Table of content 1- Heat exchanger design (cooler ) 2- Distillation column design. 3- Valve.

Heat Exchanger Design Objectives: E102 - To decrease temperature of stream which exit from R-100. E103 - To decrease temperature of stream which exit from E102.

Assumptions: 1. Assume the water inter in tube side. 2. Use shell and tube heat exchanger. 3. Shell and tube heat exchanger counter flow is used because it is more efficient than the parallel flow. 4. The value of the overall heat transfer coefficient was assumed based on the fluid assigned in both sides. 5.The outer, the inner diameter, the length of the tube, and the number of passes were assumed.

For a good design : 1.The assumed overall heat coefficient has to be equaled to the calculated overall heat transfer coefficient. 1. The assumed overall heat coefficient has to be equaled to the calculated overall heat transfer coefficient. 2. The pressure drop in the tube side has to be lower than 1 bar. 2. The pressure drop in the tube side has to be lower than 1 bar. 3. The pressure drop in the shell side has to be lower than 1 bar. 3. The pressure drop in the shell side has to be lower than 1 bar.

Design procedure of Heat Exchanger 1.Define the duty: heat transfer rate, fluid flow rates, temperature. 2.Collect together the fluid physical properties required: density, viscosity,Thermal conductivity. 3.Select a trail value for the overall coefficient, U. 4.Calculate the mean temperature difference, ΔTm. 5.Calculate the area required from Q=UAΔTm. 6.Calculate the bundle and shell diameter 7.Calculate the individual coefficients. 8.Calculate the overall coefficient and compare with the trail value. 9.Calculate the exchanger pressure drop. 10.Calculate thickness of the shell. 11.Find the price of the heat exchanger based on the heat transfer area and the material of construction

Calculation procedure of shell and tube heat exchanger: 1.Heat load,(kW) 2. Log mean Temperature, (˚C) Where T1 - T1 : Inlet shell side fluid temperature ( ˚ C). T2 - T2 : Outlet shell side fluid temperature ( ˚ C). t1 - t1 : Inlet tube side temperature ( ˚ C). t2 - t2 : Outlet tube temperature ( ˚ C).

3.Provisional Area, (m 2 ) Where: - True temperature difference. - Temperature correction factor Where: F t : is the temperature correction factor R: is the shell side flow *specific heat / tube side flow*specific heat, (Dimensionless). S: is temperature efficiency of the heat exchanger, (dimensionless)  t F

4. Area of one tube, m 2. Where: - d o : Outer diameter (mm) - L : Length of tube (mm) -Number of tubes = provisional area / area of one tube

5. Overall heat transfer coefficient, W/m 2 o C. Where: - Outside coefficient (fouling factor). - Inside coefficient (fouling factor). 6. Bundle diameter. Where: - D b : Outside diameter (mm). - N t : Number of tubes. - K 1 & n 1 are constant.

7. Shell diameter. 8. Shell thickness. Where: - t: shell thickness (in). - P: internal pressure (psig). - r i : internal radius of shell (in). - E J : efficiency of joints. - S: working stress (psi). - C c : allowance for corrosion (in).

9-Pressure drop Tube side: Where: ΔP t : tube side pressure drop (N/m2= pa) N p : number of tube side passes u : tube side velocity (m/s) L: length of one tube, (m) Shell side Linear velocity = Gs /р Where: L: tube length, (m) l b : baffle spacing (m) Use fig.(12.30) to get j f.

