Equipments Designed Done By Hessa Al-Sahlawi Kuwait University College of Engineering & Petroleum Depatment of Chemical Engineering Production of Synthesis Gas From Natural Gas By Steam Reforming Supervised By: Prof. Mohamed Fahim Eng. Yusuf Ismail Equipments Designed Done By Hessa Al-Sahlawi

Table Of Content; -Introduction of Absorber. -Design Of Absorber. -Introduction Of Compressor. -Design Of Compressor. -Introduction Of Separator. -Design Of Separator. -Introduction Of Heat Exchanger. -Design Of Heat Exchanger.

1.Absorber Design: When the two contacting phases are a gas and a liquid , this operation is called Absorption . In our design we use Packed Column for CO2 absorber; the objective of the CO2 absorber is to remove CO2 from the effluent gas using Methyl-diethanolamine (MDEA) solvent

-Packed Bed: Packed Towers are used for continuous countercurrent contacting of gas and liquid in absorption as well as for vapor – liquid contacting in Distillation. -Type of Packing: Common types of packing which are dumped at random in the tower as shown

-Design Parameter; Selection of solvent: The essential elements of solvent selection criterion are feed gas characteristics (composition, pressure, temperature, etc.) and the treated gas specifications (i.e. the process requirements). -Design Parameter; Diameter , height and cost.

Design procedure of Packed Bed Absorber 1.Define fluid flow rates & Collect together the fluid physical properties required: density, viscosity, surface tension. 2.Define the equilibrium and Operating line.

3.get (m) slope of Equilibrium line. 4. get NOG From figure by calculate y1/y2 & m Gm/Lm 5.Calculate the column diameter by Calculate the Vw*. - Calculate . Lw: liquid flow rate, kg/hr ρL: liquid density,kg/m3 Vw: vapor flow rate, kg/hr ρv :vapor density, kg/m3 FLv: liquid-vapor flow factor

- Design for pressure 20 mmH2O/m packing . - From the Figure get K4 & K4 Flooding (Pressure drop interfere with high Correction factor ).

-Get K3 (Percentage flooding Correction factor) -Column Area Required = Gm/V*w Where; Gm: gas mass flow rate (kg/s) -Column Diameter=(4/π)*Area Column 6. Estimate the HOG then get Z ( Height ) estimate. USE CORNELL`S METHOD: -Get K3 (Percentage flooding Correction factor) -Get ψh (HG Factor) from Figure -Get φh (HL Factor) from Figure

- Assume HOG ( Height of heat transfer ) then Z=HOG*NOG -Then Calculate HL & HV ( height of liquid and gas respectively) Where Sc: is the Schmidt number (μ/D*ρ), μ (Viscosity ) ,D (diffusivity) , ρ (Density) -then Calculate; 7.Calculate Thickness: t=(Pri/(SEJ-0.6P))+Cc

8.Calculate Cost -Calculate Cost of packing by table: -Calculate Cost of Column by www.match.com

Material of Construction Absorber Equipment Name To remove CO2 from the effluent gas using methyl-diethanolamine (MDEA) solvent. Objective C-201 Equipment Number Hessa Al-sahlawi Designer (Continuous packing column) Type After flash tank V-104. Location Carbon steel Material of Construction Glass wool Insulation 214304.49137 $ Cost ($) Column Flow Rates 1725.513082 Liquid flow rate (kgmole/hr) 1.7844E4 Gas flow rate(kgmole/hr) Dimensions 6 Height (m) 2 Diameter (m) 3 NOG Intalox saddles ceramic (38mm) Type of Packing HOG Cost $14303.49137 Packing $200000 Column

2.Compressor Design: Objective To increase the pressure of the feed from 14.7 psia to 18 psia Choosing the compressor type. Choosing the compressor type from figure

R is the ratio of the specific heat capacities (Cp/Cv) 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) 2. Calculate the work done in Btu/lbmol by: 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: 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. Match . com

To increase the pressure of stream 18 Objective K101 Equipment Number Compressor Equipment Name To increase the pressure of stream 18 Objective K101 Equipment Number Hessa Al-Sahlawi Designer Centrifugal Compressor ( Base From Figure A.2-1) Type Inlet air feed Location Carbon steel Material of Construction Quartz wool Insulation 1424500 Cost Operating Condition 579.2 Outlet Temperature (oR) 536.7 Inlet Temperature (oR) 18 Outlet Pressure (psia) 14.7 Inlet Pressure (psia) 6008.014 Power (Hp) 75.00 Efficiency (%)

