1. Propylene Oxide Production by ARCO Process Done By Fiasal Juhail

2. Out Line:  Distillation column  Reactor  Pump  Separator

3.   1.Distillation ColumnT-(100):   Objective :   To separate TBA from TBHP to fed it to the second reactor.

4.   Assumptions   1-Tray spacing= 0.6 m   2-Percent of flooding at maximum flow rate=85%   3- Percent of downcomer area of total area=12%   4- The hole area =10% the active area.   5-weir height=50 mm   6-Hole diameter=5 mm   7-Plate thickness=5 mm

5.  Design Procedure 1. Collect the system physical properties. 2. Calculate liquid - vapor flow factor. = vapor mass flow rate, Kg/s = liquid mass flow rate, Kg/s = vapor density, Kg/m3 = liquid density, Kg/m3

6. 3-Select trial plate spacing from 0.15m to 1m. 4. Calculate the net area required. = volumetric flow rate, m3/s = flooding at maximum flow rate, m/s

7. 5. Calculate total column cross sectional area. 6. Calculate the column diameter.

8. 7. Calculate number of holes. Where = net area, m2 = cross sectional area of downcomer, m2

9. Where = active area, m2 Where = hole area, m2 Area of one hole = Number of holes = Ah / area of one hole

10. 8. Calculate height of the column. 9. Calculate thickness of the column. S = column thickness, in = maximum pressure, psi = column radius, in = stress of metal, psi = joint efficiency Where

11. 10. Select the material of construction. 11. Select the material of insulation. 12. Estimate the cost of the equipment.

12. Equipment Namedistillation ObjectiveSeparation TBA from TBHP Equipment NumberT-100 DesignerFaisal TypeTray column Material of ConstructionCarbon steel Insulation Glass wool Cost ($) 410200 $ Column Flow Rates Feed (kgmole/hr)885.8664Recycle (kgmole/hr) 2656.45 Distillate (kgmole/hr)95.45Bottoms (kgmole/hr)790.4 Key Components LightTBAHeavyTBHP Dimensions Diameter (m) 16.5300 Height (m) 40.5300 Number of Trays40Reflux Ratio5 Tray Spacing0.6 mType of tray Sieve trays Number of Holes 830497.002 Cost Vessel 117100 Trays 60000 Condenser Unit 108100 Reboi ler 125000

13. Equipment Namedistillation ObjectiveSeparation TBA from TBHP Equipment NumberT-101 DesignerFaisal TypeTray column Material of ConstructionCarbon steel Insulation Glass wool Cost ($) 399700 $ Column Flow Rates Feed (kgmole/hr) 95.45 Recycle (kgmole/hr) 633.0926 Distillate (kgmole/hr) 94.22 Bottoms (kgmole/hr) 1.229 Key Components LightTBAHeavyTBHP Dimensions Diameter (m) 19.9 Height (m) 39.7 Number of Trays 33 Reflux Ratio 1 Tray Spacing 0.6 m Type of tray Sieve trays Number of Holes 1203626.69 Cost Vessel 117100 Trays 49500 Condenser Unit 108100 Reboil er 125000

14. Centrifugal Pump Centrifugal pumps are essentially a type of enclosed pump in which a liquid is drawn in and delivered in a continuous stream by the rotation of a fan.

15.  Assume: ή = 75%  The head of the pump (H) = Where:  H= the static head of the pump in m.  ρ= the density of the fluid kg/m3  Break horse power (BHP)  Where,  BHP =is the break horsepower of the pump in watt  Q= flow rate in m3/s  H= the static head of the pump in m.  ρ= the density of the fluid kg/m3  Calculate the discharge diameter of the pipe (D)

16.  horse power(HP): Calculate the discharge diameter using the following equation:  Where,  ∆P is the pressure difference between the inlet and outlet streams in kpa  G: flow rate kg/s  ρ: the density of the fluid kg/m3  μ: viscosity cp  D: pipe diameter mm

17. Equipment NamePump (2) ObjectiveTo increase pressure Equipment NumberP-100 TypeCentrifugal Pump Material of ConstructionCarbon steel InsulationQuartz wool or Glass wool Cost3900 $ Inlet Temp. ( o C)53.06Outlet Temp. ( o C)53.22 Inlet Press. (psia)67Outlet Pres. (psia)101.5 Efficiency (%)75H Power9.4

18. Reactor CRV 100 : It is a CSTR Reactor Which convert i-butane Into TBA and TBHP. - Oxidization of i-butane by O2

19.  Procedure Design:  To calculate volume of reactor:  V=(Fao-Fa)/-ra = (Fao-Fa)/kCao(1-X)  Assume H/D = 4  V = 3.14/4 * D^2  FA0=Molar flow rate .-rA =Reaction rate.  FA=Molar flow rate of outlet  X=Conversion.  K= Constant of rate of reaction  CA0= Entering concentration.  H = Height of reactor  D = Diameter of reactor  V = Volume of the reactor.

20. Equipment NameReactor ObjectiveOxidization of i-butane to get TBHP Equipment NumberCRV-100 DesignerFaisal TypeCSTR Material of ConstructionCarbon steel Operating Condition Operating Temperature ( o C)136.7Volume of Reactor (m 3 ) 404.665 Operating Pressure (psia)450Reactor Height (m) 20.20453 Feed Flow Rate (mole/s)1145Reactor Diameter (m) 5.051131 Conversion (%)36.9 Cost ($) 287400

21. Separator Design  Objectives: -To separate vapor gases from the liquid

22.  Design Procedure  1) Calculate the settling velocity.  2) Calculate vapor volumetric flow rate.  3) Calculate liquid volumetric flow rate.  4) Determine the volume held in vessel using the above information's.  5) Then calculate the minimum vessel diameter.  6) Calculate the liquid depth.  7) Determine the thickness of the wall.  8) Calculate the length of the vessel.  9) Then calculate the volume of metal using the difference between volumes using inside and outlet diameters.  10) Calculate the weight of the metal.  11) Calculate the cost.

23.  Correlations Used in Design Settling velocity: Settling velocity:  Where:  Ut=Settling velocity (m/s)  ρL= density of liquid  ρV; density of vapor

24. - Calculate vapor volumetric flowrate. - Calculate liquid volumetric flowrate. - Determine the volume held in vessel using the above information's. - Then calculate the minimum vessel diameter.

25. Liquid Depth (HV): Length (h) :  - Surface area of the vessel: (2*pi*(Dv/2)*h)

26.   - Determine the thickness of the wall.   Where:   TH: thickness (in)   P: internal pressure (psig)   RI: internal radius of shell (in)   Ej: efficiency   S: working stress (psi) =13700 for Carbon Steel   Cc: allowance for corrosion (in)

27. Volume of metal: Weight of metal:

28. Equipment Nameseparator ObjectiveSeparate liquid from vapor Equipment NumberV-103 Designerfaisal TypeVapor liquid separator Material of ConstructionCarbon steel Cost ($) 125000 Operating Condition Operating Temperature ( o C)108.1 Operating Pressure (psig) 435.1 Design Considerations Liquid Density (kg/m 3 ) 570.381 Gas Density (kg/m 3 ) 42.95451 Viscosity (cp)0.15611Z factor1.00 Gas Flow rate (kg/hr) 35473.66 Liquid Flow rate (kg/hr) 45137.64 Dimensions Diameter (m) 2.81825 Height (m) 9.561032

29. Thank You For Listening