Professional Documents
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Production of Formaldehyde From Methanol
Production of Formaldehyde From Methanol
Production of Formaldehyde From Methanol
Production of Formaldehyde
from Methanol
Integrated Final Report
Done by team 3:
Mohammed Ahmad Sanhoob
ID: 200723450
Abdullah Al-Sulami
ID: 200848200
Fawaz Al-Shehri
ID: 200763230
Sabil Al-Rasheedi
ID: 200715130
Table of Contents
PAGE
EXCUTIVE SUMMARY ....................................................................................................................................V
1. LITERATURE REVIEW OF THE PRODUCTION PROCESS ...................1
1.1. Summary of the project ....................................................................................................2
1.2. Problem Information .......................................................................................................3
1.3. Initial Block Diagram .......................................................................................................5
1.4. Kinetic Data for the Problem ..................9
1.5. Safety nad Environment precautions .............10
1.6. Preliminary cost of material..............13
2. MASS BALANCE.................................................. 14
2.1.
4. PROCESS SIMULATION................................................................................................................................52
4.1. VALIDATION.......................................................................53
4.1.1 Flowrate Spreadsheet...................................................................................................................... 54
4.1.2 Energy Spreadsheet..............................................................................................................................57
4.1.3 Discussion of Mass Balance..............................................................................................................58
4.1.4 Discussion of Energy Balance..........................................................................................................59
4.2. SIMULATION..............................................................................................................................................60
WATER FEED VARIATION TO THE ABSORBER.................................................................................63
VARIATION OF INLET TEMPERATURE TO THE ABSORBER........................................................64
4.3. ALTERNATIVE PROCESS............................................................................................................................66
4.3.1 Reactors Cooler (E-100)...................................................................................................................69
4.3.2 Productivity of the Process................................................................................................................69
4.3.3 Reactors Volume....................................................................................................................................69
4. EQUIPMENT SIZING.................70
EQUIPMENT & LINING LIST............................................................................................71
REACTION DESIGN....................................................................................................................................72
6.1. Reactor Design Equation......................................................72
6.2. Mole BALANCE...........73
6.3. Net Rate Law...........74
6.4. Rate Law...................................................................................................................................................74
6.5. Stoichiometry..........76
6.6. Combination.............................................................................................................................................77
6.7. Pressure Drop.........................................................................................................................................78
6.8. Energy Balance.......................................................................................................................................80
6.9. Heat Exchanger inside the reactor.........83
6.10. Arrangement of The Tubes..............................................................................................................., 88
6.11. Other Parameters Evaluation.........89
6.11.1.
6.11.2.
6.11.3.
6.11.4.
6.12. Results......................,,,,,,,,,,,,.............90
6.12.1. POLYMATH REASULTS......................................................................................................90
6.12.1.1. Differential equations......................................................................................90
II
5. ABSORBER DESIGN...................................................99
7.1. Packed Bed Absorber...............................................................................................................................99
7.2. Sizing of Packed Tower........................................................................................................................100
7.3. Control Loop System .......................................................................................................................105
7.4. Design Summary....................................................................................................................................106
.......................................................................................................................130
III
8.H.DESIGN SIMULATION............................................................................................................................131
