1. Equipments Designed Done By Hessa Al-Sahlawi
Kuwait University
College of Engineering & Petroleum
Depatment of Chemical Engineering
Production of Synthesis Gas From Natural Gas By Steam Reforming
Supervised By:
Prof. Mohamed Fahim
Eng. Yusuf Ismail
Equipments Designed Done By Hessa Al-Sahlawi

2. Table Of Content; -Introduction of Absorber. -Design Of Absorber.
-Introduction Of Compressor.
-Design Of Compressor.
-Introduction Of Separator.
-Design Of Separator.
-Introduction Of Heat Exchanger.
-Design Of Heat Exchanger.

3. 1.Absorber Design:
When the two contacting phases are a gas and a liquid , this operation is called Absorption .
In our design we use Packed Column for CO2 absorber; the objective of the CO2 absorber is to remove CO2 from the effluent gas using Methyl-diethanolamine (MDEA) solvent

4. -Packed Bed:
Packed Towers are used for continuous countercurrent contacting of gas and liquid in absorption as well as for vapor – liquid contacting in Distillation.
-Type of Packing:
Common types of packing which are
dumped at random in the tower as shown

5. -Design Parameter; Selection of solvent:
The essential elements of solvent selection criterion are feed gas characteristics (composition, pressure, temperature, etc.) and the treated gas specifications (i.e. the process requirements).
-Design Parameter;
Diameter , height and cost.

6. Design procedure of Packed Bed Absorber
1.Define fluid flow rates & Collect together the fluid physical properties required: density, viscosity, surface tension.
2.Define the equilibrium and Operating line.

7. 3.get (m) slope of Equilibrium line.
4. get NOG From figure by calculate y1/y2 & m Gm/Lm
5.Calculate the column diameter by Calculate the Vw*.
- Calculate .
Lw: liquid flow rate, kg/hr
ρL: liquid density,kg/m3
Vw: vapor flow rate, kg/hr
ρv :vapor density, kg/m3
FLv: liquid-vapor flow factor

8. - Design for pressure 20 mmH2O/m packing .
- From the Figure get K4 & K4 Flooding (Pressure drop interfere with high Correction factor ).

9. -Get K3 (Percentage flooding Correction factor)
-Column Area Required = Gm/V*w
Where; Gm: gas mass flow rate (kg/s)
-Column Diameter=(4/π)*Area Column
6. Estimate the HOG then get Z ( Height ) estimate.
USE CORNELL`S METHOD:
-Get K3 (Percentage flooding Correction factor)
-Get ψh (HG Factor) from Figure
-Get φh (HL Factor) from Figure

10. - Assume HOG ( Height of heat transfer ) then Z=HOG*NOG
-Then Calculate HL & HV ( height of liquid and gas respectively)
Where Sc: is the Schmidt number (μ/D*ρ),
μ (Viscosity ) ,D (diffusivity) , ρ (Density)
-then Calculate;
7.Calculate Thickness: t=(Pri/(SEJ-0.6P))+Cc

11. 8.Calculate Cost
-Calculate Cost of packing by table:
-Calculate Cost of Column by

12. Material of Construction
Absorber
Equipment Name
To remove CO2 from the effluent gas using methyl-diethanolamine (MDEA) solvent.
Objective
C-201
Equipment Number
Hessa Al-sahlawi
Designer
(Continuous packing column)
Type
After flash tank V-104.
Location
Carbon steel
Material of Construction
Glass wool
Insulation $
Cost ($)
Column Flow Rates
Liquid flow rate (kgmole/hr)
1.7844E4
Gas flow rate(kgmole/hr)
Dimensions 6
Height (m) 2
Diameter (m) 3
NOG
Intalox saddles ceramic (38mm)
Type of Packing
HOG
Cost $
Packing
$200000
Column

13. 2.Compressor Design: Objective
To increase the pressure of the feed from 14.7 psia to 18 psia
Choosing the compressor type.
Choosing the compressor type from figure

14. R is the ratio of the specific heat capacities (Cp/Cv)
1.Calculate the compression factor (n) using the following equation:
Where,
P1,2 : is the pressure of inlet and outlet respectively (psia)
T1,2 : is the temperature of the inlet and outlet respectively (R)
2. Calculate the work done in Btu/lbmol by:
R is the ratio of the specific heat capacities (Cp/Cv)
3. Calculate the horse power, Hp using the following equation:
Hp=W*M
Where, M is the molar flow rate in lbmol/s

15. 4. Calculate the efficiency of the compressor using the following equation:
Where ,
Mw :is the molecular weight of the gas in the stream
CP :is the specific heat capacity (Btu/lb◦ F )
5. Calculate the cost of the compressor from www. Match . com

