1. Production of ethanol From syngas Design presentation Done by: SARA BADER AL- SAFI Supervised by: Prof. M. fahim

2. My equipments 1-Reactor 2-Condenser 3- Separator

3. First reactor R-101(fixed bed reactor) The main reaction : 2CO+4H2 CH3CH2OH+H2O

4. Assumption taken to design reactor: * to calculate conversion I assumed that this is the only reaction for producing ethanol ethanol out =1834 ibmole/hr=X * CO in/2 X=12.6% * there is 3 reactor in parallel having same conversionAssumption taken to design reactor: * to calculate conversion I assumed that this is the only reaction for producing ethanol ethanol out =1834 ibmole/hr=X * CO in/2 X=12.6% * there is 3 reactor in parallel having same conversion

5. Design equation Rate low ra = - k pH2^0.9*pCO^-0.76 Where:PCO=Ca*R*T=ca0*(1-x)*(T/To)/(1+ex)*R*TPH2=Cb*R*T=ca0*(θB-b/ax)*(T/To)/(1+ex)*R*T

6. V=Faoƒdx/-ra= Faoƒ(1/k *Pco*Ph2) Taking space velocity 4000 and volume of one reactor 176.05m2 from SRI report Then rate constant k= 4.516 kmole/volume^0.86/hr Taking L/D= 4 L=15.3m & D=3.8m Cost of one reactor=842400 US$ Cost of 3 reactor=2527200 US$ From actual plant cost=8186400 $

7. Catalyst: Taking catalyst to be cobalt oxide And assuming prosity =o.4 density = 1830 kg/m3 Weight of catalyst =(1- porpsity)*volume*density=193304.54 kg cat

8. Condenser E-103 Objective: **To condense alcohol mixture and water by cooled them to 140F ** using 3 condenser with same flow rate

9. Design equation Inlet T=187.8 oC Outlet T=60 oC Using cooling water with inlet t=25 oC Outlet t=50 oC

10. Qh = mh *Cp * (T1-T2) ∆Tlm =(T1-t2)-(T2-t1) / ln((T1-t2)/(T2-t1)) Ft is correction factor using figure and R=(T1-T2)/(t2-t1)S=(t2-t1)/(T1-t1) ∆Tm = Ft * ∆Tlm Assuming u to be 700 then provisional area =A= Q / U * ∆Tm

11. Area of one tube = L* do *π Where L = tube length do=tube outside diameter do=tube outside diameter Number of tubes = provisinal area / area of one tube Shell Ds = Db + Bundle diametrical clearance Where Db = (do)*( Nt / K1)^ (1/n1)

12. Bundle diametrical clearance From fig 12.10 Overall heat transfer coefficient= 1/Uo =(1/ho) + (1/hod) + ( do(ln(do/di))/2kw) + (do/di) * (1/hid) + (do/di) * (1/hi) Outside coefficient(fouling factor)=hod Inside coefficient(fouling factor) =hid

13. Pressure drop ΔPt = Np [ 8jf (L/di)(µ/µw)^(-m) +2.5 ] ρut²/2 where ΔPt = tube side pressur drop (N/m²)(pa) Np = number of tube side passes ut = tube side velosity (m/s) L = length of one tube Jf=tube side friction factor

14. ΔPs = 8jf (Ds/de)(L/Lb)( ρus^2/2)(µ/µw)^(- 0.14) where: Lb : baffle spacing Jf: shell side factor from RE and fig

15. Result: for 3 condenser cost=591300$ 591300

16. separator Objective: to separate vapor from liquid which is alcohol mixture Assumption 1- vertical separator 2- using demister pad 3- 4 separator are used with same flow rate

17. Calculation 1-Settling Velocity Ut =0.07*(rL-rv)/rv^.5) 2-Volumetric flow rate= mass flow/density 3-Using demister pad us=ut Dv=(4*Vv/3.14*us)^.5 4-Liquid depth hv=volume held up /vessel area

18. 5-Volume of cylinder using Dv 6-Thickness= (p*ri)/((s*Ej)-(0.6*p))+co Total height= hv+Dv/2+Dv+0.4+DV/2+Dv/2 7-Area of vessel=2*3.14*Dv/2*ht 8-Volume of metal= thickness* area 9-Weight of metal=volume*density Cost= 89800US$ For 4 separator= 359200

19. Result for 4 separatorcost=359200$