8. HEAT EXCHANGER DESIGN ........................................................................................................................132
Sample Calculation.........................................................................................................................................132
Design of E-101................................................................................................................................................140
Design of E-102................................................................................................................................................142
Design of E-103................................................................................................................................................143
Design of E-106................................................................................................................................................144
Design of Condenser and Reboiler..........................................................................................................145
Design of Condenser E-104........................................................................................................................146
Design of Reboiler E-105 .......................................................................................................................147
Pinch Analysis for E-101 .......................................................................................................................148
Pinch Analysis for E-102 ....................................................................................................................., 149
Pinch Analysis for E-103 .......................................................................................................................150
Pinch Analysis for E-106 .......................................................................................................................151
Pinch Analysis for Condenser
.......................................................................................................152
Pinch Analysis for Reboiler .......................................................................................................................153
9. PUMPS, COMPERSSOR & PIPING DESIGN..............................................................................................154
PUMP P-101.............................................................................................................................................................154
PUMP P-102.............................................................................................................................................................155
PUMP P-103.............................................................................................................................................................156
COMPRESSOR C-101 .......................................................................................................................................157
VISCOSITY ESTIMATION...................................................................................................................................158
DENSITY ESTIMATION.......................................................................................................................................160
PIPING SCHEMATICS..........................................................................................................................................163
HAZOB ANALYSIS..............................................................................................................................................172
ECONOMICS AND COST ESTIMATION......................................................................................................177
A. Carbon Steel...........................................................................................................................................179
B. Stainless Steel.......................................................................................................................................183
CONCLUSION.......................................................................................................................................................187
REFERENCES.......................................................................................................................................................188
IV
EXECUTIVE SUMMARY
This work is a fully integrated and detailed report for the senior design
project on the PRODUCTION OF FORMALDEHYDE FROM METHANOL. The
compilation of this report was done gradually and chronologically over
a period of four months taking into account every aspect of design from
a chemical engineering point of view. The starting point of the design
project was a background research for the process literature. This
research included a summary of the project, problem information and
kinetics, physical and chemical properties of the participating materials
in the plant, literature review of alternative production routes, safety
precautions and environmental preservation for the process. The
second report was a quantitative analysis for the mass and energy
balances of the plant. Detailed calculations were performed in this
report for all equipment and streams in the plant, taking into account
the required process conditions to achieve a production capacity of
60000 ton/year of formalin. The third task was to simulate the plants
units and operations by utilizing the chemical simulation software
Aspen Hysys to gain an optimized view of the process conditions. Design
and sizing for all units and equipment in the plant were performed in
the fourth task. The designed units included the reactor, the absorber,
