Equipments Design presentation Done By: Amer M. Al-Najdi

Agenda: Distillation Absorber Heat Exchanger Cooler Air cooler Pump Compressor

Distillations What is distillation : Distillation is a method used to separate chemical compounds. It is based on the difference between a liquid mixture and the vapor formed from it. The composition difference of its products depends dissimilar of the volatilities or vapor pressure of the components of the liquid mixture. If such a dissimilar does not exist, then such a separation is not possible.

Distillation T-105 T-add T-105 T-add

Design calculations Assumptions  The total column efficiency (around 80%).  The tray spacing (0.5 or 0.65 m).  The flooding percentage (85%).  The down comer area.  The hole area is about (0.1 to 0.2) of the active area.  The weir height is about (40 to 100) mm.  The hole diameter is about 1 to 10 mm.  The plate thickness is about 10 to 30 mm.  The turn down percent is about 70 to 90 %.  The unperforated strip round plate edge is about 50 mm.  The wide calming zone is about 50 mm.

Calculation Procedure: Properties The actual number of trays Column diameter

Liquid flow pattern Provisional Plate design Checking Weeping

Calculation Procedure Down comer back up Residence time Entrainment

Perforated Area Number of holes Estimating thickness & cost

Distillation columnEquipment Name T-105Equipment Number Amer Al-NajdiDesigner Tray columnType PO production Second section Location Carbon steelMaterial of Construction foam woolInsulation 4.73E+05$ Cost ($) (equipment + insulation) Column Flow Rates 2254Recycle (kgmole/hr)716.1Feed (kgmole/hr) 351.2Bottoms (kgmole/hr)292.4Distillate (kgmole/hr) Key Components EBperoxidHeavyPOLight Dimensions 28.55Height (m)5.2999Diameter (m) 3.2Reflux Ratio59Number of Trays Sieve trayType of tray0.45Tray Spacing Number of Caps/Holes Number of Holes Cost( $) 4500Trays1.7x10 5 Vessel 2300Reboiler2350Condenser Unit

Distillation Column Distillation columnEquipment Name Purification of styreneObjective T-addEquipment Number Amer Al-NajdiDesigner Tray columnType Styrene production sectionLocation Carbon steelMaterial of Construction foam woolInsulation 2.07E+05$ Cost ($) (equipment + insulation) Column Flow Rates 5608Recycle (kgmole/hr)555.1Feed (kgmole/hr) Bottoms (kgmole/hr) Key Components ACPHeavystyreneLight Dimensions 9.2Height (m)5.4189Diameter (m) 5Reflux Ratio12Number of Trays Sieve trayType of tray0.6Tray Spacing Number of Caps/Holes Number of Holes Cost( $) 5500Trays1.2x10 5 Vessel 2100Reboiler4300Condenser Unit

stripper stripper is a mass transfer operation in which a soluble gaseous component is removed from a gas stream by dissolving in a liquid. stripper can be used to recover valuable gaseous components such as hydrocarbons or to remove unwanted gaseous components such as hydrogen sulfide from a steam. Liquid and recovered in a pure, concentrated from by distillation or stripping (desertion).

stripper Abs.(T-100)

- DESIGN PROCEDURES:  Specify the properties of outlets streams  Calculate the maximum liquid and vapor outlet flow rate.  FLV = ( LW/VW)*( ρv / ρL)^.  Choose tray spacing and then determine K1 and K2  Calculate correction factor for Bottom K1 and Top K1.  K1correction = (σ/0.02)*K1  Design for X% flooding at maximum flow rate for top and bottom part of distillation.  uf= K1 ((ρL- ρv)/ ρv) 0.5 (bottom)  uf= K2 ((ρL- ρv)/ ρv) 0.5(Top)  uv = uf*x  Calculate the maximum flow rates of liquid.  Max liquid flow-rate = (Lw*Mwt / ρL*3600)  Calculate Net area required. Anet = Mmax/uv  Take down comer area as %Y of the total column cross sectional area.  Ad = An/(1-y*10^-2)  Calculate the column diameter. D = Ad/(4/3.14).

