Download - PROPYLEN OXIDE CO-PRODUCTION WITH t-BUTYL ALCOHOL BY THE TEXACO HYDROPEROXIDATION PROCESS
PROPYLEN OXIDE CO-PRODUCTION WITH t-BUTYL ALCOHOL BY THE TEXACO HYDROPEROXIDATION
PROCESS
Designer: Sultan Alharbi
Supervised by:Prof.M.Fahim
ENG: Yousif Ismail
Outline :
1 -Heat exchanger ( heater , cooler )
2 -Distillation column
3 -Reactor
4 -Pump design
5 -Compressor
Heat Exchanger Design
For E-104:
- To increase the temperature
For E-103:
- To decrease the temperature
Objectives:
Assumptions: - Use shell and tube heat exchanger.
- Assume the refrigent inter in tube side in cooler and steam in heater
The value of the overall heat transfer coefficient was assumed to be:
- For (E-103) = 300 w/m^2C. - For (E-104) = 900 w/m^2C. - For E-103 refrigent inlet temperature (t1) = -10 Crefrigent outlet temperature (t2) = 35 C -For E-104
Steam inlet temperature (t1) = 200 C
Steam outlet temperature (t2) = 70 C
Main design procedures: Main design procedure:Calculate the duty or heat load.
Where,m: mass flow rate, kg/hrCp: specific heat, kJ/kg°C
∆T: temperature difference, °CCollect physical properties.
coldphotp TmCTmCQ
• -Calculate Log mean Temperature
Where,
Tm = Ft Tlm.
∆Tlm : log mean temperature difference.
T1 : inlet shell side fluid temperature.
T2 : outlet shell side temperature fluid temperature.
t1 : inlet tube side fluid temperature .
t2 : outlet tube side fluid temperature.
-Assume U : overall heat transfer coefficient, W/m2oC
-Calculate heat transfer area required. mo TU
QA
12
21
1221
lntTtTtTtT
Tlm
- Calculate area of one tube, m2.
Where
-Outer diameter (do), (mm)
-Length of tube (L), (mm)
- Calculate number of tubes = provisional area / area of one tube
LdA o
- Calculate bundle diameter.
Where
- Outside diameter (mm).
- Number of tubes.
- K1 & n1 are constant.
1
1
10 )( nt
b K
NdD
- Calculate shell diameter.
Ds = Db + Bundle diametrical clearance
- Find tube side heat transfer coefficient hi, W/m2°C
- Find shell side heat transfer coefficient ho, W/m2°C
• Calculate U overall heat transfer coefficient using:
Where :
- Uo : overall coefficient based on outside area of the tube ,w/m^2.C - ho : outside fluid film coefficient, w/m^2.C, from Table (12.2) - hi : inside fluid film coefficient ,w/m^2, from Table (12.2) - hod : outside dirt coefficient (fouling factor) ,w/m^2.C - hid : inside dirt coefficient (fouling factor),w/m^2.C - kw : thermal conductivity of the wall material w/m.Cs for cupronickel - di : tube inside diameter m - do : tube outside diameter m
SdSw
i
oo
i
o
idio hhk
d
dd
d
d
hhU
11
2
ln111
-Calculate tube and shell side pressure drop.
- Calculate Shell thickness.
Where
- t: shell thickness (in).
- P: internal pressure (psig).
- ri: internal radius of shell (in).
- EJ: efficiency of joints.
- S: working stress (psi).
- Cc: allowance for corrosion (in).
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Results Equipment NameHerter
ObjectiveTo increase temperature of isobutene stream
Equipment NumberE-104
DesignerSultan Al-Harbi
TypeShell And Tube
LocationBefore recycle
Material of ConstructionCarbon Steel
InsulationGlass wool
Cost ($)44000
Operating Condition
Shell Side
Inlet temperature (oC)3.1Outlet temperature (oC)134
Tube Side
Inlet temperature (oC)200Outlet temperature (oC)70
Number of Tube Rows2Number of Tubes241
Tube bundle Diameter (m)
0.472Shell Diameter (m)0.5307
Q total (KW)7912LMTD (oC)53.157
U (Btu/hr. oF . ft2)900.1Heat Exchanger Area
(m2)68.96
Equipment NameCooler
ObjectiveTo decrease temperature of Isobutane stream
Equipment NumberE- 103
DesignerSultan Al-Harbi
TypeShell And Tube
LocationBefore separator V-102
Material of ConstructionCarbon Steel
InsulationGlass wool
Cost ($)90000
Operating Condition
Shell Side
Inlet temperature (oC)116.8Outlet temperature (oC)1.39
Tube Side
Inlet temperature (oC)-10Outlet temperature (oC)35
Number of Tube Rows2Number of Tubes1020
Tube bundle Diameter (m)
0.7113301
Shell Diameter (m)0.77533
Q total (KW)7540LMTD (oC)30.36941
1
U (Btu/hr. oF . ft2)299.864Heat Exchanger Area (m2)391.125
Distillation ColumnT-(102) design
Objective :To separate TBHP from t-ButanolTo separate TBHP from t-Butanol
Assumptions
1 .Tray column.2 .Sieve plate.