the distillation column, the compressor, heat exchangers and pumps. A
piping sizing of the plants layout and connections is presented at the
end of end of the design chapter. Operability, efficiency and economic
feasibility were the basis of the design and sizing of these units. The
final task of this project covered the estimation of the capital costs of the
production process and its profitability. Cumulative cash flow diagrams
were the introduced in the analysis to demonstrate these costs in
relation to the production revenues and returns.
IV
LITERATURE REVIEW OF
THE PRODUCTION
PROCESS
CH 3 OH 12 O2 HCHO H 2O
CH 3OH HCHO H 2
(1)
(2)
The desired reaction is the first which is exothermic with a selectivity of 9, while the
second is an endothermic reaction. The projects target is to design a plant with a
capacity of 60,000 tons formalin/year. This plant is to include three major units; a
reactor, an absorber and a distillation column. Also it includes pumps, compressors
and heat exchangers. All are to be designed and operated according to this
production capacity.
2
PROBLEM INFORMATION
Formaldehyde is to be commercially manufactured on an industrial scale
from methanol and air in the presence of a sliver catalyst or the use of a
metal oxide catalyst. The former of these two gives a complete reaction of
oxygen. However the second type of catalyst achieves almost complete
methanol conversion. The silver catalyzed reactions are operated at
atmospheric pressure and very high temperatures (600oC 650oC)
presented by the two simultaneous reactions above (1) and (2). The
standard enthalpies of these two reactions are Ho1 = -156 KJ and Ho2 = 85
KJ respectively. The first exothermic reaction produces around 50 % -- 60
% of the total formed formaldehyde. The rest is formed by the second
endothermic reaction. These reactions are usually accompanied by some
undesired byproducts such as Carbon Monoxide (CO), Carbon Dioxide
(CO2), Methyl Formate (C2H4O2) and Formic Acid (CH2O2). Below is table of
these side reactions that may take place in the process:
Number
Reaction
HR,973 K(kJ/mol)
(3)
CH2O CO+H2
+12
676
(4)
(5)
CH2O+O2 CO2+H2O
519
314
(6)
(7)
CH3OH C+H2O+H2
31
(8)
CO+H2 C+H2O
136
(9)
CO+H2O CO2+H2
35
Formaldehyde
Water
Formalin
Formula
Methanol
Oxygen
Air
Formaldehyde
Hydrogen
Water
Formalin
Silver
CH3OH (g)
O2 (g)
Gas
HCHO (g)
H2 (g)
H2O (l)
HCHO (l)
Ag (s)
Molecular
weight (g/mol)
32.042
31.999
28.851
30.026
2.016
18.015
30.03
107.8682
Boiling
point
oC
64.7
-183
-194.5
-19.3
-252.7
100
96
1950
Hv
kJ/mole
35.27
6.82
--24.48
0.904
40.656
---
1950
k1 pm
1 k2 pm
Where T is in Kelvin, the rate data as follows for the side reaction:
CH 3OH HCHO H 2
0.5
k1' p m
0.5
1 k 2' p m
Standard enthalpies of reaction (298 K, 1 atm) for the two reactions are
given as:
H1o = - 156 kJ/mol methanol
H 2o = + 85 kJ/mol methanol
9
METHANOL
Flash point
1112 C
385 C
Explosive limits
36%
6% (NFPA, 1978)
Products of Combustion
EXPOSURE
Exposure to methanol can be treated fast and efficiently. If the contact
was to the eyes or skin, flushing with water for 15 minutes would be the
first course of action. Contaminated clothing or shoes are to be removed
immediately. If the contact is much more series, use disinfectant soap,
then the contaminated skin is covered in anti-bacteria cream. Inhalation
of methanol is much more hazardous than mere contact. If breathing is
difficult, oxygen is given, if not breathing at all artificial respiration.
REACTIVITY
Methanol has an explosive nature in its vapor form when in contact with
heat of fires. In the case of a fire, small ones are put out with chemical
powder only. Large fires are extinguished with alcohol foam. Due to its
low flash point, it forms an explosive mixture with air. Reaction of
methanol and Chloroform + sodium methoxide and diethyl zinc creates
an explosive mixture. It boils violently and explodes.
STORAGE
The material should be stored in cooled well-ventilated isolated areas.
All sources of ignition are to be avoided in storage areas.
64 C
430 C
Explosive limits
36%
6% (NFPA, 1978)
Products of Combustion
11
EXPOSURE
Exposure to methanol can be treated fast and efficiently. If the contact was
to the eyes or skin, flushing with water for 15 minutes would be the first
course of action. If the contact is much more series, use disinfectant soap,
then the contaminated skin is covered in anti-bacteria cream. Inhalation of
methanol is much more hazardous than mere contact. The inhalator should
be taken to a fresh air.
Material
PELEMINIARY COST
Methanol
Formalin
Silver
Hydrogen
DI Water
10 cents / gallon
13
14
1.
MASS BALANCE
m : methanol
H2: hydrogen
N2: nitrogen
f: formaldehyde
O2: oxygen
15
1.1.
First Run
n8 = 282.26 kmol/hr.
xM = 0.3465
xO = 0.1363
xW= 0.0046
xN = 0.5126
Reactor
n9 = 329.21 kmol/hr.
xM = 0.0374
xF = 0.2596
xW= 0.2376
xH = 0.0258
xN = 0.4395
Conversion = 0.874 =
Selectivity = 9 =
From & :
16
1 = 7.866 kmol/h
2 = 0.874 kmol/h
Substituting 1& 2 in previous equations:
Eqn#1 nm, 9 = 10 7.866 0.874 = 1.26
Eqn#2 0 = nO2, 8 (0.5) * 1 nO2, 8 = (0.5)* 1 = 0.5 * 7.866 =
3.933
nN2, 8 =nN2, 9 = nO2, 8 *
Eqn#3 nH2, 9 = 2 = 0.874
Eqn#4 nH2O, 9 = 1= 7.866
Eqn#5 nF, 9 = 1 + 2 = 7.866 + 0.874 = 8.74
nF1 = nM1 = 1 = 7.866
nF2 = nM2 = 2 = 0.874
nM, 8 = 10
, nO2, 8 = 3.933
nH2, 8 = 0
, nF, 8 = 0
, nH2O, 8 = 0
, nN2, 8 = 14.796
xO2 =
xN2 =
xi 1
nM, 9 = 1.26
nH2, 9 = 0.874
, nO2, 9 = 0
, nF, 9 = 8.74
, nH2O, 9 = 7.866
, nN2, 9 = 14.796
17
yO2 =
yH2O =
yF =
yN2 =
yi 1
ABS.
n10 = 329.21 kmol/hr
xM = 0.0374
xF = 0.2596
xW= 0.2376
xH = 0.0258
xN = 0.4395
18
Thus,
0.011255 kmol Methanol ==============>
kmol water
19
Assuming that all N2 ,H2 are streamed out through off gas:
nN2, 12 = nN2, 10 = 14.796
nH2, 12 = nH2, 10 = 0.874
nF, 13 = 0.26062 * 33.536 * 0.99 = 8.6528 kmol/h.