Calculate the column height using the actual number of stage. Actual number of stages = (hysys number stages/η) Calculate column area, down comer area, active area, net area, hole area and weir length. H= (Tray spacing * actual NO. stage ) + D Calculate the actual min vapor velocity. MVL = (Lbottom*Mwt)/(3600* ρL) Calculate Back-up in down comer. Check residence time. tr = Percent flooding= Calculate number of holes. Area of one hole = (π/4)*(5E-03)2, m2 Total number of holes = Ah / 1.964E-05 Holes on one plate = total Number of holes/Area of one Calculate Thickness of the Absorber Thickness = [(ri P)/(Ej S-0.6P)]+Cc

Spec sheet stripper columnEquipment Name Recover EB from reactor gases & recycle it back Objective T-100Equipment Number Amer Al-NajdiDesigner Tray stripper Type EB oxidation section First section Location Carbon steelMaterial of Construction Foam woolInsulation 22.4E+05$ Cost ($) (equipment + insulation) Operating Condition 3028Feed Flow Rate (Kmole/hr)115Operating Temperature ( o C) 2.84x10 4 Steam Flow Rate (Kmole/hr)45Operating Pressure (psia) steamInert Type8744Feed Flow Rate (mole/s) 5Number of Beds4.81Diameter (m) 5.5Height of Bed/s (m)5.5Height (m) 2.84x10 4 Volume of Inert (m 3 ) Thickness (m)

Heat Exchanger What is Heat Exchanger ? Heat exchangers are the devises employed for transmitting heat from one fluid stream to another by indirect means. Therefore, there is a barrier which separates the fluids and permits heat to flow from the hotter to the colder stream without mixing of the streams.

Heat Exchanger E-108 propene Propene&PO

Calculation procedure Define the duty Collect together the fluid physical properties required Select a trail value for the overall coefficient, U. Calculate the mean temperature difference, ΔTm. Calculate the area required from Q=UAΔTm. Decide the exchanger layout. Calculate the individual coefficients. Calculate the overall coefficient and compare with the trail value calculated value differs significantly from the estimated value calculated for the estimated value and return to step f. Calculate the exchanger pressure

Calculations procedure and equations  heat Load:  Log mean temperature:

Heat transfer Area : Number of tubes

 Bundle and shell diameter : Tube side heat transfer coefficient Shell side heat transfer coefficient

Overall coefficient Tube Side pressure Drop  Shell side pressure drop

Estimating thickness :

Spec sheet Heat exchangerEquipment Name Decrease Temperature of liquid effluent of CRV-101 Increase Temperature of recycled propylene Objective E-108Equipment Number Amer Al-NajdiDesigner Shell and tubeType PO production sectionLocation Carbon steelMaterial of Construction Foam glassInsulation 1.08E+04 $ Cost ($) (equipment + insulation) Operating Condition Shell Side 70.17Outlet temperature ( o C)57.84 Inlet temperature ( o C ) Tube Side 105Outlet temperature ( o C)115Inlet temperature ( o C) 167Number of Tubes4Number of Tube Rows 2.687Shell Diameter (m)2.599Tube bundle Diameter (m) LMTD (C) 5.27E+05 Q total (W) 78Heat Exchanger Area (m 2 )150 U ( W/m2.C )

coolers E-114 E-104-2

Spec sheet Heat exchangerEquipment Name Decrease Temperature of stream fed to T-103-2Objective E-104-2Equipment Number Amer Al-NajdiDesigner Shell and tubeType Styrene production sectionLocation Cooling waterUtility Carbon steelMaterial of Construction Foam woolInsulation 1.78E+04 Cost ($) (equipment+ insulation) Operating Condition Shell Side 50Outlet temperature ( o C)25Inlet temperature ( o C) Tube Side 106Outlet temperature ( o C)120Inlet temperature ( o C) 1555Number of Tubes6Number of Tube Rows 3.94Shell Diameter (m)3.86Tube bundle Diameter (m) 74.61LMTD ( o C) 2.19E+05 Q total (W) Heat Exchanger Area (m 2 )23 U ( W/C.m 2 )

Spec sheet Heat exchangerEquipment Name Decrease Temperature of hydrogen feedObjective E-114Equipment Number Amer Al-NajdiDesigner Shell and tubeType Styrene production sectionLocation Cooling waterUtility Carbon steelMaterial of Construction Foam woolInsulation 3.35E+03 $ Cost ($) (equipment + insulation) Operating Condition Shell Side 50 Outlet temperature ( o C) 25Inlet temperature ( o C) Tube Side 149 Outlet temperature ( o C) 470.1Inlet temperature ( o C) 89Number of Tubes6Number of Tube Rows 1.297Shell Diameter (m)1.219Tube bundle Diameter (m) 237.8LMTD ( o C) 1.82E+05 Q total (W) 7.66 Heat Exchanger Area (m 2 ) 100 U ( W/C.m 2 )

Air cooler What is air cooler? Air coolers are devices to reject heat from a process fluid directly to ambient air.

