1. Sara Saad Al-Quhaim (Group leader)
Equipment Design
Done by:
Sara Saad Al-Quhaim (Group leader)

2. Equipment Design: Distillation Column ( C-201)
Cooler (E-103)
Compressor ( K-100)

3. Distillation Design: Number of Stages
(No. of stages) min = 25 (from HYSYS)
Efficiency = 75% (Assumed)
Actual stages = (No. of stages) min / Efficiency
=33

4. Calculation of actual number of stages ( Short-cut Method):
Water ( heavy) a= b= c= d=
API method:
Pr vap= Pc*100*EXP((Tr^-1)*( at+bt^1.5+ct^2.6+dt^5) Y=
α= 1 (relative volatility)

5. Methanol ( light ) a= b= c= d=
XF= 0.096
XD= 0.996
XB=
API method:
Pr vap= Pc*100*EXP((Tr^-1)*( at+bt^1.5+ct^2.6+dt^5) Y= α=

6.  [  xf - ] = 1-q ( Fenske equation)α F D B
water 1
87.4
heavy
Methanol
12.6
light
( Fenske equation)
Nm = Log [ XLK/ XHK]d [XLK/ XHK]b ( minimum number of stages)
Log LK
q= (liquid) 
[  xf - ] = 1-q

7.   = 3.013 by interpolation [  xd - ] = Rm +1 xf α α * xf ө=2.8
ө=3.1 1
0.874
0.531
 = by interpolation 
[  xd - ] = Rm +1

8. R= 2.8 Rm= 2.50548777 Rm/(Rm+1)= 0.714732994 R/(R+1)= 0.736842105 xd α 1
8E-04
4.211
Rm=
Rm/(Rm+1)=
R= 2.8
R/(R+1)=

9. Note: The actual number of stages =33 stages
Nm/N= 0.33 N=
Note: The actual number of stages = stages

10. Lw: liquid flow rate, kmol/hr ρL: liquid density,kg/m3
Where:
Lw: liquid flow rate, kmol/hr
ρL: liquid density,kg/m3
Vw: vapor flow rate, kmol/hr
ρv :vapor density, kg/m3
FLv: Liquid-vapor factor
Tray spacing= 0.55 ( from hysys)
Using figure to find K1

11. uf : flooding vapor velocity, m/s
uv: maximum velocity, m/s.
x: percentage of flooding at max flowrate.( assume 85”% )
Maximum volumetric flow rate

12. Column Diameter Anet: Net area required, m2 Taking downcomer area
as 12 percent of total
Cross sectional area of downcomer=
Column Diameter

13. Maximum volumetric liquid rate
Column Height
Maximum volumetric liquid rate
Liquid flow arrangement

14. Total column cross sectional area Net area available for vapor liquid
Ac = π/4 Dc2
Net area available for vapor liquid
Active or bubbling area
Hole area
Ah = 0.1 Aa

15. Find lw/Dc from Figure Ad/Ac*100 Minimum liquid rate = 0.7* Max (Lw)
Find Weir Length (lw)
Minimum liquid rate = 0.7* Max (Lw)

16. Maximum how =750(Lw/(ρL lw))(2/3) Minimum how =750(Lw/(ρL lw))(2/3)
Weir crest
At minimum rate hw=50mm + how, from Figure Find K2

17. uh (min) =(K2-0.90(25.4-dh))/ρv0.5
Hole diameter =5mm
uh (min) =(K2-0.90(25.4-dh))/ρv0.5
Minimum vapor velocity
actual minimum vapor velocity = min vapor rate /Ah
Hole area
Note: actual minimum vapor velocity should be greater than Uh
Taking;
Plate thickness/hole dia. = 1
Ah/Ap ( perforated area) = Ah/Aa
from figure ( orifice cofficient) Co = 0.84

18. Total plate pressure drop (ht) = hd+hw+how+hr
Vapor velocity
Dry plate drop=
hd = 51(uh/Co)2(ρv/ρL)
Residual head (hr) = (12.5*103)/ρL
Total plate pressure drop (ht) = hd+hw+how+hr

19. Back-up in downcomer (hb) = hw+how+ht+hdc
Downcomer pressure drop (hap) = hw-10
Area under apron (Aap) = lw *hap*0.001
Head loss in downcomer
hdc=
hdc =
Weir crest
Back-up in downcomer (hb) = hw+how+ht+hdc
hb less than tray spacing , so tray spacing is acceptable.

20. Residence Time Uv = Bottom V / An Percent flooding=
Down comer backup
Downcomer area
Residence Time
tr: residence time, should be > 3 s
Uv = Bottom V / An
Percent flooding=
From figure, find ψ below 0.1
( fractional entrainment)

21. Calculate lw/Dc
From figure find 

22. Angle subtended by the edge of the plate=180- θc
Mean length, unperforated edge strips =
Area of unperforated edge strips=0.05*mean length
Mean length of calming zone =
Area of calming zone =2*mean length of calming zone *0.05
Total area for perforations, Ap =Aa - area of unperforated edge strips - area of
calming zone

23. satisfactory within 2.5 to 4
Ah/Ap from figure, find lp/dh
satisfactory within 2.5 to 4

24. Number of holes: For condenser: Material Carbon Steel
Area of one hole=
Total number of holes = Ah / 1.963E-05
Holes on one plate = total Number of holes/Area of one
For condenser:
Material Carbon Steel
Area of condenser =