3 .Material of the distillation is carbon steel.4 .Plate spacing= 0.6 m
5 .Efficiency = 50%6 .Flooding % = 85%
7 .Weir height = 50 mm8 .Hole diameter = 5 mm9 .Plate thickness =5 mm
1 (Actual number of stages = (hysys number stages/η)
2 (FLV= ( Lw / Vw)*( ρv / ρL)^.5
Where-: Lw: liquid flow rate
ρL: liquid densityVw: vapor flow rate,ρv :vapor densityFLv: liquid-vapor flow factor
3 (Find K1 (Top) & K1 (Bottom) from fig .
K1correction = (σ/0.02)^.2*K1 Where: -
σ: Surface tension
Main design procedures:
4( Uf (bottom)= K1 ((ρL- ρv)/ ρv) 0.5 Uf (Top) = K2 ((ρL- ρv)/ ρv) 0.5
Where:
Uf : flooding vapor velocity K1: constant obtained from figure
5 (uv = uf * x
Where-: Uv : maximum velocity
X : percentage of flooding at max flow
6 (Max flow-rate = (Lw*Mwt / ρL*3600)
Where -: Max.: Maximum Volumetric Flow rate .
Lw: liquid flow rate ρL: liquid density
M.wt: molecular weight
7 (Anet = Mmax/uv
Where-: Anet: Net area required
8 (Ad = An/(1-y*10^-2) Where: Ad: down comer area
9 (D =(Ad*4/(3.14))^.5
Where-: D: column diameter
10 (H= (Tray spacing * actual NO. stage ) + D
Where-: H: Column height
11 (MVL =(Lbottom*Mwt)/(3600* ρL)
Where-: MVL: maximum volumetric liquid rate
12 (Ac = (3.14/4)*D^2
Ad = 0.12Ac An = Ac-Ad
Aa = Ac-2Ad Ah take %10 Aa as first trial = %10*Aa
Where- :
Ac: column area
Aa: active area Ah: hole area
Ad= Downcomer area
13( max Lw = Lw*Mwt/3600
min Lw @ % turn down = %*max Lw
max how =750 (max Lw/ρL*wierlength)^(2/3)
min how =750 (min Lw/ ρL*wierlength)^(2/3)
actual minimum vapor = vapor rate min/Ah
Where-: max Lw: maximum liquid rate.
min Lw : minimum liquid rate.
14 (The actual min vapor velocity = vapor rate min/An
15 (uh = Vw max/Ah
hr = 12.5E+03/ ρL
Where-:
uh: maximum vapor velocity through holes
max.Vw: maximum volumetric flow rate
hd: dry plate drop
hr: Residual head
Aap= wier length*hap hdc= 166*(max liquid flowrate/ ρL*Aap)^2 hb= Minimum rate (hw + how) + ht + hdc
Where:- Aap: Area under arpon hdc: head losses in the down comer
17)tr =
Where :
tr : residence time , should be > 3 s
flowmassliquid
ρhA Lbδ
18) Percent flooding =
f
v
u
u
Where :- uv: vapor velocity, uf: flooding vapor velocity
19 (Number of holes Area of one hole = (π/4)*(hole diameter^2)
Total number of holes = Ah / area of one hole Holes on one plate = total Number of holes/number of stages
20 (Area of condenser& reboiler = Q/(U*∆T)
21 (Thickness = [(ri P)/(Ej S-0.6P)]+Cc
Where -: ri = Inside radius of the shell
P =Maximum allowable internal pressure
S = Maximum allowable working stress
EJ = Efficiency of joints Cc = Allowance for corrosion
Equipment NameDistillation column
ObjectiveTo separate TBHP from t-Butanol
Equipment NumberC-101
DesignerSultan Al-Harbi
TypePlate column
LocationAfter reactor 101
Material of ConstructionCarbon steel
InsulationGlass wool
Cost ($)515350
Column Flow Rates
Feed (kgmole/hr)897Recycle (kgmole/hr)-
Distillate (kgmole/hr)1059Bottoms (kgmole/hr)1378
Dimensions
Diameter (m)2.6039Height (m)41.6039
Number of Trays65Reflux Ratio1
Tray Spacing0.6Type of traySieve
single pass
Number of Holes20608Number of Caps/Holes-
Cost
Vessel164200Trays68250
Condenser Unit75400Reboiler207500
Reactor Design
Objectives:
- R-101: To produce TBHP from Isobutane
and oxygen.