16. To increase the pressure of stream 18 Objective K101 Equipment Number
Compressor
Equipment Name
To increase the pressure of stream 18
Objective
K101
Equipment Number
Hessa Al-Sahlawi
Designer
Centrifugal Compressor ( Base From Figure A.2-1)
Type
Inlet air feed
Location
Carbon steel
Material of Construction
Quartz wool
Insulation
Cost
Operating Condition
579.2
Outlet Temperature (oR)
536.7
Inlet Temperature (oR) 18
Outlet Pressure (psia)
14.7
Inlet Pressure (psia)
Power (Hp)
75.00
Efficiency (%)

17. 3.Separator Design:
-Separators are mechanical devices for removing and collecting liquids from natural gas.
-There are Two type of two phase Separator
a. Vertical Separator
b. Horizontal Separator.
in our project the separator was Horizontal

18. Design procedure of Horizontal Separator
1.calculate the settling velocity of the liquid droplet using the following equation :-
Where:
Ut=Settling velocity (m/s)
ρL= density of liquid
ρV; density of vapor
2- assume there is no demister
3-calculate the actual settling velocity in m/s
Where:
Ua=actual settling velocity (m/s)

19. Volume = Area of Column * Length
4- Calculate the minimum vessel diameter.
- Take hv( height of the vessel) =0.5 Dv (Diameter)
& Lv (length of vessel) /Dv=4
-Cross Section Area for Vapor = π*Dv²/4 *0.5
-Vapor Velocity Uv= Volumetric / Cross Section Area for Vapor.
- Vapor Resistance time = hv/Uv
- Actual Vapor Resistance time = vessel length / Vapor velocity
- Then For Satisfactory Separation required residence time = Actual
- Then Get Minimum vessel diameter (Dv) & Length of Vessel
5- assume 10 min hold – up.
6-Determine the volume held in vessel using the above information's
Volume = Area of Column * Length
7- Hold Up Time = Liquid Volume (m3) /Liquid volumetric Flow rate(m3/s)

20. 8-Calculate the thickness of the separator using the following equation:
t=(Pri/(SEJ-0.6P))+Cc
9- Calculate The Cost:
From

21. TO separate H2O from the other gases
separator
Equipment Name
TO separate H2O from the other gases
Objective
V-102
Equipment Number
Hessa Al-sahlawi
Designer
Horizontal
Type
Heat Recovery Section 100
Location
Carbon Steel
Material of Construction
Glass wall and quartz
Insulation
377500
Cost ($)
Operating Condition
289
Operating Pressure (psig)
159
Operating Temperature (˚C)
Design Considerations
15.718
Gas Density (kg/m3)
989
Liquid Density (kg/m3)
0.998
Z factor
Viscosity (cp)
Liquid Flow rate (kg/s)
Gas Flow rate (kg/s)
Dimensions
Gallon
26558
Volume Hold Up 16
Length (m) 4
Diameter (m)

22. TO separate H2O from the other gases
separator
Equipment Name
TO separate H2O from the other gases
Objective
V-103
Equipment Number
Hessa Al-sahlawi
Designer
Horizontal
Type
Heat Recovery Section 100
Location
Carbon Steel
Material of Construction
Glass wall and quartz
Insulation
260200
Cost ($)
Operating Condition
287
Operating Pressure (psig)
144
Operating Temperature (˚C)
Design Considerations
16.718
Gas Density (kg/m3)
Liquid Density (kg/m3)
0.998
Z factor
Viscosity (cp)
Liquid Flow rate (kg/s)
342464
Gas Flow rate (kg/s)
Dimensions
Gallon
16306
Volume Hold Up
13.6
Length (m)
3.4
Diameter (m)

23. TO separate H2O from the other gases
separator
Equipment Name
TO separate H2O from the other gases
Objective
V-104
Equipment Number
Hessa Al-sahlawi
Designer
Horizontal
Type
Heat Recovery Section 100
Location
Carbon Steel
Material of Construction
Glass wall and quartz
Insulation
373700
Cost ($)
Operating Condition
285
Operating Pressure (psig) 49
Operating Temperature (˚C)
Design Considerations
16.8
Gas Density (kg/m3)
1000.6
Liquid Density (kg/m3)
0.998
Z factor
Viscosity (cp)
81099
Liquid Flow rate (kg/s)
261365
Gas Flow rate (kg/s)
Dimensions
Gallon
26558
Volume Hold Up 16
Length (m) 4
Diameter (m)

24. 4.Heat Exchanger Design:
-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 Heat Exchanger which used is a shell and tube heat exchanger.
-the chose for shell and tube because it has a lot of advantage :
1- easy to clean.
2-The configuration gives a large surface area in a small volume.
3-Can be constructed from a wide range of materials.

