1. Done by: Sabah Alfadly Supervised by: Prof. Mohammed Fahim Eng. Yusuf Ismail

2. Agenda  Reactor design.  Distillation column design.  Heat exchanger design.  Pump design.  Compressor design.

3. introduction to Reactor design there are three main types of reactors which are: Batch CSTR FBR

4. Reactor design (CRV-101-2) Hydrogenation reactor: hydrogenation of ACP to MBA in a Packed bed reactor. taking ACP as limiting reactant and writing the rate eqn.

5. Reactor design Volume of reactor and dimension of tube: Where; dt: is the diameter of a tube (m). At : is the area of a tube (m2). L: is the length of a tube (m). V: is the volume of a tube (m3). Vtotal:is the volume of tubes (m3).

6. Reactor design Weight of the catalyst: Where; is the density of the catalyst.( kg/m3). is the porosity of catalyst. W is the weight of catalyst. (kg).

7. Reactor design Finding the rate constant K : Where, X: conversion of the reactor K: rate constant W: weight of the catalyst : concentration of ACP : molar flow of ACP in the feed

8. Reactor design height of the reactor : Where; V is the volume of reactor (m3). D is the diameter of reactor (m). H is the Height of reactor (m).

9. Reactor design Thickness calculation : Where; D is the diameter of reactor in m rj is internal radius in (in). P is the operating pressure in psi S is the working stress (psi). E is the joint efficiency Cc is the allowance for corrosion (in). T is thickness of the column in (in).

10. Reactor design Specs sheet for CRV-101-2: Pt/ Hydrogenation ReactorEquipment Name Convert ACP to MBA to Enhance the YieldObjective CRV-101-2Equipment Number Sabah AbdullahDesigner Packed bed ReactorType Styrene production SectionLocation Stain steelMaterial of Construction Foam glassInsulation Operating Condition 51.91 Volume of Reactor (m 3 ) 83.086Operating Temperature ( o C) Pt/Al2O3Catalyst Type1250Operating Pressure (psia) 770 Catalyst Density (Kg/m 3 ) 57.27507Feed Flow Rate (mole/s) 0.05 Catalyst Diameter (m) 90Conversion (%) 14.51 Reactor Height (m) 44197.23Weight of Catalyst (Kg) 2.134 Reactor Diameter (m) 500Number of Beds 0.221 Reactor Thickness (m) 14.51Height of Bed/s (m) 536544 Cost ($)14.51Height of Reactor (m)

11. Distillation Design Distillation column is used to separate components according to their boiling point temperature.

12. Distillation column design Assumptions: For Additional distillation: Sieve plate. Material of the distillation is carbon steel. Plate spacing= 0.6 m Efficiency = 80% Flooding % = 75% Weir height = 50 mm Hole diameter = 12 mm Plate thickness =10 mm

13. Distillation column design Assumptions: For t-103 : Sieve plate. Material of the distillation is stain steel. Plate spacing= 0.6 m Efficiency = 80% Flooding % = 70% Weir height = 50 mm Hole diameter = 10 mm Plate thickness =12 mm

14. Distillation column design Getting the physical properties of the streams. Calculating actual no. of stages: Actual Number of stage = Nm/ efficiency Where, Nm : no of theoretical stages Efficiency = 80%

15. Distillation column design Column diameter:

16. Distillation column design Liquid flow pattern:

17. Distillation column design Provisional plate design: where, Iw : the weir length

18. Distillation column design Residence time: where, Lwd : the liquid flow rate in the down comer Ad: down comer area

19. Distillation column design Number of holes: where, Ah: the total area of the holes Dh: the hole diameter

20. Distillation column design Thickness calcultion: where, D is the column diameter in m rj is internal radius in (in). P is the operating pressure in psi S is the working stress (psi). E is the joint efficiency Cc is the allowance for corrosion (in). T is thickness of the column in (in).

21. Distillation column design Cost estimation: where, H: column height V: volume of the column M: mass of the column

22. Distillation column design Specs sheet for additional distillation: Additional DistillationEquipment Name To separate styrene from ACP & E.B.H.PObjective Additional DistillationEquipment Number Sabah AbdullahDesigner Tray columnType Styrene production sectionLocation Carbon steelMaterial of Construction Foam GlassInsulation 43400Cost ($) Column Flow Rates 87.88Recycle (kgmole/hr)98.077Feed (kgmole/hr) 91.374Bottoms (kgmole/hr)6.7038Distillate (kgmole/hr) Key Components E.B.H.PHeavystyreneLight Dimensions 9.2Height (m)1.102Diameter (m) 10Reflux Ratio12Number of Trays Sieve trayType of tray0.6Tray Spacing -------Number of Caps/Holes1275.45Number of Holes Cost 5400$Trays30000$Vessel 1400 $Reboiler3400 $Condenser Unit