Heat exchanger Equipment Name To cool the mixture of Ethanol,Methanol,Propanol,water and syn-gas using cooled water Objective E-102 Equipment Number Noura Manahi Designer Shell and tube heat exchanger Type After Reactor R-101 Location Cooled water Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $ Cost ($) Operating Condition Shell Side Outlet temperature ( o C) 320 Inlet temperature ( o C) Tube Side Outlet temperature ( o C) 25 Inlet temperature ( o C) 3369 Number of Tubes 2 Number of Tube Rows Shell Diameter (m) Tube bundle Diameter (m) LMTD ( o C) Q total (Kw) Heat Exchanger Area (m 2 ) 85 U (W/m 2 o C)

Cooler Equipment Name To cool the mixture of Ethanol,Methanol,Propanol,water and syn-gas using cooled water. Objective E-103 Equipment Number Noura Manahi Designer Shell and tube heat exchanger Type After Heat Exchanger Location Cooled water Utility Carbon steel Material of Construction Quartz wool – Glass wool Insulation $ Cost ($) Operating Condition Shell Side 60 Outlet temperature ( o C) Inlet temperature ( o C) Tube Side 95 Outlet temperature (oC) 25 Inlet temperature ( o C) 1613 Number of Tubes 2 Number of Tube Rows 2728 Shell Diameter (m) Tube bundle Diameter (m) LMTD (oC) Q total (Kw) Heat Exchanger Area (m2) 560 U (W/m 2 o C)

Distillation ColumnT-(102) design Objective : - To separate water from a mixture of ethanol and propanol. Assumptions: 1.Tray column. 2. Sieve plate. 3. Material of the distillation is carbon steel. 4. Plate spacing= 0.55 m 5. Efficiency = 75% 6. Flooding % = 85% 7. Weir height = 50 mm 8. Hole diameter = 5 mm 9. Plate thickness =5 mm

Good Design: 1.No weeping. 2.Down comer back up is less than half ( plate thickness+ weir height). 3.No entrainment. 4.Calculated percentage flooding equal to the assumed one. 5.Residence time exceeds 3 secs.

Design procedure of Distillation Column 1. Specify the properties of outlets streams: (flow rate, density and surface tension) for both vapor and liquid from HYSYS. 2. Calculate the maximum liquid and vapor outlet flow rate. 3. Choose tray spacing and then determine K 1 and K 2. 4.Calculate correction factor for Bottom K 1 and Top K Design for X% flooding at maximum flow rate for top and bottom part of distillation. 6. Calculate the maximum flow rates of liquid. 7. Calculate Net area required. 8. Take down comer area as %Y of the total column Cross sectional area. 9. Calculate the column diameter. 10. Calculate the column height using the actual number of stage.

11. Calculate column area, down comer area, active area, net area, hole area and weir length. 12. Calculate the actual min vapor velocity. 13. Calculate Back-up in down comer. 14. Check residence time. 15. Check entrainment. 16. Calculate number of holes. 17. Calculate area of condenser and reboiler. 18. Calculate Thickness of the distillation. 19. Calculate cost.

Calculation procedure of Distillation Column For column diameter 1-Calculate the liquid –vapors flow factor for top and bottom FLV= L W / V w * (ρ v / ρ l ) ½ Where: L W = liquid mole flow rate in kmol /h V w = vapors mole flow rate in kmol / h ρ v = density of the vapors in kg / m³ ρ l = density of the liquid in kg / m³ 2-From fig get constant for the top and the bottom top k1 and bottom k1 3-Calculate the correction factor for top and the bottom K = (σ / 0.02) ^0.2 * K 1 σ = liquid surface tension in N/m

4-calculate the flooding velocity for top and bottom U f = K *( (ρ l –ρ V ) / ρ v )½ Where: U f = flooding vapor velocity in m/s K= constant obtain from fig (11.27) ρ l = density of liquid in kg / m³ ρ v = density of vapour in kg / m³ 5-Assume the flooding percentage is 85% at max flow rate for the top and the bottom U V = 0.85 * U f 6-Calculate the net area for the top and the bottom A n = V / U V Where: A n = net area in m² V = Volumetric flow rate in m³ / s U V = vapour velocity in m/s

