Equipments Design PO/Styrene Plant Prof. M. Fahim Eng. Yousef Ismael Done By: Salem Alkanaimsh
Agenda Reactor Design. Heat Exchangers Design. Distillation Columns Design. Pumps Design. Compressors Design.
Reactor Design Chemical reactors are the heart of chemical processes. Reactors can be divided into: Batch reactors. Continues reactors. CSTR. PFTR. Example: Petroleum Refinery.
Reactor Design Finding The rate equation: Design Equation
Reactor Design Thickness of Reactor Diameter and length of reactor Where; t: thickness of reactor. P: internal pressure . ri: radius of the vessel . Ej: joint efficiency . S: stress of carbon steal . Cc: corrosion allowance
Material of Construction Reactor Equipment Name Oxidation Of Ethyl Benzene. Objective CRV-100 Equipment Number Eng. Salem Alkanaimsh Designer CSTR Reactor Type Ethyl benzene oxidation section Location Carbon Steel Material of Construction Foam Glass Insulation 851796 Cost Operating Condition 784.376 Volume of Reactor (m3) 190 Operating Temperature (oC) - Catalyst Type 50 Operating Pressure (psia) Catalyst Density (Kg/m3) 2226 Feed Flow Rate (mole/s) Catalyst Diameter (m) 1.908 Conversion (%) 25.195 Reactor Height (m) Weight of Catalyst (Kg) 6.29875 Reactor Diameter (m) Number of Beds 0.085 Reactor Thickness (m) Height of Bed/s (m) Cost ($) Height of Reactor (m)
Heat Exchanger Design Definition. Service. Exchanger. Condenser. Heater. Type. Shell and tube. Air cooled HX.
Shell and Tube HX Tubes. Pattern of Tubes. Shell and nozzle. Baffles.
Shell & Tube Heat Exchanger Design. Assumptions: Shell and tube heat exchanger counter flow is used because it is more efficient than the parallel flow. The value of the overall heat transfer coefficient was assumed based on the fluid assigned in both sides. The outer, the inner diameter , the length of the tube, and the number of passes were assumed. For a good design : The assumed overall heat coefficient has to be equaled to the calculated overall heat transfer coefficient., The pressure drop in the tube side has to be lower than 1 bar. The pressure drop in the shell side has to be lower than 1 bar.
Shell & Tube Heat Exchanger Design. Log mean Temperature Heat Load Where; T1 is temperature of inlet hot stream. (oC) T2 is the temperature of outlet hot stream. (oC) .t1 is the temperature of inlet cold stream. (oC) .t2 is the temperature of outlet cold stream. (oC).
Shell & Tube Heat Exchanger Number of tubes Heat Transfer Area Shell and Bundle diameter Where ; Nt is the number of tubes. K1, n1 are constants. Db is the bundle diameter (mm) Ds is the shell diameter. (mm)
Shell & tube heat exchanger Design Tube Side Heat Transfer Coefficient Shell side heat Transfer Coefficient Where is the density of fluid (kg/m3). is the thermal conductivity (W/m.C). is specific heat (kJ/kg.k). Re is the Reynolds number. Pr is the Prandtl number. Nu is the Nusselt number. is the convective heat transfer coefficient (W/m2.C). Where; .pt is the tube pitch (mm). .lB is the baffle spacing (mm). As is the cross flow area (m2) us is the velocity (m/s). de is the equivalent diameter for triangular arrangement (mm). jh is the heat transfer factor hs is the convective heat transfer coefficient (W/m2.C).
