGE PRESSURE (BAR ) 19.0000
REFLUX RATIO -3.85000
DISTILLATE VAPOR FRACTION 0.0
*** RESULTS ***

DISTILLATE TEMP. (C ) -26.4474
BOTTOM TEMP. (C ) 34.4486
MINIMUM REFLUX RATIO 1.22610
ACTUAL REFLUX RATIO 4.72049
MINIMUM STAGES 3.46720
ACTUAL EQUILIBRIUM STAGES 4.38310
NUMBER OF ACTUAL STAGES ABOVE FEED 3.19522
DIST. VS FEED 0.49771
CONDENSER COOLING REQUIRED (CAL/SEC ) 830,350.
NET CONDENSER DUTY (CAL/SEC ) -830,350.
REBOILER HEATING REQUIRED (CAL/SEC ) 547,511.
NET REBOILER DUTY (CAL/SEC ) 547,511.
162 | P a g e
STREAM SECTION
1 10 11 2 3
-----------
STREAM ID 1 10 11 2 3
FROM : ---- T-101 T-101 P-101 E-101
TO : P-101 ---- ---- E-101 REACTOR
SUBSTREAM: MIXED
PHASE: LIQUID LIQUID LIQUID LIQUID VAPOR
COMPONENTS: KMOL/HR
ETHYLENE 0.0 183.5623 20.3958 0.0 0.0
PROPENE 0.0 20.4003 183.6027 0.0 0.0
WATER 0.0 1.1871-03 1.4344 0.0 0.0
METHANOL 1030.9854 1.4960-05 0.4050 1030.9854 1030.9854
TOTAL FLOW:
KMOL/HR 1030.9854 203.9638 205.8379 1030.9854 1030.9854
KG/HR 3.3035+04 6008.0916 8337.1161 3.3035+04 3.3035+04
L/MIN 694.3737 219.2951 290.9100 694.8297 2.2631+04
STATE VARIABLES:
TEMP C 25.0000 -26.4474 34.4486 25.4375 400.0000
PRES BAR 1.0000 19.0000 19.0000 40.0000 40.0000
VFRAC 0.0 0.0 0.0 0.0 1.0000
LFRAC 1.0000 1.0000 1.0000 1.0000 0.0
SFRAC 0.0 0.0 0.0 0.0 0.0
ENTHALPY:
CAL/MOL -5.7632+04 8536.1612 1751.8829 -5.7590+04 -4.3167+04
CAL/GM -1798.6358 289.7871 43.2528 -1797.3305 -1347.2019
CAL/SEC -1.6505+07 4.8363+05 1.0017+05 -1.6493+07 -1.2362+07
ENTROPY:
CAL/MOL-K -59.6046 -32.3280 -46.8213 -59.6131 -27.7387
CAL/GM-K -1.8602 -1.0975 -1.1560 -1.8605 -0.8657
DENSITY:
MOL/CC 2.4746-02 1.5501-02 1.1793-02 2.4730-02 7.5927-04
GM/CC 0.7929 0.4566 0.4776 0.7924 2.4329-02
AVG MW 32.0422 29.4567 40.5033 32.0422 32.0422
163 | P a g e
STREAM SECTION
4568
-------
STREAM ID 4 5 6 8
FROM : REACTOR E-102 S-101 S-101
TO : E-102 S-101 T-101 ----
SUBSTREAM: MIXED
PHASE: VAPOR MIXED VAPOR LIQUID
COMPONENTS: KMOL/HR
ETHYLENE 204.1351 204.0012 203.9581 4.3088-02
PROPENE 204.1351 204.0131 204.0030 1.0065-02
WATER 1020.6756 1021.1887 1.4356 1019.7531
METHANOL 10.3099 10.2989 0.4050 9.8939
TOTAL FLOW:
KMOL/HR 1439.2557 1439.5018 409.8017 1029.7002
KG/HR 3.3035+04 3.3035+04 1.4345+04 1.8690+04
L/MIN 3.2378+04 2686.0828 2366.4854 319.5974
STATE VARIABLES:
TEMP C 400.0000 40.0000 40.0000 40.0000
PRES BAR 39.5000 38.0000 38.0000 38.0000
VFRAC 1.0000 0.2847 1.0000 0.0
LFRAC 0.0 0.7153 0.0 1.0000
SFRAC 0.0 0.0 0.0 0.0
ENTHALPY:
CAL/MOL -3.4874+04 -4.6689+04 7613.1727 -6.8301+04
CAL/GM -1519.3681 -2034.4948 217.4866 -3762.9860
CAL/SEC -1.3942+07 -1.8669+07 8.6664+05 -1.9536+07
ENTROPY:
CAL/MOL-K -11.3179 -36.8561 -30.8230 -39.2571
CAL/GM-K -0.4931 -1.6060 -0.8805 -2.1628
DENSITY:
MOL/CC 7.4085-04 8.9319-03 2.8861-03 5.3698-02
GM/CC 1.7005-02 0.2050 0.1010 0.9747
AVG MW 22.9528 22.9489 35.0052 18.1507
164 | P a g e
PROBLEM STATUS SECTION
BLOCK STATUS
------------
****************************************************************************
* *
* Calculations were completed normally *
* *
* All Unit Operation blocks were completed normally *
* *
* All streams were flashed normally *
* *
****************************************************************************
Figure 11.1: step one components selection
165 | P a g e
Figure 11.2: property method selection
Figure 11.3: step 3 simulation, process flow diagram
Figure 56: step 3 simulation, process flow diagram
Figure 11.4: heat exchanger 1 summary
166 | P a g e
Figure 11.5: heat exchanger 2 summary
Figure 58: heat exchanger 2 summary
Figure 11.6: pump (101) summary
Figure 59: pump (101) summary
Figure 11.7: Reactor (101) summary
167 | P a g e
Figure 11.8: separator (S-101) summary
Figure 11.9: distillation column (T-101) summary
Figure 11.10: overall calculations status
168 | P a g e
Bibliography
 Gael D. Ulrich P. T. Vasudeva “A Guide to Chemical Engineering Process Design and