3.Separator Design: -Separators are mechanical devices for removing and collecting liquids from natural gas. -There are Two type of two phase Separator a. Vertical Separator b. Horizontal Separator. in our project the separator was Horizontal

Design procedure of Horizontal Separator 1.calculate the settling velocity of the liquid droplet using the following equation :- Where: Ut=Settling velocity (m/s) ρL= density of liquid ρV; density of vapor 2- assume there is no demister 3-calculate the actual settling velocity in m/s Where: Ua=actual settling velocity (m/s)

Volume = Area of Column * Length 4- Calculate the minimum vessel diameter. - Take hv( height of the vessel) =0.5 Dv (Diameter) & Lv (length of vessel) /Dv=4 -Cross Section Area for Vapor = π*Dv²/4 *0.5 -Vapor Velocity Uv= Volumetric / Cross Section Area for Vapor. - Vapor Resistance time = hv/Uv - Actual Vapor Resistance time = vessel length / Vapor velocity - Then For Satisfactory Separation required residence time = Actual - Then Get Minimum vessel diameter (Dv) & Length of Vessel 5- assume 10 min hold – up. 6-Determine the volume held in vessel using the above information's Volume = Area of Column * Length 7- Hold Up Time = Liquid Volume (m3) /Liquid volumetric Flow rate(m3/s)

8-Calculate the thickness of the separator using the following equation: t=(Pri/(SEJ-0.6P))+Cc 9- Calculate The Cost: From www.Match.com

TO separate H2O from the other gases separator Equipment Name TO separate H2O from the other gases Objective V-102 Equipment Number Hessa Al-sahlawi Designer Horizontal Type Heat Recovery Section 100 Location Carbon Steel Material of Construction Glass wall and quartz Insulation 377500 Cost ($) Operating Condition 289 Operating Pressure (psig) 159 Operating Temperature (˚C) Design Considerations 15.718 Gas Density (kg/m3) 989 Liquid Density (kg/m3) 0.998 Z factor 0.013377 Viscosity (cp) 79885.8 Liquid Flow rate (kg/s) 399141.2 Gas Flow rate (kg/s) Dimensions Gallon 26558 Volume Hold Up 16 Length (m) 4 Diameter (m)

TO separate H2O from the other gases separator Equipment Name TO separate H2O from the other gases Objective V-103 Equipment Number Hessa Al-sahlawi Designer Horizontal Type Heat Recovery Section 100 Location Carbon Steel Material of Construction Glass wall and quartz Insulation 260200 Cost ($) Operating Condition 287 Operating Pressure (psig) 144 Operating Temperature (˚C) Design Considerations 16.718 Gas Density (kg/m3) 1000.64 Liquid Density (kg/m3) 0.998 Z factor 0.012963 Viscosity (cp) 56676.6 Liquid Flow rate (kg/s) 342464 Gas Flow rate (kg/s) Dimensions Gallon 16306 Volume Hold Up 13.6 Length (m) 3.4 Diameter (m)

TO separate H2O from the other gases separator Equipment Name TO separate H2O from the other gases Objective V-104 Equipment Number Hessa Al-sahlawi Designer Horizontal Type Heat Recovery Section 100 Location Carbon Steel Material of Construction Glass wall and quartz Insulation 373700 Cost ($) Operating Condition 285 Operating Pressure (psig) 49 Operating Temperature (˚C) Design Considerations 16.8 Gas Density (kg/m3) 1000.6 Liquid Density (kg/m3) 0.998 Z factor 0.011941 Viscosity (cp) 81099 Liquid Flow rate (kg/s) 261365 Gas Flow rate (kg/s) Dimensions Gallon 26558 Volume Hold Up 16 Length (m) 4 Diameter (m)

4.Heat Exchanger Design: -Heat exchanger is a device designed to transfer heat from one fluid (liquid or gases) to another where the two fluids are physically separated. - In our design we assumed that the Heat Exchanger which used is a shell and tube heat exchanger. -the chose for shell and tube because it has a lot of advantage : 1- easy to clean. 2-The configuration gives a large surface area in a small volume. 3-Can be constructed from a wide range of materials.