Shell & Tube Heat Exchanger Design. Overall Heat Transfer coefficient Shell Side Pressure Drop Thickness Tube side pressure Drop Where; D is the shell diameter in m Rj is internal radius in (in). P is the operating pressure in psi S is the working stress (psi). E is the joint efficiency
Material of Construction Heater Equipment Name Increase Temperature of liquid effluent of CRV-100 Objective E-102 Equipment Number Eng. Salem Alkanaimsh Designer Shell & tube. Type Oxidation of EB section Location Low pressure Steam Utility Carbon steel Material of Construction Foam Glass Insulation 17000 $ Cost ($) Operating Condition Shell Side 158.79 Outlet temperature (oC) Inlet temperature (oC) Tube Side 97 80 347 Number of Tubes 6 Number of Tube Rows 3 Shell Diameter (m) 0.03 Tube bundle Diameter (m) 69.94 LMTD (oC) 16958400 Q total (Btu/hr) 114.8 Heat Exchanger Area (m2) 101.8965 U (Btu/hr. oF . ft2)
Material of Construction Heater Equipment Name Increase Temperature of liquid effluent of CRV-100 Objective E-104 Equipment Number Eng. Salem Alkanaimsh Designer Shell & tube. Type Oxidation of EB section Location Low pressure Steam Utility Carbon steel Material of Construction Foam Glass Insulation 85000 Cost ($) Operating Condition Shell Side 158.79 Outlet temperature (oC) Inlet temperature (oC) Tube Side 141 94.89 5730 Number of Tubes 6 Number of Tube Rows 8.3 Shell Diameter (m) 0.03 Tube bundle Diameter (m) 36 LMTD (oC) 43334350 Q total (Btu/hr) 1758 Heat Exchanger Area (m2) 31.1307 U (Btu/hr. oF . ft2)
Material of Construction Heater Equipment Name Increase Temperature of EB fed to T-100 Objective E-105 Equipment Number Eng. Salem Alkanaimsh Designer Shell & tube. Type Oxidation of EB section Location Low pressure Steam Utility Stainless Steel Material of Construction Foam Glass Insulation 8000 Cost ($) Operating Condition Shell Side 158.79 Outlet temperature (oC) Inlet temperature (oC) Tube Side 40 25.128 3149 Number of Tubes 4 Number of Tube Rows 1.45 Shell Diameter (m) 0.07 Tube bundle Diameter (m) 126 LMTD (oC) 7984440.5 Q total (Btu/hr) 24.728 Heat Exchanger Area (m2) 130.581 U (Btu/hr. oF . ft2)
Material of Construction Cooler Equipment Name Decrease Temperature of recycle EB Objective E-116 Equipment Number Eng. Salem Alkanimsh Designer Shell & Tube Type EB oxidation Location Cooling water Utility Stainless Steel Material of Construction Foam Glass Insulation 15000 Cost ($) Operating Condition Shell Side 186.78 Outlet temperature (oC) 196.4 Inlet temperature (oC) Tube Side 30 25 3354 Number of Tubes 8 Number of Tube Rows 2.5 Shell Diameter (m) 0.07 Tube bundle Diameter (m) 162.44 LMTD (oC) 5015866.5 Q total (Btu/hr) 90.35 Heat Exchanger Area (m2) 17.73 U (Btu/hr. oF . ft2)
Distillation column A separation unit based on the difference between a liquid mixture and the vapor formed from it. It can be subdivided according to: How complex the unit is: Simple Distillation. Flash distillation. Fractionation. The internal Design of the column: Tray Column. Packing Column.
Distillation Column Design. Assumptions: Column Efficiency. Tray spacing. Flooding Percentage. Down Comer Area. Hole area( 0.1 of Active area). Weir height ( 40~100)mm. Hole diameter (10 mm). Plate Thickness (10~30 mm). Turn down Percentage (70%) Good Design: No weeping. Down comer back up is less than half ( plate thickness+ weir height). No entrainment. Calculated percentage flooding equal to the assumed one. Residence time exceeds 3 secs.
Distillation Column Design. Actual Number of trays Column Diameter Where; FLV is the vapor-liquid flow factor. is the density in (kg/m3). is the surface tension in (mN/m). uf is the velocity of vapor in (m/s). D is the column diameter (m).
