2. Table of Content Introduction of heat exchanger. Design of Coolers.

3. Continue Introduction of fixed bed reactors. Design of reactors.

4. Heat exchanger 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 cooler which used is a shell and tube heat exchanger. The advantages of shell and tube heat exchanger are: 1.The configuration gives a large surface area in a small volume. 2.Can be constructed from a wide range of materials. 3.Easily cleaned.

5. Assumptions: 1- Use shell and tube heat exchanger, two shell and four tube passes. 2- Assume the outer, the inner diameter and the length of the tube.

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

7. 3.Provisional Area, (m 2 ) Where - True temperature difference. - ( Temperature correction factor) 4. Area of one tube, m 2. Where -Outer diameter (d o ), (mm) -Length of tube (L), (mm) - Number of tubes = provisional area / area of one tube  t F

8. 5. Overall heat transfer coefficient, W/m 2 o C. Where - Outside coefficient (fouling factor). - Inside coefficient (fouling factor). 6. Bundle diameter. Where - Outside diameter (mm). - Number of tubes. -K1 & n1 are constant.

9. 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).

10. Results CoolerEquipment name To cool the feed stream and prepare it to inter the separator Objective E-103Equipment Number Shell and tube heat exchanger Type After the reactor (CRV-100)Location Sea waterUtility Carbon steelMaterial of construction Quartz wool – Glass wool Insulation 200Shell Side Inlet temperature (oC) 40Shell Side Outlet temperature (oC) 35Tube Side Inlet temperature (oC) 94.439Tube Side Outlet temperature (oC)

11. 1169.316Heat load (kW) 300Overall heat transfer coefficient (W/m 2 o C) 32.972LMTD ( o C) 470Number of tubes 4.88Tube length (m) 0.63354Tube diameter (m) 144.161 Heat Exchanger area (m 2 ) 18.5Thickness (mm) 0.69554Shell diameter (m) 4Number of tube Rows $93,200Cost $

12. Reactors In our plant, the reactor used is catalytic fixed bed reactor. catalytic fixed bed reactor is a cylindrical tube, randomly filled with catalyst particles which may be spheres or cylindrical pellets to optimize flow distribution patterns and to alternate the speed of reaction. It is used very commonly in industry because it has many valuable features such as: 1.It gives the highest conversion. 2.Efficient heat transfer. 3.Temperature uniformity. 4.Less severe pressure drop.

13. Design Procedure of Catalytic Fixed Bed Reactor For CH 4 +CO 2  2CO+2H 2 1.Get reaction rate constant (k). 2. Calculate the concentration for carbon dioxide. 3. Calculate the rate of reaction. 4. Calculate the weight of catalyst.

14. 5. Calculate the volume of reactor. 6. Assume the ratio of length to diameter of reactor (L / D). 7. Calculate the height of reactor. 8. Calculate the flow rate of heating the reactor. 9. Calculate the thickness of reactor. 10. Calculate the cost.

15. Results reactorEquipment name To convert CO2 and CH4 to CO Objective ERV-100 (flow sheet 1)Equipment Number Catalytic fixed bed reactorType After Furnace F-100Location Carbon steelMaterial of construction Quartz wool – Glass woolInsulation 800Operating temperature (oC) 14.696Operating pressure (psia) 52.174 Feed Flow Rate (mole/s) 92.22Conversion

16. Results 1000Weight of Catalyst (Kg) 1.9409 Height of Bed/s (m) 0.4187Volume of reactor (m 3 ) Ni-Al 2 O 3 Catalyst Type 3980Catalyst Density (Kg/m3) 3.4261 Reactor Height (m) 0.4852Reactor Diameter (m) 10Reactor thickness (m) 13631.388CO 2 Flow rate for heating reactor kg/h $32300Cost $

17. Results reactorEquipment name To convert CO2 and CH4 to CO Objective ERV-100 (flow sheet 2)Equipment Number Catalytic fixed bed reactorType After Furnace F-100Location Carbon steelMaterial of construction Quartz wool – Glass woolInsulation 800Operating temperature (oC) 14.696Operating pressure (psia) 52.735 Feed Flow Rate (mole/s) 91.58Conversion