Additionally,
So,
20
, yO2 =
yH2=
, yH2O =
, yF =
, yN2 =
yi 1
Gas Outlet Stream
n12 = 28.9214 kmol/h, nM, 12 = 0 kmol/h, nO2, 12 = 0 kmol/h, nH2O, 12 =
13.164 kmol/h
nH2, 12 = 0.874 kmol/h, nF, 12 = 0.0874 kmol/h, nN2, 12 = 14.796 kmol/h
Thus,
yM =
yH2=
, yO2 =
, yH2O =
, yF=
, yN2 =
yi 1
Liquid Outlet Stream
n13 = 23.29 kmol/h, nM, 13 = 1.26 kmol/h, nH2O, 13 = 13.378 kmol/h, nF,
13 = 8.6526 kmol/h
Thus,
yM =
yi 1
, yH2O =
, yF =
21
1.1.3.
STILL
Assumptions:
1- Light Key : methanol
2- Heavy key: H20
3- Non-heavy key: formaldehyde
4- Constant Molal Overflow (CMO)
n14 =L1= D + B . (1)
Fractional Recovery 1 = 99.7%
Fractional Recovery 1 = 99 %
Dx, M = frac.1 * n14 * xM, 14 = 0.997 * 23.29 * 0.054 = 1.2534 kmol
Methanol/h
Bx, M = (1 frac.1) * n14* xM, 14 = 0.0038 kmol Methanol/h
Bx, H2O = frac.2 * n14 * xH2O, 14 = 0.99 * 23.29 * 0.5744 = 13.244 kmol
water/h
Dx, H2O = (1 frac.2) * n14 * xH2O, 14 = (1 -0.99) * 23.29 * 0.5744 = 0.1338
kmol water/h
22
Material
Methanol
Formalde
hyde
Water
Mole
Fraction
yi
0.00017
4
0.60475
0.39508
ni =
yintot
0.0038
8.65223
5
13.244
Molecular
mi = niMW
Weight
Mass Fraction
(xi = mi/mtot)
32.042
0.12176
0.000244
30.026
259.792
0.52135
18
238.392
Sum =
498.306
0.4784
23
1.2.
Second Run
24
From conversion:
= 0.874
1+ 2= 8.74
25
F ======================> X
water
26
27
xH2O, D = 0.0.0966
Component
Methanol
Formaldehyde
Water
Mol
fraction
(yi)
0.00173
0.39345
0.60637
xH2O, B= 0.60637
nj = y i *
ntot
Molecular
weight
mi = ni *
M
0.0038
8.6425
13.3194
32.042
30.026
18
0.12176
259.5
239.73
Mass
faction xi =
mi/Mtot
0.006244
0.51965
0.4801
28
2
3
4
5
6
7
8
8.7466 10
10
0
10
0
10
0
0
0
3.933
0
3.933 3.933
0
0
0
0
0
0
0
0 0.13378 0.13378 0 0.13378 0 0.13378
0
0
0
0
0
0
0
0
0
0
14.796
0
14.796 14.796
8.7466 10.13378 10.13378 18.729 10.13378 18.729 28.86278
9
1.26
0
8.74
7.99978
0.874
14.796
33.66978
10
11
12
13
14
15
16
1.26
0
0
1.26 1.26 1.25755 0.0038
0
0
0
0
0
0
0
8.74
0
0.0874 8.6526 8.6526
0
8.6425
7.99978 18.675 13.23 13.445 13.445 0.13454 13.3197
0.874
0
0.874
0
0
0
0
14.796
0
14.796
0
0
0
0
33.66978 18.675 28.9874 23.3576 23.3576 1.39209 21.966
17
18
19
0.0038
0
0.0038
0
0
0
8.6425
0
8.6425
13.3197 11.16667 24.48637
0
0
0
0
0
0
21.966 11.16667 33.13267
20
0.0038
0
8.6425
24.48637
0
0
33.13267
stream number
1
2
3
4
5
6
7
8
9
10
11
methanol
0 280.2586 320.42 320.42 0 320.42 0 320.42 40.37292 40.37292 0
oxygen
125.856 0
0
0 125.856 0 125.856 125.856 0
0
0
formaldehyde
0
0
0
0
0
0
0
0 262.4272 262.4272 0
water
0
0 2.40804 2.40804 0 2.40804 0 2.40804 143.996 143.996 336.15
hydrogen