Distillation Column Design Provisional Plate design Liquid Flow Pattern
Distillation Column Design Checking Weeping Down Comer Back up Residence time
Distillation column design Estimating the Thickness Entrainment Cost Number of holes
Material of Construction Distillation Column Equipment Name Separates the Final product (PO) Objective T-104 Equipment Number Eng. Salem Alkanimsh Designer Sieve Tray distillation column Type Epoxidation of Propylene section Location Carbon Steel Material of Construction Insulation 216,000 Cost ($) Column Flow Rates 4372 Recycle (kgmole/hr) 852.6 Feed (kgmole/hr) 441.5 Bottoms (kgmole/hr) 411.1 Distillate (kgmole/hr) Key Components Ethyl bezene Heavy PO Light Dimensions 29 Height (m) 4.37 Diameter (m) 10 Reflux Ratio 30 Number of Trays Sieve Type of tray 0.9 Tray Spacing (m) Number of Caps/Holes 91248 Number of Holes Cost 36000 $ Trays 180000 $ Vessel 10000 Reboiler 2500 $ Condenser Unit
Material of Construction Distillation column Equipment Name Separates Styrene from H2O. Objective 2nd dis. Equipment Number Eng. Salem Alkanaimsh Designer Tray Distillation column Type Styrene Production section Location Stainless Steel Material of Construction Foam Glass Insulation 186500 Cost ($) Column Flow Rates 399.2 Recycle (kgmole/hr) 566.9 Feed (kgmole/hr) 555.2 Bottoms (kgmole/hr) 11.74 Distillate (kgmole/hr) Key Components Styrene Heavy Water Light Dimensions 12 Height (m) 2.183 Diameter (m) 34 Reflux Ratio 11 Number of Trays Sieve Type of tray 0.9 Tray Spacing Number of Caps/Holes 142988 Number of Holes Cost 16500 $ Trays 170000 $ Vessel 6500 $ Reboiler 2300 $ Condenser Unit
Pump Design Definition. Suction Calculations. Discharge Calculations. NPSH.
Pump Design. Actual Head of pump Water horse Power Efficiency
Increase pressure of EB Feed to CRV-100 & T-100 Pump Equipment Name Increase pressure of EB Feed to CRV-100 & T-100 Objective P-100 Equipment Number Eng. Salem Alkanaimsh Designer Centrifugal Pump Type EB oxidation section Location Stainless Steel Material of Construction Insulation 20000 $ Cost Operating Condition 25.09 Outlet Temperature (oC) 25 Inlet Temperature (oC) 50 Outlet Pressure (psia) 14.7 Inlet Pressure (psia) 343 Power (Hp) 75 Efficiency (%)
Increase pressure of EB recycled in 1st section Pump Equipment Name Increase pressure of EB recycled in 1st section Objective P-101 Equipment Number Eng. Salem Alkanaimsh Designer Centrifugal Pump Type EB oxidation section Location Carbon Steel Material of Construction Insulation 20,000 $ Cost Operating Condition 50.15 Outlet Temperature (oC) 50.11 Inlet Temperature (oC) 14.7 Outlet Pressure (psia) 1.094 Inlet Pressure (psia) 123 Power (Hp) 27 Efficiency (%)
Compressor Design Definition. Types: Compression: Centrifugal. Axial. Reciprocating. Compression: Adiabatic. Isothermal. Intercooler stage Pressure Ratio (PR). Reduce temperature and work required.
Efficiency =0.8 Isentropic Compression Compressors Design. Work Efficiency =0.8 Isentropic Compression
Increase Pressure of air fed to CRV-100 Objective Compressor Equipment Name Increase Pressure of air fed to CRV-100 Objective K-100 Equipment Number Eng. Salem Alkanimsh Designer reciprocating Compressor Type Oxidation of EB. Location Stainless Steel Material of Construction Insulation 100000$ Cost Operating Condition 50 Outlet Temperature (oC) 25 Inlet Temperature (oC) 188.2 Outlet Pressure (psia) 14.7 Inlet Pressure (psia) 3980 Power (Hp) 80 Efficiency (%)
Increase Pressure of outlet of V-104 Objective K-101 Equipment Number Compressor Equipment Name Increase Pressure of outlet of V-104 Objective K-101 Equipment Number Eng. Salem Alkanimsh Designer recirocating Compressor Type Oxidation of EB. Location Carbon Steel Material of Construction Insulation 202270$ Cost Operating Condition 97 Outlet Temperature (oC) Inlet Temperature (oC) 3.094 Outlet Pressure (psia) 1.094 Inlet Pressure (psia) 5150 Power (Hp) 80 Efficiency (%)
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