18. Results 1000Weight of Catalyst (Kg) 1.9409 Height of Bed/s (m) 0.4187Volume of reactor (m 3 ) Ni-Al 2 O 3 Catalyst Type 3980Catalyst Density (Kg/m3) 3.4261 Reactor Height (m) 0.4852Reactor Diameter (m) 10Reactor thickness (m) 13792.75CO 2 Flow rate for heating reactor kg/h $32300Cost $

19. Equilibrium Reactor 2 (flow sheet 2) CO+2H 2  CH 3 OH Assumption: Set Hydrogen as a limiting reactant. The porosity of the catalyst Φ=0.3 the ratio of length to diameter (L/D)=4

20. Design Procedure of Catalytic Fixed Bed Reactor 1.Get reaction rate constant (k). 2. Calculate the concentration. 3. Calculate the rate of reaction. 4. Calculate the weight of catalyst.

21. 5. Calculate the volume of reactor. 6. Assume the ratio of length to diameter of reactor (L / D). 7. Calculate the height of reactor. 8. Calculate the flow rate of cooling the reactor. 9. Calculate the thickness of reactor. 10. Calculate the cost.

22. Results reactorEquipment name To convert CO and H2 to methanol Objective ERV-101 (flow shee2)Equipment Number Catalytic fixed bed reactorType After cooler E-101Location Carbon steelMaterial of construction Quartz wool – Glass woolInsulation 250Operating temperature (oC) 1469.6Operating pressure (psia) 229.34 Feed Flow Rate (mole/s) 30.11Conversion

23. Results 2323.88Weight of Catalyst (Kg) 3.24459 Height of Bed/s (m) 1.956128Volume of reactor (m 3 ) CuO/ZnO/Al2O3 Catalyst Type 1980Catalyst Density (Kg/m3) 5.055742 Reactor Height (m) 0.811148Reactor Diameter (m) 57.9Reactor thickness (m) 13792.75H 2 Flow rate for cooling reactor kg/h $95,300Cost $

24. Design Procedure of Catalytic Fixed Bed Reactor CO+CH 3 OH  CH 3 COOH 1.Get reaction rate constant (k). 2. Calculate the partial pressure for CO and CH 3 OH. 3. Calculate the rate of reaction. 4. Calculate the weight of catalyst.

25. 5. Calculate the volume of reactor. 6. Assume the ratio of length to diameter of reactor (L / D). 7. Calculate the height of reactor. 8. Calculate the flow rate of cooling the reactor. 9. Calculate the thickness of reactor. 10. Calculate the cost.

26. Results reactorEquipment name To convert CO and CH3OH to CH3COOH Objective CRV-101 (flow sheet 1)Equipment Number Catalytic fixed bed reactorType After cooler E-100Location Carbon steelMaterial of construction Quartz wool – Glass woolInsulation 200Operating temperature (oC) 517Operating pressure (psia) 152.7 Feed Flow Rate (mole/s) 90Conversion

27. Results 451.0188Weight of Catalyst (Kg) 1.7925 Height of Bed/s (m) 0.3298Volume of reactor (m 3 ) CH3I Catalyst Type 2278.9Catalyst Density (Kg/m3) 3.24066 Reactor Height (m) 0.4481Reactor Diameter (m) 13.1Reactor thickness (m) 7999.6617H 2 Flow rate for cooling reactor kg/h $12,800Cost $

28. Results reactorEquipment name To convert CO and CH3OH to CH3COOH Objective CRV-100 (flow sheet 2)Equipment Number Catalytic fixed bed reactorType After cooler E-102Location Carbon steelMaterial of construction Quartz wool – Glass woolInsulation 200Operating temperature (oC) 515Operating pressure (psia) 185.26 Feed Flow Rate (mole/s) 90Conversion

29. Results 350.8217Weight of Catalyst (Kg) 1.6485 Height of Bed/s (m) 0.08382Volume of reactor (m 3 ) CH3I Catalyst Type 2278.9Catalyst Density (Kg/m3) 3.06067 Reactor Height (m) 0.41213Reactor Diameter (m) 12.3Reactor thickness (m) 4102.094H 2 Flow rate for cooling reactor kg/h $11,200Cost $

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