25. Design procedure of shell and tube heat exchanger:
Assumptions:
1- Use shell and tube heat exchanger, two shell and Multiple tube passes.
2- Assume the outer, the inner diameter and the length of the tube.
********************************
1. Heat Load (Kw)
2.Log mean Temperature.
Where
-T1: Inlet shell side fluid temperature (˚C).
-T2: Outlet shell side fluid temperature (˚C).
-t1: Inlet tube side temperature (˚C).
- t2:Outlet tube temperature (˚C).

26. 4.Calculate the two dimensionless temperature ratios:
R = (Thi - Tho) /(tco – tci)
S = (tco - tci)/(Thi - tci)
From Figure we get Ft
Where ; Ft is temperature correction factor
5. Calculate True temperature difference
∆Tm= Ft *∆T lm
6.Choose U from table depending on the type of flows in shell and tube side
U: Over all heat transfer coefficient

27. 7. Calculate provisional area :
8.Assume inlet tube diameter, outlet tube diameter, and tube length.
9. Calculate area of one tube
Where:
L: Tube length ( m)
do: outlet diameter (mm)
10.Calculate Number of tubes = provisional area / area of one tube.
11.Calculate bundle diameter
Db = Do (Nt /K1)^(1/n1)
Db: bundle diameter (mm).
Do: tube outer diameter (mm).
Nt: number of tubes.
K1 and n1 are constant from table .

28. 12. From Figure determine bundle diametrical clearance.
13. Calculate shell diameter Ds = Db + Dc
Where:
Db : bundle diameter( mm)
( Dc : clearance diameter( mm

29. 14-For Tube side coefficient calculate:
- Mean temperature =((t1+t2)/2)
- Tube cross sectional area
A= (π/4)*di
Tubes per pass = (Nt/Np) where Np: number of the tubes passes.
-Total Flow area=(Tubes per pass * A*10-6)
Where:
A : Tube cross sectional area , m2
- mass velocity = (m/ Total Flow area)
m : mass Flow rate Tube side , kg/s
- Linear velocity = (mass velocity/ ρ)
ρ : Tube Flow density , kg/m3

30. hi = ((4200*( *t)*ut0.8)/di0.2)
Where:
hi : Tube inside coefficient , W/m^2.˚c
t : Mean temperature , ˚C
ut : Linear velocity , m/s
di : Tube inside diameter , mm
**The coefficient can also be calculated by:
hi =( kf*jh*Re*Pr0.33 / di )
kf : Thermal conductivity , W/m.˚c
jh : Factor obtained from Figure
di : inside diameter , mm
Re = (u*di*ρ/μ)
Pr = (Cp*μ/ kf)
μ : viscosity , mNs/m2

31. - As = ((pt – do)*DslB/pt) Where: As : Cross Flow area , m2
15-For Shell side coefficient calculate:
- baffle spacing lB = (Ds/5)
- Tube pitch (Triangular Pitch)= 1.25 * do
- As = ((pt – do)*DslB/pt)
Where:
As : Cross Flow area , m2
pt : tub pitch
lB : baffle spacing , m
-Gs = (Ws / As)
Ws : Fluid flow rate on the shell side , kg/s
- Equivalent diameter= (1.1/do)*(pt do2)
- Mean Shell side temperature = (T1+T2/2)
- hs = (kf*jh*Re*Pr(1/3)/de)
jh : determine from the Figure by choosing buffle percent.

32. 16- Calculate over all coefficient
1/Uo= (1/ho)+(1/hod)+(doln(do/di)/(2kw))+(do/di)
(1/hid)+(do/di)(1/hi)
Where:
Uo: the overall coefficient , W/m^2.oC
ho: outside fluid film coefficient, W/m^2 oC
hi: inside fluid film diameter
hod : outside dirt coefficient (fouling factor)
hid: inside dirt coefficient, W/m^2.oC
kw: thermal conductivity of the tube wall material
di : tube inside diameter, m
do : tube out side diameter, m

33. 17-Calculate pressure drop for:
- Tube side:
∆Pt = Np(8*jf*(L/di)+2.5)*(ρut2/2)
Where:
∆Pt : tube side pressure drop , psia
Np : number of tube side passes
ut : tube side velocity , m/s
L : length of one tube , m
jf : From Fig

34. - Shell side :
∆P = 8*jf*(Ds/de)*(L/lB)*(ρ*us2/2)
Where:
∆P : shell side pressure drop , psia
Ds : shell diameter , m
lB : baffling spacing , m
jf : From Fig