)CH3 (3 CH + O2 → (CH3)3COOH
-The limiting reactant is (CH3) 3 CH in the R-101 reactor.
-The conversion equal to 0.24 in the R-101 reactor
Assumptions:
Main design procedures:
1.Find Volume:
V=(Fao-Fa)/-ra = (Fao-Fa)/kCao(1-X)
Where Fao : inlet mass flow Fa : outlt mass flow
K : kinetic rate Cao : density*Fao/total mass
flow rate X : conversion
2. Find diameter of reactor
Volume = PI * (D/2)^2 * H = PI * D^3
Where H = 4D
D = (V/PI)^1/3
3. Calculate the height of reactor:
Height of reactor (H) = 4 * Diameter
Total height of reactor = 0.5 + 0.5 + H+ 2 (D/2)
4. Calculate the thickness
Where,
t is thickness in inch
P is internal pressure in psig,
ri is the radius of the reactor, in,
S is the stress value of carbon steel (S=13700 psia),
Ej is the joint efficiency (Ej=0.85 for spot examined
welding),
Cc is the corrosion allowance (Cc=1/8 in)
6. Calculate cost from www.matche.com
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6.0
Pr
Equipment NameReactor
ObjectiveProducing TBHP
Equipment NumberR-101
DesignerSultan Al-Harbi
TypeCSTR Reactor
LocationBefore distillation column C-101
Material of ConstructionCarbon steel
InsulationGlass Fiber
Operating Condition
Operating Temperature (oC)
134Volume of Reactor (m3)248
Operating Pressure (kpa)2114Reactor Height (m)18
Feed Flow Rate (Kgmole/h)
2535Reactor Diameter (m)4.5
Conversion (%)24Reactor Thickness (m)0.07
Cost ($)302900
Compressor Design
Objectives:
-To increase gases pressure.
Main design procedures: • 1.Calculate the compression factor (n) using the
following equation:
•
Where,
P1,2 : is the pressure of inlet and outlet respectively (psia)
T1,2 : is the temperature of the inlet and outlet respectively (R)
11 1
2 2
n
nP T
P T
2. Calculate the work done in Btu/lbmol by:
1 2( )
1
nR T TW
n
Where ,
R is the ratio of the specific heat capacities (Cp/Cv)
3. Calculate the horse power, Hp using the following equation:Hp=W*M
Where, M is the molar flow rate in lbmol/s
4 .Calculate the efficiency of the compressor using the following equation :
1
1
nnEp
KK
1.986p
p
MwCK
MwC
Where ,
Mw :is the molecular weight of the gas in the stream
CP :is the specific heat capacity (Btu/lb◦ F )
5. Calculate the cost of the compressor from www. Matche . com
Equipment NameCompressor
Equipment NumberK-100
ObjectiveTo compress feed sour gas
DesignerSultan Al-Harbi
TypeCentrifugal Compressor
Material of ConstructionCarbon steel
Cost ($)184000
Operating Condition
Feed flow rate (kg/hr) 52150
Inlet pressure (psia)14.7
outlet pressure (psia)306
Inlet temperature (Cº)25
Outlet temperature (Cº)134
Power ( hp)590.4
Efficiency (%) 75
Pump Design
Assumptions:Centrifugal pump.
Design procedures:
1.Calculate the flow rate
m= ρ *Q
2.Calculate the work shift
Ws = -ha * g
3.Assume efficiency ζ.
4.Calculate the Brake horse power
-) =Ws * m) / (ζ * 1000(
5.Calculate the diameter, d.
Where,∆P is the pressure difference between the inlet and outlet streams in kpa
Q: flow rate kg/sρ: the density of the fluid kg/m3μ: viscosity cpD: pipe diameter mm
84.4116.084.11013.4 dQEP
66 . .Calculate the cost of the compressor fromCalculate the cost of the compressor from www. Matche . com
Equipment NamePump
ObjectiveTo increase pressure of Isobutane stream
Equipment NumberP-101
DesignerSultan Al-Harbi
TypeCentrifugal pump
LocationBefore R-101
Material of ConstructionCast Iron
Insulation-
Cost ($)6600
Operating Condition
Inlet Temperature (oC)44Outlet Temperature (oC)45
Inlet Pressure (psia)689.48Outlet Pressure (psia)2117
Efficiency (%)62Power (KW)2697.75
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