Sara Saad Al-Quhaim (Group leader) Equipment Design Done by: Sara Saad Al-Quhaim (Group leader)

Equipment Design: Distillation Column ( C-201) Cooler (E-103) Compressor ( K-100)

Distillation Design: Number of Stages (No. of stages) min = 25 (from HYSYS) Efficiency = 75% (Assumed) Actual stages = (No. of stages) min / Efficiency =33

Calculation of actual number of stages ( Short-cut Method): Water ( heavy) a= -7.831 b= 1.7399 c= -2.2505 d= -1.9828 API method: Pr vap= Pc*100*EXP((Tr^-1)*( at+bt^1.5+ct^2.6+dt^5) Y= 18.9621182 α= 1 (relative volatility)

Methanol ( light ) a= -8.6413 b= 1.0671 c= -2.3184 d= -1.678 XF= 0.096 XD= 0.996 XB= 0.0000005 API method: Pr vap= Pc*100*EXP((Tr^-1)*( at+bt^1.5+ct^2.6+dt^5) Y= 79.90817981 α= 4.21409565

 [  xf - ] = 1-q ( Fenske equation)   α F D B water 1 87.4 0.009602458 87.391972 heavy Methanol 4.21409565 12.6 12.57922028 0.0192049 light ( Fenske equation) Nm = Log [ XLK/ XHK]d [XLK/ XHK]b ( minimum number of stages) Log LK q=0.98909 (liquid)  [  xf - ] = 1-q

  = 3.013 by interpolation [  xd - ] = Rm +1 xf α α * xf ө=2.8 ө=3.1 0.874015748 1 0.874 -0.485564304 -0.416198 0.125984252 4.21409565 0.531 0.375441144 0.4765387  = 3.013 by interpolation  [  xd - ] = Rm +1

R= 2.8 Rm= 2.50548777 Rm/(Rm+1)= 0.714732994 R/(R+1)= 0.736842105 xd α 0.000762777 1 8E-04 -0.000378925 0.999237223 4.21409565 4.211 3.505866695 Rm= 2.50548777 Rm/(Rm+1)= 0.714732994 R= 2.8 R/(R+1)= 0.736842105

Note: The actual number of stages =33 stages Nm/N= 0.33 N= 32.866 Note: The actual number of stages =33 stages

Lw: liquid flow rate, kmol/hr ρL: liquid density,kg/m3 Where: Lw: liquid flow rate, kmol/hr ρL: liquid density,kg/m3 Vw: vapor flow rate, kmol/hr ρv :vapor density, kg/m3 FLv: Liquid-vapor factor Tray spacing= 0.55 ( from hysys) Using figure to find K1

uf : flooding vapor velocity, m/s uv: maximum velocity, m/s. x: percentage of flooding at max flowrate.( assume 85”% ) Maximum volumetric flow rate

Column Diameter Anet: Net area required, m2 Taking downcomer area as 12 percent of total Cross sectional area of downcomer= Column Diameter

Maximum volumetric liquid rate Column Height Maximum volumetric liquid rate Liquid flow arrangement

Total column cross sectional area Net area available for vapor liquid Ac = π/4 Dc2 Net area available for vapor liquid Active or bubbling area Hole area Ah = 0.1 Aa

Find lw/Dc from Figure Ad/Ac*100 Minimum liquid rate = 0.7* Max (Lw) Find Weir Length (lw) Minimum liquid rate = 0.7* Max (Lw)

Maximum how =750(Lw/(ρL lw))(2/3) Minimum how =750(Lw/(ρL lw))(2/3) Weir crest At minimum rate hw=50mm + how, from Figure 11.30 Find K2

uh (min) =(K2-0.90(25.4-dh))/ρv0.5 Hole diameter =5mm uh (min) =(K2-0.90(25.4-dh))/ρv0.5 Minimum vapor velocity actual minimum vapor velocity = min vapor rate /Ah Hole area Note: actual minimum vapor velocity should be greater than Uh Taking; Plate thickness/hole dia. = 1 Ah/Ap ( perforated area) = Ah/Aa from figure ( orifice cofficient) Co = 0.84

Total plate pressure drop (ht) = hd+hw+how+hr Vapor velocity Dry plate drop= hd = 51(uh/Co)2(ρv/ρL) Residual head (hr) = (12.5*103)/ρL Total plate pressure drop (ht) = hd+hw+how+hr

Back-up in downcomer (hb) = hw+how+ht+hdc Downcomer pressure drop (hap) = hw-10 Area under apron (Aap) = lw *hap*0.001 Head loss in downcomer hdc= hdc = Weir crest Back-up in downcomer (hb) = hw+how+ht+hdc hb less than tray spacing , so tray spacing is acceptable.

