2. Distillation column design ( 2 ) Packed column ( 2 ) Heat exchanger design ( 2 Cooler )

3. Distillation Column Design Objective To separate PO desired product from by-products (PDC DCIPE). Assumptions Tray spacing= 0.6 m Percent of flooding at maximum flow rate=85% Percent of downcomer area of total area=12% The hole area =10% the active area. weir height=50 mm Hole diameter=5 mm Plate thickness=5 mm

4. Main Design Procedures Specify the properties of outlets streams for both vapor and liquid from HYSYS. Column Diameter Where FLv: liquid-vapor flow factor Lw: liquid flow rate, kmol/hr ρL: liquid density,kg/m3 Vw: vapor flow rate, kmol/hr ρv :vapor density, kg/m3

5. Get k1 for both bottom and top from figure 11.27 then use correction factor K = (σ / 0.02) ^0.2 * K1 Where: σ = liquid surface tension in N/m calculate the flooding velocity for top and bottom Uf = K *( (ρ l –ρ V ) / ρ v)½ Where: U f = flooding vapour velocity in m/s K= Surface tention correction factor ρ l = density of liquid in kg / m³ ρ v = density of vapour in kg / m³

6. Assume the flooding percentage is 85% at max flow rate for the top and the bottom U V = 0.85 * U f calculate the net area for the top and the bottom An = V / U V Where: An = net area in m² V = Volumetric flow rate in m³ / s U V = vapour velocity in m/s Assume as first trail take down comer as 12% of total cross sectional area Ac = An /(1- 0.12) Where: Ac = cross sectional area in m²

7. Calculate the diameter for the top and the bottom D = ((4 /π) * Ac) ½ Calculate the column height using the actual number of stage H= (Tray spacing * actual NO. stage ) + D Aa = Ac – 2Ad Ah = 0.1 * Aa Where: Aa = active area in m² Ah = hole area in m²

8. Check Weeping Where: max Lw: maximum liquid rate, (kg/s). min Lw : minimum liquid rate, (kg/s). max how: mm liquid. min how : mm liquid. Calculate the actual vapor velocity Calculate the actual vapour velocity = min vapour rate / Ah U h(min) =[K 2 -0.90(25.4-d h )]/  g 0.5

9. Calculate Pressure Drop: HD = 51 * (Uh/ C0)² * ρ V / ρL Hr = 12.5E3 / ρL H t = H D + H W + H OW + H R Where: Hd = dry plate drop Uh = min vapour velocity in m/s Hr = residual head Ht = total pressure drop in mm

10. Downcomer backup

11. Calculate the residence time TR = (Ad * hb * ρ l) / lwd Calculate the flooding percentage Flooding percentage = UV / uf * 100 Calculate the area of the hole A = (3.14 / 4 ) * (dh * 0.001 )² Calculate number of hole Number of hole = A h / A

12. Calculate the thickness Where: t: thickness of the separator in (in) P: operating pressure in Pisa ri: radius of the separator in (in) S: is the stress value of carbon steel = 13700 Pisa Ej: joint efficiency (Ej=0.85 for spot examined welding) C0: corrosion allowance = 0.125

13. Equipment NameDistillation Column Objective To separate by-product (DCIPE & PDC) from propylene oxide Equipment NumberT-100 DesignerAbdulrahman Habib Type Continuous Distillation Column LocationAfter separator (V-101) Material of ConstructionCarbon Steel Cost ($)$ 400,810 Result

14. Column Flow Rates Feed (kgmole/hr)893Recycle (kgmole/hr)23.1 Distillate (kgmole/hr)460.7Bottoms (kgmole/hr)455.3 Dimensions Diameter (m) Two sizes 2.91 and 3.11 Height (m)16.3 Number of Trays22Reflux Ratio4 Tray Spacing0.6Type of traySieve trays Number of Holes29541 Cost Vessel$ 88,300Trays$59,510 Condenser Unit$196,200Reboiler$56,800