0
0
0
0
0
0
0
0
1.748 1.748
0
nitrogen
414.288 0
0
0 414.288 0 414.288 414.288 414.288 414.288 0
summation kg/hr 540.144 280.2586 322.828 322.828 540.144 322.828 540.144 862.972 862.8322 862.8322 336.15
29
12
0
0
2.624272
238.14
1.748
414.288
656.8003
13
40.37292
0
259.803
242.01
0
0
542.1859
14
15
16
17
18
19
20
40.37292 40.29442 0.12176 0.12176 0 0.12176 0.12176
0
0
0
0
0
0
0
259.803 0 259.4997 259.4997 0 259.4997 259.4997
242.01 2.42172 239.7546 239.7546 201 440.7546 440.7546
0
0
0
0
0
0
0
0
0
0
0
0
0
0
542.1859 42.71614 499.3761 499.3761 201 700.3761 700.3761
stream number
1
2
3
4
5
6
7
8
9
10
11
methanol
0 24009.26 27449.82 27449.82 0 27449.82 0 27449.82 3458.678 3458.678 0
oxygen
10781.865 0
0
0 10781.86 0 10781.86 10781.86 0
0
0
formaldehyde
0
0
0
0
0
0
0
0 22481.69 22481.69 0
water
0
0 206.2926 206.2926 0 206.2926 0 206.2926 12335.89 12335.89 28797.39
hydrogen
0
0
0
0
0
0
0
0 149.7481 149.7481 0
nitrogen
35491.333 0
0
0 35491.33 0 35491.33 35491.33 35491.33 35491.33 0
summation ton/yr 46273.198 24009.26 27656.12 27656.12 46273.2 27656.12 46273.2 73929.31 73917.33 73917.33 28797.39
12
0
0
224.8169
20401.04
149.7481
35491.33
56266.94
13
3458.678
0
22256.87
20732.58
0
0
46448.12
14
15
16
17
18
3458.678 3451.953 10.43093 10.43093 0
0
0
0
0
0
22256.87 0 22230.89 22230.89 0
20732.58 207.4645 20539.36 20539.36 17219.32
0
0
0
0
0
0
0
0
0
0
46448.12 3659.417 42780.68 42780.68 17219.32
19
10.43093
0
22230.89
37758.68
0
0
60000
20
10.43093
0
22230.89
37758.68
0
0
60000
10
11
12
13
107942
0
0
107942
0
0
0
0
748740.6 0 7487.406 741253.2
685327.2 1599855 1133391 1151810
74279.82 0 74279.82 0
1267548 0 1267548 0
2883837 1599855 2482706 2001005
14
15
16
17
18
107942 107732.1 325.5394 325.5394 0
0
0
0
0
0
741253.2 0
740388 740388
0
1151810 11525.81 1141076 1141076 956628.9
0
0
0
0
0
0
0
0
0
0
2001005 119257.9 1881789 1881789 956628.9
19
325.5394
0
740388
2097704
0
0
2838418
20
325.5394
0
740388
2097704
0
0
2838418
stream number
1
2
3
4
5
6
7
8
methanol
0
749306 856682.6 856682.6 0 856682.6 0 856682.6
oxygen
336933.27 0
0
0 336933.3 0 336933.3 336933.3
formaldehyde
0
0
0
0
0
0
0
0
water
0
0 11460.7 11460.7 0 11460.7 0 11460.7
hydrogen
0
0
0
0
0
0
0
0
nitrogen
1267547.6 0
0
0 1267548 0 1267548 1267548
summation kmol/year1604480.9 749306 868143.3 868143.3 1604481 868143.3 1604481 2472624
9
107942
0
748740.6
685327.2
74279.82
1267548
2883837
30
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
1
0.00
38.46
0.00
0.00
0.00
144.70
183.16
2
85.54
0.00
0.00
0.00
0.00
0.00
85.54
3
97.79
0.00
0.00
1.31
0.00