Procedure for calculation of Air Coolers calculate the heat duty Q= m Cp ΔT calculate the LMTD Δtm=((Ue+1)/10)*((Δtm/2)-t1)) calculate the extended surface area Ae=Q/UeΔtm calculate # of tubes Nt=Ae/Af*L

Procedure for calculation of Air Coolers calculate the mass flow of tube G=( lbs/ (hr of tube side fluid * Np * 144) )/(Nt *At *3600) calculate Reynolds number for tube side Re=di*G/µ calculate the inside film coefficient hi= K/D*((C µ/K)^(1/3))*(( µ/ µw)^.14). Ф(DG/Z) calculate the weight of the air weight =Q/(Cair*Δt air)

calculate mass velocity of the air Ga =(lb per hr of air flow)/(Af) calculate overall heat transfer coefficient 1/Uo=(1+(rt*Ft)+rw+1)/At) calculate required fan area Fan area = (0.4 * Face area Af)/(Assumed no. of fans) calculate the pressure drop ΔP= ΔPa * #of rows/ Dr calculate horse power Hydraulic HP = ( ACFM * Density of air * Diff head in ft)/33000 Diff head = (Total fan in ins H2O *5.193)/Density Bhp = Hydraulic HP/ η

Spec sheet Heat exchangerEquipment Name Decrease Temperature of vent gasObjective E-100Equipment Number Amer Al-NajdiDesigner Air coolerType EB oxidation section First section Location Carbon steelMaterial of Construction Foam glassInsulation 5.72E+04$ Cost ($) (equipment + insulation) Operating Condition Shell Side 158 Outlet temperatur e ( o F) 90Inlet temperature ( o F) Tube Side 49 Outlet temperatur e ( o C) 173.5Inlet temperature ( o C) - Number of Tubes -Number of Tube Rows - Shell Diameter (m) -Tube bundle Diameter (m) LMTD ( o F) Q total (Btu/hr) Heat Exchanger Area (ft 2 ) U (Btu/hr. o F. ft 2 )

pump What is pump? It is a device that convert energy of a prime mover (a electric motor or turbine) first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped

pumps P-107 P-102

Design (centrifugal pump ) Actual Head of pump Water Horse Power Overall Efficiency

Spec sheet PumpEquipment Name Increase pressure of EBHP fed to CRV- 101 Objective p-102Equipment Number Amer Al-NajdiDesigner Centrifuge pumpType EB oxidation section First section Location Carbon steelMaterial of Construction Foam woolInsulation 25164$Cost (equipment + insulation) Operating Condition 97 Outlet Temperat ure ( o C) 97Inlet Temperature ( o C) 320 Outlet Pressure (psia) 1.09Inlet Pressure (psia) Power (Hp) 17Efficiency (%)

Spec sheet pumpEquipment Name Increase pressure of ACP & MBA fed to CRV Objective P-107Equipment Number Amer Al-NajdiDesigner Centofugal pumpType PO production section Second section Location Carbon steelMaterial of Construction Foam woolInsulation 5076$Cost Operating Condition Outlet Temperature ( o C) Inlet Temperature ( o C) 20 Outlet Pressure (psia) 3.86Inlet Pressure (psia) 3.057Power (Hp)0.5Efficiency (%)

compressor What is compressor? A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume

compressor K-100-2

Design equations Finding outlet pressure Power in (ft.Ibf/Ibm)

Spec sheet compressorEquipment Name Increase Pressure of hydrogen fed to CRV-101-2Objective k-100-2Equipment Number Amer Al-NajdiDesigner reciprocating CompressorType Styrene production sectionLocation Carbon steelMaterial of Construction Foam woolInsulation $ Cost (equipment + insulation) Operating Condition 470 Outlet Temp eratur e ( o C) 25Inlet Temperature ( o C) 200 Outlet Pressu re (psia) 14.7Inlet Pressure (psia) Power (Hp) 75Efficiency (%)

Thank you