Design procedure of shell and tube heat exchanger: Assumptions: 1- Use shell and tube heat exchanger, two shell and Multiple tube passes. 2- Assume the outer, the inner diameter and the length of the tube. ******************************** 1. Heat Load (Kw) 2.Log mean Temperature. Where -T1: Inlet shell side fluid temperature (˚C). -T2: Outlet shell side fluid temperature (˚C). -t1: Inlet tube side temperature (˚C). - t2:Outlet tube temperature (˚C).

4.Calculate the two dimensionless temperature ratios: R = (Thi - Tho) /(tco – tci) S = (tco - tci)/(Thi - tci) From Figure we get Ft Where ; Ft is temperature correction factor 5. Calculate True temperature difference ∆Tm= Ft *∆T lm 6.Choose U from table depending on the type of flows in shell and tube side U: Over all heat transfer coefficient

7. Calculate provisional area : 8.Assume inlet tube diameter, outlet tube diameter, and tube length. 9. Calculate area of one tube Where: L: Tube length ( m) do: outlet diameter (mm) 10.Calculate Number of tubes = provisional area / area of one tube. 11.Calculate bundle diameter Db = Do (Nt /K1)^(1/n1) Db: bundle diameter (mm). Do: tube outer diameter (mm). Nt: number of tubes. K1 and n1 are constant from table .

12. From Figure determine bundle diametrical clearance. 13. Calculate shell diameter Ds = Db + Dc Where: Db : bundle diameter( mm) ( Dc : clearance diameter( mm

14-For Tube side coefficient calculate: - Mean temperature =((t1+t2)/2) - Tube cross sectional area A= (π/4)*di Tubes per pass = (Nt/Np) where Np: number of the tubes passes. -Total Flow area=(Tubes per pass * A*10-6) Where: A : Tube cross sectional area , m2 - mass velocity = (m/ Total Flow area) m : mass Flow rate Tube side , kg/s - Linear velocity = (mass velocity/ ρ) ρ : Tube Flow density , kg/m3

hi = ((4200*(1.35+0.02*t)*ut0.8)/di0.2) Where: hi : Tube inside coefficient , W/m^2.˚c t : Mean temperature , ˚C ut : Linear velocity , m/s di : Tube inside diameter , mm **The coefficient can also be calculated by: hi =( kf*jh*Re*Pr0.33 / di ) kf : Thermal conductivity , W/m.˚c jh : Factor obtained from Figure di : inside diameter , mm Re = (u*di*ρ/μ) Pr = (Cp*μ/ kf) μ : viscosity , mNs/m2

- As = ((pt – do)*DslB/pt) Where: As : Cross Flow area , m2 15-For Shell side coefficient calculate: - baffle spacing lB = (Ds/5) - Tube pitch (Triangular Pitch)= 1.25 * do - As = ((pt – do)*DslB/pt) Where: As : Cross Flow area , m2 pt : tub pitch lB : baffle spacing , m -Gs = (Ws / As) Ws : Fluid flow rate on the shell side , kg/s - Equivalent diameter= (1.1/do)*(pt2-0.917do2) - Mean Shell side temperature = (T1+T2/2) - hs = (kf*jh*Re*Pr(1/3)/de) jh : determine from the Figure by choosing buffle percent.

16- Calculate over all coefficient 1/Uo= (1/ho)+(1/hod)+(doln(do/di)/(2kw))+(do/di) (1/hid)+(do/di)(1/hi) Where: Uo: the overall coefficient , W/m^2.oC ho: outside fluid film coefficient, W/m^2 oC hi: inside fluid film diameter hod : outside dirt coefficient (fouling factor) hid: inside dirt coefficient, W/m^2.oC kw: thermal conductivity of the tube wall material di : tube inside diameter, m do : tube out side diameter, m

17-Calculate pressure drop for: - Tube side: ∆Pt = Np(8*jf*(L/di)+2.5)*(ρut2/2) Where: ∆Pt : tube side pressure drop , psia Np : number of tube side passes ut : tube side velocity , m/s L : length of one tube , m jf : From Fig