Economics” 2nd ed, Process publishing, 1993
 Coulson and Richardson's Chemical Engineering Volume 6 - Chemical Engineering
Design (2nd Edition)
 Elements of Chemical Reaction Engineering, H. Scott Fogler, 4th Edition
 Chemical engineering design by Coulson and Richardson’s volume 6, 4th edition
 Plant design and economics for chemical engineers by Timmerhaus 5th edition
 . Rules of Thumb for Chemical Engineers by Carl R. Branan
 Applied Process Design for Chemical and Petrochemical Plants, Volume 2, By Ernest E.
Ludwig
 Process Heat Transfer by D.Q Kern
 American Institute of Chemical Engineers, Design Institute for Physical Property Data,
(DIPPR File), University Park, Pa., 1989. For other listings of properties, see Beilsteins
Handbuch der Organischen Chemie, Springer-Verlag, Berlin, Vol. 1 and supplement; and
J. A. Riddick, W. B. Bunger, and T. K. Sakano, "Organic Solvents, Physical Properties,
and Methods of Purification," in Techniques of Organic Chemistry, Vol. 2, John Wiley &
Sons, Inc., New York, 1986.
 R. C. Weast and J. G. Grasselli, eds., Handbook of Data on Organic Compounds, 2nd ed.,
Vol. 6, CRC Press, Inc., Boca Raton, Fla., Compound no. 21433, p. 3731.
 Fire Hazard Properties of Flammable Liquids, Gases, and Volatile Solids, Report 325M-
1984, National Fire Codes, Vol. 8, National Fire Protection Association, Batterymarch
Park, Quincy, Mass.
 R. A. Smiley, "Nitriles" in M. Grayson, ed., Kirk-Othmer Encyclopedia of Chemical
Technology, 3rd ed., Vol. 15, Wiley-Interscience, New York, 1981, p. 901.
 U.S. Pat. 2,827,494 (Mar. 18, 1958), J. H. Brown, Jr., and N. B. Lorette (to The Dow
Chemical Company); Chem. Abstr. 52, 14655i (1958). U.S. Pat. 2,827,495 (March 18,
1958), G. C. Bond and L. A. Klar (to The Dow Chemical Company); Chem. Abstr. 52,
14656a (1958). N. B. Lorette, W. L. Howard, and J. H. Brown, Jr., J. Org. Chem. 24, 1731
(1959); Chem. Abstr. 55, 12275g (1961).
 Distillation Control: An Engineering Perspective By Cecil L. Smith
 Pradeep B. Deshpande, “Distillation Dynamics and Control” Creative Publishers Inc.
New York.
 Henry Z. Kister, “Distillation Design”, Mcgraw Hill Inc.
 Carl Branan, “Rules of Thumb for Chemical Engineers” ,Gulf Professional Publishing
 Unit operation of chemical engineering by Warren Lee McCabe, Julian Cleveland Smith,
Peter Harriott 5th edition.
169 | P a g e
Important website References:
1. https://www.tlv.com/global/TI/calculator/steam-table-pressure.html
2. www.che.cemr.wvu.edu/publications/projects/acetone/acetone-a.PDF
3. http://www.owlnet.rice.edu/~ceng403/gr1998/acetone.html
4. http://www.scribd.com/doc/30134032/Isopropyl-Alcohol
5. www.annualreviews.org/doi/pdf/.../annurev.matsci.35.100303.12073
6. www.jbrwww.che.wisc.edu/home/jbraw/chemreacfun/.../slides-masswrxn.p
7. https://www.trademap.org/Index.aspx
8. https://irpc.listedcompany.com/misc/PRESN/20150515-propylene-market-analyst.pdf
170 | P a g e