15. Equipment NameDistillation Column ObjectiveTo increase purity of Equipment NumberT-101 DesignerAbdulrahman Al-Damaj Type Continuous Distillation Column LocationAfter Distillation (T-100) Material of ConstructionCarbon Steel Cost ($)$1,083,616

16. Column Flow Rates Feed (kgmole/hr)460.7Recycle (kgmole/hr)- Distillate (kgmole/hr)437.6Bottoms (kgmole/hr)23.1 Dimensions Diameter (m) Two sizes 3.141 and 3.256 Height (m)16.5 Number of Trays22Reflux Ratio4 Tray Spacing0.6Type of traySieve trays Number of Holes32232 Cost Vessel$87,100Trays$61,816 Condenser Unit$184,000Reboiler$750700

17. Objective To produce PCH from react C 3 H 6 + Cl 2 + H 2 O PCH + HCl Assumptions " 3/4 in " Berl Saddles E j = 0.85 C c = 0.125 in Percent of flooding at maximum flow rate=90%

18. V G Determine V G Calculate (∆P = 2 ;Fp= 175 since ¾ Bearl Saddle) Then new capacity parameter is known (from figure 10.6-5) First: Calculate Diameter (D) Determine the mass ratio

19. Determine G G at 90% Flooding: G G = 0.9 * V G * ρ G (Ib/s.ft 2 ) Diameter (D): Area = Feed Gas x (1/Gg) Diameter = ( Area * π/4 ) 0.5 ft Second: Calculate Height (HETP) Determine Gx & Gy Gy = FG / Area (Ib/hr.ft 2 ) Gx = FL / Area (Ib/hr.ft 2 )

20. Determine the H G & H L H L = H G = Determine N OG OG N OG = m (Y-Y*) m =

21. YA Calculate the KYA Kya = Kxa = YA 1/K YA = Determine the Height (HETP) Method # 1 Method # 2 H OG = Height = H OG x N OG

22. Calculate Thickness (T): Where: t: thickness of the separator in (in) P: operating pressure in Pisa ri: radius of the separator in (in) S: is the stress value of carbon steel = 13700 Pisa Ej: joint efficiency (Ej=0.85 for spot examined welding) C0: corrosion allowance = 0.125

23. Result Equipment NamePacked Column ObjectiveTo produce PCH from react C 3 H 6 + Cl 2 + H 2 O Equipment NumberCRV-100 DesignerAbdulrahman Al-Damaj TypePacked LocationFirst Part of the Plant Material of ConstructionCarbon steel Cost ($)21,805.1

24. Operating Condition Temperature ( o C)40Diameter (ft)5.94 Pressure (psia)60 Height (ft)25.28 Type of packing “ ¾ ” Berl Saddles Thickness (in)0.309

25. Equipment NamePacked Column ObjectiveTo strip the H 2 O Equipment NumberX-100 DesignerAbdulrahman Al-Damaj TypePacked LocationAfter mix. 100 Material of ConstructionCarbon steel Cost ($)6,591.716

26. Operating Condition Temperature ( o C)90Diameter (ft)2.54 Pressure (psia)15 Height (ft)21.23 Type of packing “ ¾ ” Berl Saddles Thickness (in)0.149

27. Heat Exchanger Design To decrease the temperature of the stream leaving the reactor and prepare it before interring the next reactor. Objective of ( E-100 )

28. Assumptions Using two shell pass and four or multiple of four tube passes. Assume the outer, the inner diameter and the length of the tube. The value of the overall heat transfer coefficient was assumed to be For = 750 w/m 2 C.