0.00
99.10
4
5
97.79 0.00
0.00 38.46
0.00 0.00
1.31 0.00
0.00 0.00
0.00 144.70
99.10 183.16
6
7
8
9
10
11
12
13
14
97.79 0.00 97.79 12.32 12.32 0.00 0.00 12.32 12.32
0.00 38.46 38.46 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 85.47 85.47 0.00 0.85 84.62 84.62
1.31 0.00 1.31 78.23 78.23 182.63 129.38 131.49 131.49
0.00 0.00 0.00 8.48 8.48 0.00 8.48 0.00 0.00
0.00 144.70 144.70 144.70 144.70 0.00 144.70 0.00 0.00
99.10 183.16 282.26 329.21 329.21 182.63 283.41 228.43 228.43
15
16
17
18
19
20
12.30 0.04 0.04 0.00 0.04 0.04
0.00 0.00 0.00 0.00 0.00 0.00
0.00 84.52 84.52 0.00 84.52 84.52
1.32 130.26 130.26 109.20 239.46 239.46
0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00
13.61 214.82 214.82 109.20 324.02 324.02
stream number
1
2
3
4
5
6
7
8
9
10
11
methanol
0 2740.783 3133.542 3133.542 0 3133.542 0 3133.542 394.8262 394.8262 0
oxygen
1230.8065 0
0
0 1230.806 0 1230.806 1230.806 0
0
0
formaldehyde
0
0
0
0
0
0
0
0 2566.402 2566.402 0
water
0
0 23.54938 23.54938 0 23.54938 0 23.54938 1408.207 1408.207 3287.373
hydrogen
0
0
0
0
0
0
0
0 17.09453 17.09453 0
nitrogen
4051.522 0
0
0 4051.522 0 4051.522 4051.522 4051.522 4051.522 0
summation kg/hr 5282.3285 2740.783 3157.091 3157.091 5282.328 3157.091 5282.328 8439.419 8438.052 8438.052 3287.373
31
12
0
0
25.66402
2328.886
17.09453
4051.522
6423.166
13
394.8262
0
2540.738
2366.732
0
0
5302.297
14
394.8262
0
2540.738
2366.732
0
0
5302.297
15
394.0585
0
0
23.68317
0
0
417.7417
16
1.190746
0
2537.773
2344.676
0
0
4883.639
17
18
19
20
1.190746 0 1.190746 1.190746
0
0
0
0
2537.773 0 2537.773 2537.773
2344.676 1965.676 4310.352 4310.352
0
0
0
0
0
0
0
0
4883.639 1965.676 6849.315 6849.315
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/year
1
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
1
2
1.0000
0.0000
0.0000
0.0000
0.0000
0.0000
1
3
0.9868
0.0000
0.0000
0.0132
0.0000
0.0000
1
4
0.9868
0.0000
0.0000
0.0132
0.0000
0.0000
1
5
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
1
6
0.9868
0.0000
0.0000
0.0132
0.0000
0.0000
1
7
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
1
8
0.3465
0.1363
0.0000
0.0046
0.0000
0.5126
1
9
0.0374
0.0000
0.2596
0.2376
0.0258
0.4395
1
10
0.0374
0.0000
0.2596
0.2376
0.0258
0.4395
1
11
0.0000
0.0000
0.0000
1.0000
0.0000
0.0000
1
12
0.0000
0.0000
0.0030
0.4565
0.0299
0.5106
1
13
0.0539
0.0000
0.3704
0.5756
0.0000
0.0000
1
14
0.0539
0.0000
0.3704
0.5756
0.0000
0.0000
1
15
0.9034
0.0000
0.0000
0.0966
0.0000
0.0000
1
16
0.0002
0.0000
0.3934
0.6064
0.0000
0.0000
1
17
0.0002
0.0000
0.3934
0.6064
0.0000