23. Distillation column design Specs sheet for t-103: Distillation t-103Equipment Name To separate propane from propeneObjective t-103Equipment Number Sabah abdullahDesigner Tray columnType PO production sectionLocation Stain steel steelMaterial of Construction Foam GlassInsulation 536000Cost ($) Column Flow Rates 270680Recycle (kgmole/hr)1759.9Feed (kgmole/hr) 121.15Bottoms (kgmole/hr)1638.8Distillate (kgmole/hr) Key Components propaneHeavypropeneLight Dimensions 62Height (m)2.5Diameter (m) 77.4Reflux Ratio100Number of Trays Sieve trayType of tray0.6Tray Spacing -------Number of Caps/Holes65.63Number of Holes Cost 75000$Trays380000$Vessel 9950 $Reboiler31200 $Condenser Unit

24. Heat Exchanger Design What is Heat Exchanger? Heat exchangers are the devises employed for transmitting heat from one fluid stream to another by indirect means. Therefore, there is a barrier which separates the fluids and permits heat to flow from the hotter to the colder stream without mixing of the streams.

25. Heat Exchanger Design 1- We use shell and tube heat exchanger counter flow because it is more efficient than the parallel flow. 2- The value of the overall heat transfer coefficient was assumed based on thefluid assigned in both sides. 3- Assume the outer, the inner diameter and the length of the tube.

26. Heat Exchanger Design Heat load : Where, Cp: Avg. specific heat of the fluid (cold or hot ). ΔT: Temperature difference. M : mass flow of the fluid

27. Heat Exchanger Design Log mean Temperature: Where; T1 is temperature of inlet hot stream. (C) T2 is the temperature of outlet hot stream.(C) t1 is the temperature of inlet cold stream. (C) t2 is the temperature of outlet cold stream.(C).

28. Heat Exchanger Design Correction factor: for more than one tube passes there is correction factor:

29. Heat Exchanger Design Heat transfer area : Where ; A is the area of exchanger (m2). Q is the duty of exchanger (kW). U is the overall heat transfer coefficient (kW/m2.C). is the log mean temperature difference (oC).

30. Heat Exchanger Design # of tubes : Where; L is the length of tube (m). do is the outer diameter of tube (mm). di is the inner diameter of tube (mm). ut is the velocity of flow rate (m/s).

31. Heat Exchanger Design Bundle and shell diameter:

32. Heat Exchanger Design Overall heat transfer coefficient: where, Uo: overall heat transfer coefficient hi: the tube side heat transfer coefficient ho: the shell side heat transfer coefficient do: outer diameter di: inner diameter Kw: wall thermal conductivity

33. Heat Exchanger Design Pressure drop for shell and tube side: Where; Np is the number of passes of tubes. jf is friction factor. ΔP is the pressure drop across the tubes (Pa).

34. Heat Exchanger Design Thickness estimation: Where; D is the shell diameter in m rj is internal radius in (in). P is the operating pressure in psi S is the working stress (psi). E is the joint efficiency Cc is the allowance for corrosion (in). T is thickness of the column in (in).

35. Heat Exchanger Design Specs sheet for E-107: Heat ExchangerEquipment Name To cool the effluent of the epoxidation reactorObjective E-107Equipment Number Sabah abdullahDesigner Shell and tube H.EType Propylene epoxidation sectionLocation Carbon steel/Stain steelMaterial of Construction FoamInsulation 123984Cost ($) Operating Condition Shell Side 78Outlet temperature ( o C)105Inlet temperature ( o C) Tube Side 102.3Outlet temperature ( o C)32.22Inlet temperature ( o C) 695.77Number of TubesNumber of Tube Rows 1.9Shell Diameter (m)1.82Tube bundle Diameter (m) 15.2177LMTD ( o C)4614479Q total (Btu/hr) 361.27Heat Exchanger Area (m 2 )52.32U (Btu/hr. o F. ft 2 )

36. Heat Exchanger Design Specs sheet for E-113 (Heater) : HeaterEquipment Name Heat the feed of 2 nd add distillation columnObjective E-113Equipment Number Sabah AbdullahDesigner Shell and tubeType Styrene production sectionLocation Low pressure steamUtility Carbon steelMaterial of Construction Foam glassInsulation 30024Cost ($) Operating Condition Shell Side 250.784Outlet temperature ( o C)250.784Inlet temperature ( o C) Tube Side 124.75Outlet temperature ( o C)45.4Inlet temperature ( o C) 8096.31Number of Tubes6Number of Tube Rows 1.73Shell Diameter (m)1.66Tube bundle Diameter (m) 107.122LMTD ( o C)1.05E7Q total (Btu/hr) 57.22Heat Exchanger Area (m 2 )89.79U (Btu/hr. o F. ft 2 )