29. Main design procedures ΔT1= Thi-Tco ΔT2= Tho-Tci Where, Thi: inlet hot stream temperature (˚C) Tho: outlet stream temperature (˚C) Tci: inlet cold stream temperature (˚C) Tco: outlet cold temperature Heat load,( k W ) Q = (m Cp ΔT) hot =(m Cp ΔT) cold Log mean Temperature, (˚C)

30. Provisional Area, (m 2 ) Where: ΔT m = F t ΔT lm Area of one tube = L t * d o *  Where: Outer diameter (d o ), (mm) Length of tube (L t ), (mm) Number of tubes Nt= provisional area / area of one tube

31. Bundle diameter Db = do( Nt / K 1 ) (1/n 1 ),mm Where : Db: bundle diameter,mm Nt : number of tubes K1, n1 : constants from table (12.4) using triangular pitch of 1.25 Shell diameter Ds = Db + (Db Clearance),mm Where : we get it from figure (12.10) using split ring floating heat type.

32. Tube side Coefficient (hi di / κ) = jh Re Pr 0.33 * (µ/µwall) 0.14 Shell side Coefficient hs = κ * jh *Re *Pr (1/3) / de

33. Overall heat transfer coefficient 1/Uo =1/ho + 1/hod + do(ln(do/di))/2kw + do/di * 1/hid + do/di * 1/hi Where : Uo : overall coefficient based on outside area of the tube,w/m^2.C ho : outside fluid film coefficient, w/m^2.C hi : inside fluid film coefficient,w/m^2 hod : outside dirt coefficient (fouling factor),w/m^2.C, from Table (12.2) hid : inside dirt coefficient (fouling factor),w/m^2.C from Table (12.2) kw : thermal conductivity of the wall material w/m.Cs for cupronickel di : tube inside diameter m do : tube outside diameter m

34. Pressure drop Tube side: ΔP = Np [ 8jf (L/di)(µ/µw)^(-m) +2.5 ] ρυ^2/2,kpa Where : ΔP : tube side pressure drop, N/m^2(pa) Np : number of tube side passes υ : tube side velocity,m/s L : length of one tube, m jf : tube side friction factor Shell side: ΔPs = 8jf (Ds/de)(L/lb)( ρυ^2/2)(µ/µw)^(-0.14),kpa Where: L : tube length,m lb : baffle spacing,m

35. Shell thickness: t = (P r i / S E - 0.6P) + Cc Where : t : shell thickness, in P : internal pressure, psi gage r i : internal radius of shell, in E : efficiency of joints S : working stress, psi (for carbon steel) Cc : allowance for corrosion, in

36. Results Equipment NameCooler Objective To cooled the feed stream and prepare it to inter the reactor Equipment NumberE-100 DesignerAbdulrahman Al-Damaj TypeShell and tube heat exchanger LocationAfter Reactor (CRV-100) UtilitySea Water Material of ConstructionCarbon steel Cost ($)$344500

37. Operating Condition Shell Side Inlet temperature ( o C)90Outlet temperature ( o C)40 Tube Side Inlet temperature ( o C)25Outlet temperature ( o C)45 Number of Tube Rows1481Number of Tubes5922 Tube bundle Diameter (m)2.88Shell Diameter (m)2.96 Q total (Kw)43439.42LMTD ( o C)27.3 U (W/m 2 o C)754.4Heat Exchanger Area (m 2 )2232.6

38. Equipment NameCooler Objective To cooled the feed stream and prepare it to inter the splitter Equipment NumberE-108 DesignerAbdulrahman Habib TypeShell and tube heat exchanger LocationAfter Distillation (T-104) UtilitySea Water Material of ConstructionCarbon steel Cost ($)$ 4900

39. Operating Condition Shell Side Inlet temperature ( o C)139.6Outlet temperature ( o C)90 Tube Side Inlet temperature ( o C)25Outlet temperature ( o C)45 Number of Tube Rows2Number of Tubes6 Tube bundle Diameter (m)0.094Shell Diameter (m)0.14 Q total (Kw)44.52LMTD ( o C)78.87 U (W/m 2 o C)750Heat Exchanger Area (m 2 )0.767