25. ri = Inside radius of the shell, in
For reboiler:
Material Carbon Steel
Area of reboiler=
Where:
ri = Inside radius of the shell, in
P =Maximum allowable internal pressure
S = Maximum allowable working stress
E = Efficiency of joints
Cc = Allowance for corrosion, in

26. Material of Construction Distillate (kgmole/hr)
Equipment Name
Distillation column
Objective
To separate methanol from Alcohols
Equipment Number
C-201
Designer
Sara Al-Quhaim
Type
Tray column
Location
Ethanol Production
Material of Construction
Carbon steel
Insulation
Minral wool and glass fiber
Cost ($)
$454,118
Column Flow Rates
Feed (kgmole/hr)
6176
Recycle (kgmole/hr) -
Distillate (kgmole/hr)
1317
Bottoms (kgmole/hr)
5474
Key Components
Light
Methanol
Heavy
Water
Dimensions
Diameter (m)
4.6
Height (m)
41.3
Number of Trays 69
Reflux Ratio 90
Tray Spacing
0.5
Type of tray
Sieve trays
Number of Holes
64266
Cost
Vessel
$194,400
Trays
$63,333
Condenser Unit
$89,000
Reboiler
$105,208

27. Material of Construction
Equipment Name
Distillation column
Objective
To separate water from Alcohols
Equipment Number
C-202
Designer
Sara Al-Quhaim
Type
Tray column
Location
After C-201
Material of Construction
Carbon steel
Insulation
minral wool and glass fiber
Cost ($)
$420,218
Column Flow Rates
Feed (kgmole/hr)
5474
Recycle (kgmole/hr) -
Distillate (kgmole/hr)
1500
Bottoms (kgmole/hr)
3974
Key Components
Light
Ethanol
Heavy
Water
Dimensions
Diameter (m)
3.59
Height (m)
31.5
Number of Trays 45
Reflux Ratio
2.5
Tray Spacing
0.5
Type of tray
Sieve trays
Number of Holes
39097
Cost
Vessel
$124,400
Trays
$48,133
Condenser Unit
$130,300
Reboiler
$115,208

28. Cooler design (heat exchanger)

29. = Heat load transfer in the hot side, KW.-
= Heat load transfer in the hot side, KW.
Mass flow rate in Kg/s.
Temperature difference of the inlet and outlet.

30. Inlet shell side fluid temperature (oC).
Outlet shell side fluid temperature (oC).
Inlet tube side temperature (oC).
Outlet tube temperature (oC).
Measure of temperature efficiency

31. Provisional area At R and S Estimate U from table 12.1
Temperature correction factor. -
Estimate U from table 12.1
Provisional area

32. A/ A one tube Take: Tube outside diameter(do) =20mm
Tube inner diameter(di) =16mm
Tube length(L) =4.88m
Area of one tube
A/ A one tube
Number of tubes
Bundle diameter
K1, n1 depend on number of passes

33. Shell diameter

34. Tube cross sectional area
Tube per passes
Total flow area
Tube mass velocity

35. Heat transfer coefficient inside the tube
Tube linear velocity
Heat transfer coefficient inside the tube

36. From l/Di and Re Inside coefficient (W/m2 oC).
Tube side heat transfer factor.
Thermal conductivity of stream.

37. Shell baffle spacing
Tube pitch
Cross flow area
Mass velocity

38. Equivalent diameter
At 25% baffle cut find jh
Pr =Cp / kf

39. hs = Overall heat transfer coefficient
Outside coefficient (fouling factor).
Inside coefficient (fouling factor).

40. Jf= friction factor

42. Shell Thickness - Shell thickness (in).
Maximum allowable internal pressure (psig).
Internal radius of shell before allowance corrosion is added (in).
Efficiency of joints.
Working stress (psi).
Allowance for corrosion (in)

43. To cooled the feed stream entering the reactor
Equipment Name
Cooler
Objective
To cooled the feed stream entering the reactor
Equipment Number
E-101
Designer
Sara Al-Quhaim
Type
Shell and tube heat exchanger(Floting head, large)
Location
After the compressor K-102
Utility
Chilled water
Material of Construction
Carbon steel
Insulation
Glass wool
Cost ($)
$570,376 (for three)
Operating Condition
Shell Side
Inlet temperature (oC)
76.11
Outlet temperature (oC)
52.738
Tube Side 25 35
Number of Tube Rows 2
Number of Tubes
3022
Tube bundle Diameter (m)
Shell Diameter (m)
Q total (Kw)
LMTD (oC)
U (W/m2 oC)
Heat Exchanger Area (m2)

44. Compressor Design

45. W = work done (Btu/Ibmol)
n = Compression factor
W = work done (Btu/Ibmol)
R = Cp/Cv
M= mol flow rate (Ibmol/hr)

46. K = (Mwt*CP)/(Mwt*CP-1.986)
Ep = Efficiency of compressor %

47. Equipment Name
Compressor
Objective
To increase the pressure of stream 25
Equipment Number
K100
Designer
Sara Saad Al-Quhaim
Type
Air, centrifugal, 125 psi
Location
After C-202
Material of Construction
Carbon steel
Insulation
Quartz wool
Cost $
Operating Condition
Inlet Temperature (oC)
67.132
Outlet Temperature (oC)
186.48
Inlet Pressure (psia)
8.7020
Outlet Pressure (psia)
Efficiency (%)
Power (Hp)

48. Thank You