Production of Olefins From Methanol

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Production of Olefins From Methanol

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Production of Olefins from Methanol (MTO) by Using

Mr. Muhammad Umar Mushtaq

Sami Ullah UW-17-Ch.E-BSc-021

Department of Chemical Engineering

This report is submitted to the department of Chemical Engineering, Wah Engineering

Department of Chemical Engineering

In this project, I would like to express my gratitude to the members of my team.

Table-1.1: Physical, chemical and thermodynamic properties of ethylene ……………..….... 6

1.8 Pakistan propylene import and export data.................................................................. 18

2.1.1.2 Syngas to methanol …………………………………………………………….25

1.1 Project Background

1.1.1 The Project's Objective

Our MTO plant's main objective are to:

 Manufacture ethylene and propylene without using petroleum as a feedstock.

1.2 Project Analysis

1.2.1 Raw material & Catalyst analysis

Figure 1.1: comparison between SAPO-32 and ZSM-5

1.2.2 Product Analysis

Figure 1.2: Block diagram of MTO

1.3 Introduction of Propylene

The most popular olefins conversion technology is methanol-to-olefins/methanol-to-propene

1.3.1 Environmental safety

1.3.1.1 Overall reaction

Δ Hr 673 K = -1431 kj/kmol

1.3.2 Industrial applications of propylene [7]

Uses of propylene in different products

films (food pakaging)

Figure 1.3: Uses of propylene over the world

1.4 Introduction of Ethylene

Table-1.1: Physical, chemical and thermodynamic properties of ethylene [2]

Critical temperature 282.35 K

Critical density 214.2 kg/m3

Melting point 104 K

Vapor density 0.98 (Air = 1)

Corrosivity Non corrosive gas

Heat of vaporization 13.53 kJ/mol

Heat of formation 52.47(kJ/mol)

1.4.1 Industrial process

1.4.2 Industrial applications [3]

 A wide range of businesses and applications, including, uses ethylene: Synthetic

1.4.3 World Wide Production of Ethylene [4]

17.065 million tons of production of ethylene in 2019

Asia North America

Figure 1.4: Production of ethylene in 2019

1.5 Shipping of the products [2]

1.5.2 Prerequisite for Seafarers

Figure 1.5: Seafarers-Maritime crane operator

1.6 World production and consumption of propylene [7]

1.6.1 Consumption of propylene in 2019

WORLD CONSUMPTION OF PROPYLENE IN 2019

Rest of the world

Figure 1.6: World consumption of propylene in 2019

Propylene demand 2005 to 2019

propylene demand, million metric tpy

Figure 1.7: Propylene in the world

1.6.2 Propylene market

1.6.3 Propylene recovery

Figure 1.8: China propylene consumption

America Propylene Outlook

1.7 World production and consumption of Ethylene

Figure 1.10: Coal Chemical Production Chain

1.7.1 Coal projects China [8]

 Tight government control