Residence Time Uv = Bottom V / An Percent flooding= Down comer backup Downcomer area Residence Time tr: residence time, should be > 3 s Uv = Bottom V / An Percent flooding= From figure, find ψ below 0.1 ( fractional entrainment)

Calculate lw/Dc From figure find 

Angle subtended by the edge of the plate=180- θc Mean length, unperforated edge strips = Area of unperforated edge strips=0.05*mean length Mean length of calming zone = Area of calming zone =2*mean length of calming zone *0.05 Total area for perforations, Ap =Aa - area of unperforated edge strips - area of calming zone

satisfactory within 2.5 to 4 Ah/Ap from figure, find lp/dh satisfactory within 2.5 to 4

Number of holes: For condenser: Material Carbon Steel Area of one hole= Total number of holes = Ah / 1.963E-05 Holes on one plate = total Number of holes/Area of one For condenser: Material Carbon Steel Area of condenser =

ri = Inside radius of the shell, in For reboiler: Material Carbon Steel Area of reboiler= Where: ri = Inside radius of the shell, in P =Maximum allowable internal pressure S = Maximum allowable working stress E = Efficiency of joints Cc = Allowance for corrosion, in

Material of Construction Distillate (kgmole/hr) Equipment Name Distillation column Objective To separate methanol from Alcohols Equipment Number C-201 Designer Sara Al-Quhaim Type Tray column Location Ethanol Production Material of Construction Carbon steel Insulation Minral wool and glass fiber Cost ($) $454,118 Column Flow Rates Feed (kgmole/hr) 6176 Recycle (kgmole/hr) - Distillate (kgmole/hr) 1317 Bottoms (kgmole/hr) 5474 Key Components Light Methanol Heavy Water Dimensions Diameter (m) 4.6 Height (m) 41.3 Number of Trays 69 Reflux Ratio 90 Tray Spacing 0.5 Type of tray Sieve trays Number of Holes 64266 Cost Vessel $194,400 Trays $63,333 Condenser Unit $89,000 Reboiler $105,208

Material of Construction Equipment Name Distillation column Objective To separate water from Alcohols Equipment Number C-202 Designer Sara Al-Quhaim Type Tray column Location After C-201 Material of Construction Carbon steel Insulation minral wool and glass fiber Cost ($) $420,218 Column Flow Rates Feed (kgmole/hr) 5474 Recycle (kgmole/hr) - Distillate (kgmole/hr) 1500 Bottoms (kgmole/hr) 3974 Key Components Light Ethanol Heavy Water Dimensions Diameter (m) 3.59 Height (m) 31.5 Number of Trays 45 Reflux Ratio 2.5 Tray Spacing 0.5 Type of tray Sieve trays Number of Holes 39097 Cost Vessel $124,400 Trays $48,133 Condenser Unit $130,300 Reboiler $115,208

Cooler design (heat exchanger)

= Heat load transfer in the hot side, KW. - = Heat load transfer in the hot side, KW. Mass flow rate in Kg/s. Temperature difference of the inlet and outlet.

Inlet shell side fluid temperature (oC). Outlet shell side fluid temperature (oC). Inlet tube side temperature (oC). Outlet tube temperature (oC). Measure of temperature efficiency

Provisional area At R and S Estimate U from table 12.1 Temperature correction factor. - Estimate U from table 12.1 Provisional area

A/ A one tube Take: Tube outside diameter(do) =20mm Tube inner diameter(di) =16mm Tube length(L) =4.88m Area of one tube A/ A one tube Number of tubes Bundle diameter K1, n1 depend on number of passes

Shell diameter

Tube cross sectional area Tube per passes Total flow area Tube mass velocity

Heat transfer coefficient inside the tube Tube linear velocity Heat transfer coefficient inside the tube

From l/Di and Re Inside coefficient (W/m2 oC). Tube side heat transfer factor. Thermal conductivity of stream.

Shell baffle spacing Tube pitch Cross flow area Mass velocity

Equivalent diameter At 25% baffle cut find jh Pr =Cp / kf

hs = Overall heat transfer coefficient Outside coefficient (fouling factor). Inside coefficient (fouling factor).

Jf= friction factor

Shell Thickness - Shell thickness (in). Maximum allowable internal pressure (psig). Internal radius of shell before allowance corrosion is added (in). Efficiency of joints. Working stress (psi). Allowance for corrosion (in)

To cooled the feed stream entering the reactor Equipment Name Cooler Objective To cooled the feed stream entering the reactor Equipment Number E-101 Designer Sara Al-Quhaim Type Shell and tube heat exchanger(Floting head, large) Location After the compressor K-102 Utility Chilled water Material of Construction Carbon steel Insulation Glass wool Cost ($) $570,376 (for three) Operating Condition Shell Side Inlet temperature (oC) 76.11 Outlet temperature (oC) 52.738 Tube Side 25 35 Number of Tube Rows 2 Number of Tubes 3022 Tube bundle Diameter (m) 0.9534365 Shell Diameter (m) 1.0234365 Q total (Kw) 5922.869045 LMTD (oC) 33.646828 U (W/m2 oC) 213..57628 Heat Exchanger Area (m2) 926.47649

Compressor Design

W = work done (Btu/Ibmol) n = Compression factor W = work done (Btu/Ibmol) R = Cp/Cv M= mol flow rate (Ibmol/hr)

K = (Mwt*CP)/(Mwt*CP-1.986) Ep = Efficiency of compressor %

Equipment Name Compressor Objective To increase the pressure of stream 25 Equipment Number K100 Designer Sara Saad Al-Quhaim Type Air, centrifugal, 125 psi Location After C-202 Material of Construction Carbon steel Insulation Quartz wool Cost $186176.25 Operating Condition Inlet Temperature (oC) 67.132 Outlet Temperature (oC) 186.48 Inlet Pressure (psia) 8.7020 Outlet Pressure (psia) 60.0000 Efficiency (%) 133.3817 Power (Hp) 543.6356

Thank You