- Shell side : ∆P = 8*jf*(Ds/de)*(L/lB)*(ρ*us2/2) Where: ∆P : shell side pressure drop , psia Ds : shell diameter , m lB : baffling spacing , m jf : From Fig

18-Thickness: (t) = ((Pri)/(SEj-0.6P)) + Cc Where : P: maximum internal pressure, psia ri: inside radius of shell, m Ej: efficiency of joints as a fraction(Ej=0.85 for spot examined welding) S: maximum allowable stress, = 13700 Pisa Cc: allowance for corrosion, m = 0.125

To cool the feed stream and prepare it to inter the separator BFW HEATER Equipment Name To cool the feed stream and prepare it to inter the separator Objective E-105 Equipment Number Hessa Al-sahlawi Designer Shell and tube heat exchanger Type After the Separator V-102 Location Water Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $784,600 Cost ($) Operating Condition Shell Side 110 Outlet temperature (oC) 35 Inlet temperature (oC) Tube Side 90.93 289 14068 Number of Tubes 2 Number of Tube Rows 3.3506 Shell Diameter (m) 3.2726 Tube bundle Diameter (m) 105.802 LMTD (oC) 25882.5 Q total (Kw) 6099.2053 Heat Exchanger Area (m2) 440 U (W/m2 oC)

To cool the feed stream and prepare it to inter the separator STEAM GENERATOR Equipment Name To cool the feed stream and prepare it to inter the separator Objective E-104 Equipment Number Hessa Al-sahlawi Designer Shell and tube heat exchanger Type After the ERV-100 Location Water Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $633,100 Cost ($) Operating Condition Shell Side 961.3 Outlet temperature (oC) 110 Inlet temperature (oC) Tube Side 391 1147 6211 Number of Tubes 6 Number of Tube Rows 3.62160 Shell Diameter (m) 3.5436 Tube bundle Diameter (m) 230.07 LMTD (oC) 310931 Q total (Kw) 4448.9552 Heat Exchanger Area (m2) 390 U (W/m2 oC)

To cool the feed stream and prepare it to inter the separator COOLER Equipment Name To cool the feed stream and prepare it to inter the separator Objective E-104. Equipment Number Hessa Al-sahlawi Designer Shell and tube heat exchanger Type After the heat exchanger E-104 Location Water Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $132,500 Cost ($) Operating Condition Shell Side 110.7 Outlet temperature (oC) 391 Inlet temperature (oC) Tube Side 150 25 2366 Number of Tubes 8 Number of Tube Rows 1.3373 Shell Diameter (m) 1.2583 Tube bundle Diameter (m) 150.202 LMTD (oC) 44073.4 Q total (Kw) 445.93974 Heat Exchanger Area (m2) 700 U (W/m2 oC)

To Heat the feed stream and prepare it to inter the Conversion reactor AIR PREHEATER Equipment Name To Heat the feed stream and prepare it to inter the Conversion reactor Objective E-103A&B Equipment Number Hessa Al-sahlawi Designer Shell and tube heat exchanger Type After Compressor K-101 Location Steam Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $759,500 Cost ($) Operating Condition Shell Side 200 Outlet temperature (oC) 390 Inlet temperature (oC) Tube Side 312 48.6 24678 Number of Tubes 2 Number of Tube Rows 4.66881 Shell Diameter (m) 4.58810 Tube bundle Diameter (m) 111 LMTD (oC) 50195.45 Q total (Kw) 5814.7225 Heat Exchanger Area (m2) 100 U (W/m2 oC)

Shell and tube heat exchanger Type After the absorber C-101 Location FEED PREHEATER Equipment Name To Heat the feed stream and prepare it to inter the Equilibrium reactor Objective E-101 Equipment Number Hessa Al-sahlawi Designer Shell and tube heat exchanger Type After the absorber C-101 Location Steam Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $606,100 Cost ($) Operating Condition Shell Side 300 Outlet temperature (oC) 580 Inlet temperature (oC) Tube Side 538 199.5 14379 Number of Tubes 4 Number of Tube Rows 4.31127 Shell Diameter (m) 4.2352 Tube bundle Diameter (m) 67 LMTD (oC) 42593.58 Q total (Kw) 4127.4438 Heat Exchanger Area (m2) 203 U (W/m2 oC)

THANK YOU FOR LISTENING