7-Assume as first - trail take down comer as 12% of total cross sectional area for the top and the bottom A d = An / 0.88 Where: A d = area of the down comer in m² A n = net area in m² 8-Calculate the diameter for the top and the bottom D = ((4 /3.14) * A d ) ½ Where: D = Diameter in m Ad = area of the down comer in m² 9-calculate the liquid flow pattern Max liquid volumetric flow rate = L m *M W / ρL * 3600

10-Calculate the areas A c = (3.14 / 4)*D² Where: A c = total cross sectional area in m² A d = 0.12 * A c Where: A d = area of the down comer in m² A n = A c –A d Where: A n = net area in m² A a = A c – 2A d Where: A a = active area in m² A h = 0.1 * A a Where:A h = hole area in m² 11-Use fig to get LW / D 12-Assume : weir length = 50 mm Hole diameter = 5 mm Plate thickness = 5 mm

13-Check weeping h ow max = 750 * (Lwd/ (Ad*ρl)) ^2/3 h ow min = 750 * (Lwd/ (LW*ρl)) ^2/3 At min rate = h w + h ow Where: h ow =Weir liquid crest 14-Calculate the weep point U h = k *(25.4-dh)/ρv½ Where: U h = min vapor velocity through the hole in m/s D h = hole diameter in m K 2 = constant from fig Calculate the actual vapor velocity Calculate the actual vapor velocity = min vapor rate / A h It should be above weep point

16-Calculate the pressure drop U H = V v / A h Where: V v = volumetric flow rate in m³ / s »A h = net area in m² H d = 51 * (Uh/ C0)² * ρ V / ρ L Where: H d = dry plate drop U h = min vapor velocity in m/s C 0 = 0.84 Continue of calculating the pressure drop Hr = 12.5E3 / ρ L Where: H r = residual head H t = H D + H W + H OW + H R Where: Ht = total pressure drop in mm

17- down comer liquid backup H ap = H w – 10 Where: H w = Weir height A ap = LW * h ap *0.001 Where: A ap = area of apron H dc = 166 * L W / ( ρ l * A ap ) Backup down comer H b = h dc + h t + h ow max + h w 18- Calculate the residence time T R = (A d * h b * ρ l) / l wd TR should be >3 s 19-Calculate the flooding percentage Flooding percentage = U v / U f * 100

20- Calculate the area of one hole A = (3.14 / 4 ) * (d h * )² Where: dh is hole diameter. 21- Calculate number of holes Number of hole = A h / A 22- Calculate the thickness Where: t: thickness of the separator in (in) P: operating pressure in Pisa r i : radius of the separator in (in) S: is the stress value of carbon steel = Pisa E j : joint efficiency (Ej=0.85 for spot examined welding) C 0 : corrosion allowance = calculate the cost

Distillation ColumnEquipment Name To separate water from a mixture of ethanol and propanol. Objective T-102Equipment Number Noura ManahiDesigner Tray columnType Seperation sectionLocation Carbon SteelMaterial of Construction Minral wool and glass fiberInsulation Cost ($) Column Flow Rates -Recycle (kgmole/hr)1321Feed (kgmole/hr) 1211Bottoms (kgmole/hr)110.1Distillate (kgmole/hr) Key Components WaterHeavyEthanolLight Dimensions 15.2Height (m)2.7Diameter (m) 12Reflux Ratio17Number of Trays Sieve traysType of tray0.55Tray Spacing 978Number of Holes Cost $1600Trays$137,300Vessel $202,000Reboiler$23,300Condenser Unit

Valve: Objective: To decrease the pressure. Assumptions: Gate valve. The diameter is 5 in.

ValveEquipment Name To decrease the pressureObjective VLV-100Equipment Number Noura AL-DosariDesigner Gate ValveType After V-100Location Quartz woolMaterial of Construction $1,500Cost Operating Condition Outlet Temperatur e ( o C) 60Inlet Temperature ( o C) 30 Outlet Pressure (psia) 869.6Inlet Pressure (psia)