37. Heat Exchanger Design Specs sheet for E-101-2 (cooler): CoolerEquipment Name Convert the vapor product from T-101-2 into liquidObjective E-101-2Equipment Number Sabah AbdullahDesigner Shell and tubeType Styrene production sectionLocation Cooling waterUtility Carbon steelMaterial of Construction Foam glassInsulation 48600Cost ($) Operating Condition Shell Side 16Outlet temperature ( o C)145.1Inlet temperature ( o C) Tube Side 15Outlet temperature ( o C)7Inlet temperature ( o C) 9978.166Number of Tubes8Number of Tube Rows 3.3Shell Diameter (m)3.23Tube bundle Diameter (m) 45.33LMTD ( o C)6.75E6Q total (Btu/hr) 176.32Heat Exchanger Area (m 2 )45.04U (Btu/hr. o F. ft 2 )

38. Heat Exchanger Design Specs sheet for E-110 (cooler): CoolerEquipment Name Cooling the feed of t-104Objective E-110Equipment Number Sabah AbdullahDesigner Shell and tubeType PO production sectionLocation Cooling waterUtility Carbon steelMaterial of Construction Foam glassInsulation 10260Cost ($) Operating Condition Shell Side 100Outlet temperature ( o C)102.9Inlet temperature ( o C) Tube Side 27Outlet temperature ( o C)25Inlet temperature ( o C) 631.875Number of Tubes2Number of Tube Rows 1.12Shell Diameter (m)1.04Tube bundle Diameter (m) 75.44LMTD ( o C)3.56E5Q total (Btu/hr) 5.58Heat Exchanger Area (m 2 )44.76U (Btu/hr. o F. ft 2 )

39. Pump Design Pumps are equipment to increase the pressure of the liquid, it helps to move the liquid from low elevation to high elevation.

40. Pump design Actual head of pump : P1 (Initial pressure) P2 (Final pressure). ρ is the density (kg/m3). g (Gravity)=9.8m2/s. ha is the head of pump. (m).

41. Pump design Water horse power: Q (volumetric rate) Pf is the water horse power (hp).

42. Pump design Overall efficiency : WHP is the horse power (hp). BHP is the brake horse power (hp)

43. Pump design Specs sheet for pump 108: PumpEquipment Name Increase the pressure of the feed for the 2 nd add distillation columnObjective P-108Equipment Number Sabah AbdullahDesigner Centrifugal pumpType Styrene production sectionLocation Cast ironMaterial of Construction Foam glassInsulation 9288Cost Operating Condition 45.4 Outlet Temper ature ( o C) 45.26Inlet Temperature ( o C) 58.78 Outlet Pressure (psia) 4Inlet Pressure (psia) 457.8 Power (Hp) 20Efficiency (%)

44. Compressor design A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible, so the main action of a pump is to transport liquids.

45. Compressor design Finding outlet pressure: Where; P1=inlet pressure,Ibf/ft^2 P2=outlet pressure, Ibf/ft^2 T1=inlet temperature, R T2=outlet temperature, R K=ratio of spesific heat of gas at constant pressure(Cp) to spesific heat of gas at constant volume(Cv).

46. Compressor design Calculating horse power: Where; HP is the horse power (HP). v1=specific volume of gas at inlet condition,ft^3/Ibm qfm1=cubic feet of gas per minute at inlet condition,ft^3/min

47. Compressor design Specs sheet for K-101-2: CompressorEquipment Name Increase the pressure of hydrogen feed of the hydrogenation reactorObjective K-101-2Equipment Number Sabah AbdullahDesigner centrifugalType Styrene production sectionLocation Carbon steelMaterial of Construction Foam glassInsulation 95000Cost Operating Condition 394.7 Outlet Temper ature ( o C) 149Inlet Temperature ( o C) 700 Outlet Pressure (psia) 198Inlet Pressure (psia) 187 Power (Hp) 80Efficiency (%)

48. Compressor design Specs sheet for Expander K-102 : ExpanderEquipment Name decrease the pressure of feed of t-102Objective K-102Equipment Number Sabah AbdullahDesigner centrifugalType PO production sectionLocation Carbon steelMaterial of Construction Foam glassInsulation 48600Cost Operating Condition 51.54 Outlet Temper ature ( o C) 115Inlet Temperature ( o C) 150 Outlet Pressure (psia) 320Inlet Pressure (psia) -8600 Power (Hp) 80Efficiency (%)

49. Thank you