35. 18-Thickness:
(t) = ((Pri)/(SEj-0.6P)) + Cc
Where :
P: maximum internal pressure, psia
ri: inside radius of shell, m
Ej: efficiency of joints as a fraction(Ej=0.85 for spot examined welding)
S: maximum allowable stress, = Pisa
Cc: allowance for corrosion, m = 0.125

36. To cool the feed stream and prepare it to inter the separator
BFW HEATER
Equipment Name
To cool the feed stream and prepare it to inter the separator
Objective
E-105
Equipment Number
Hessa Al-sahlawi
Designer
Shell and tube heat exchanger
Type
After the Separator V-102
Location
Water
Utility
Carbon steel
Material of Construction
Quartz wool – Glass wool
Insulation
$784,600
Cost ($)
Operating Condition
Shell Side
110
Outlet temperature (oC) 35
Inlet temperature (oC)
Tube Side
90.93
289
14068
Number of Tubes 2
Number of Tube Rows
3.3506
Shell Diameter (m)
3.2726
Tube bundle Diameter (m)
LMTD (oC)
Q total (Kw)
Heat Exchanger Area (m2)
440
U (W/m2 oC)

37. To cool the feed stream and prepare it to inter the separator
STEAM GENERATOR
Equipment Name
To cool the feed stream and prepare it to inter the separator
Objective
E-104
Equipment Number
Hessa Al-sahlawi
Designer
Shell and tube heat exchanger
Type
After the ERV-100
Location
Water
Utility
Carbon steel
Material of Construction
Quartz wool – Glass wool
Insulation
$633,100
Cost ($)
Operating Condition
Shell Side
961.3
Outlet temperature (oC)
110
Inlet temperature (oC)
Tube Side
391
1147
6211
Number of Tubes 6
Number of Tube Rows
Shell Diameter (m)
3.5436
Tube bundle Diameter (m)
230.07
LMTD (oC)
310931
Q total (Kw)
Heat Exchanger Area (m2)
390
U (W/m2 oC)

38. To cool the feed stream and prepare it to inter the separator
COOLER
Equipment Name
To cool the feed stream and prepare it to inter the separator
Objective
E-104.
Equipment Number
Hessa Al-sahlawi
Designer
Shell and tube heat exchanger
Type
After the heat exchanger E-104
Location
Water
Utility
Carbon steel
Material of Construction
Quartz wool – Glass wool
Insulation
$132,500
Cost ($)
Operating Condition
Shell Side
110.7
Outlet temperature (oC)
391
Inlet temperature (oC)
Tube Side
150 25
2366
Number of Tubes 8
Number of Tube Rows
1.3373
Shell Diameter (m)
1.2583
Tube bundle Diameter (m)
LMTD (oC)
Q total (Kw)
Heat Exchanger Area (m2)
700
U (W/m2 oC)

39. To Heat the feed stream and prepare it to inter the Conversion reactor
AIR PREHEATER
Equipment Name
To Heat the feed stream and prepare it to inter the Conversion reactor
Objective
E-103A&B
Equipment Number
Hessa Al-sahlawi
Designer
Shell and tube heat exchanger
Type
After Compressor K-101
Location
Steam
Utility
Carbon steel
Material of Construction
Quartz wool – Glass wool
Insulation
$759,500
Cost ($)
Operating Condition
Shell Side
200
Outlet temperature (oC)
390
Inlet temperature (oC)
Tube Side
312
48.6
24678
Number of Tubes 2
Number of Tube Rows
Shell Diameter (m)
Tube bundle Diameter (m)
111
LMTD (oC)
Q total (Kw)
Heat Exchanger Area (m2)
100
U (W/m2 oC)

40. Shell and tube heat exchanger Type After the absorber C-101 Location
FEED PREHEATER
Equipment Name
To Heat the feed stream and prepare it to inter the Equilibrium reactor
Objective
E-101
Equipment Number
Hessa Al-sahlawi
Designer
Shell and tube heat exchanger
Type
After the absorber C-101
Location
Steam
Utility
Carbon steel
Material of Construction
Quartz wool – Glass wool
Insulation
$606,100
Cost ($)
Operating Condition
Shell Side
300
Outlet temperature (oC)
580
Inlet temperature (oC)
Tube Side
538
199.5
14379
Number of Tubes 4
Number of Tube Rows
Shell Diameter (m)
4.2352
Tube bundle Diameter (m) 67
LMTD (oC)
Q total (Kw)
Heat Exchanger Area (m2)
203
U (W/m2 oC)

41. THANK YOU FOR LISTENING