0.0000
1
7- Whole plant process stream conditions (after scaling and used in energy balance calculations):
stream number
Temperature (oC)
Press (atm)
Total kg/h
Total kmol/h
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
1
25
1
5282.328
183.1599
0.0000
38.4627
0.0000
0.0000
0.0000
144.6972
2
25
1
2740.783
85.5372
3
31.13
1
3157.091
99.1031
4
31.13
3
3157.091
99.1031
5
37.3
3
5282.328
183.1599
Component kmol/h
85.5372
97.7948
0.0000
0.0000
0.0000
0.0000
0.0000
1.3083
0.0000
0.0000
0.0000
0.0000
97.7948
0.0000
0.0000
1.3083
0.0000
0.0000
0.0000
38.4627
0.0000
0.0000
0.0000
144.6972
32
18
0.0000
0.0000
0.0000
1.0000
0.0000
0.0000
1
19
0.0001
0.0000
0.2608
0.7390
0.0000
0.0000
1
20
0.0001
0.0000
0.2608
0.7390
0.0000
0.0000
1
stream number
Temperature (oC)
Press (atm)
Total kg/h
Total kmol/h
6
150
3
3157.091
99.1031
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
97.7948
0.0000
0.0000
1.3083
0.0000
0.0000
stream number
Temperature (oC)
Press (atm)
Total kg/h
Total kmol/h
11
20
1
3287.373
182.6318
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
0.0000
0.0000
0.0000
182.6318
0.0000
0.0000
7
150
3
5282.328
183.1599
8
150
3
8439.419
282.2630
9
200
10
165
8438.052
329.2052
8438.052
329.2052
Component kmol/h
0.0000
97.7948
38.4627
38.4627
0.0000
0.0000
0.0000
1.3083
0.0000
0.0000
144.6972
144.6972
12.3221
0.0000
85.4727
78.2337
8.4794
144.6972
12.3221
0.0000
85.4727
78.2337
8.4794
144.6972
13
89.31
1.2
5302.297
228.4252
14
102
1.2
5302.297
228.4252
15
68.3
1.2
417.742
13.6139
Component kmol/h
0.0000
12.3221
0.0000
0.0000
0.8547
84.6179
129.3825
131.4851
8.4794
0.0000
144.6972
0.0000
12.3221
0.0000
84.6179
131.4851
0.0000
0.0000
12.2982
0.0000
0.0000
1.3157
0.0000
0.0000
12
89.31
1
6423.166
283.4139
33
stream number
Temperature (oC)
Press (atm)
Total kg/h
Total kmol/h
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
16
110
1
4883.639
214.8161
0.0372
0.0000
84.5192
130.2598
0.0000
0.0000
17
110
3
4883.639
214.8161
18
30
3
1965.676
109.2042
19
48
3
6849.315
324.0203
20
30
3
6849.315
324.0203
Component kmol/h
0.0372
0.0000
0.0000
0.0000
84.5192
0.0000
130.2598
109.2042
0.0000
0.0000
0.0000
0.0000
0.0372
0.0000
84.5192
239.4640
0.0000
0.0000
0.0372
0.0000
84.5192
239.4640
0.0000
0.0000
34
2.
ENERGY BALANCE
Phase
Liquid
Gas
water
Liquid
Gas
Formaldehyde
Gas
N2
Gas
O2
Gas
H2
Gas
C1
C2
C3
75.86e-3 16..83e-5
0
42.93e-3 8.301e-5
-1.87e-8
75.4e-3
0
0
33.46e-3 0.688e-5 0.7604e-8
34.28e-3 4.268e-5
0
29e-3
0.2199e-5 0.5723e-8
29.1e-3
1.158e-5 -0.6076e8
28.84e-3 0.00765e- 0.3288e-8
5
C4
0
-8.03e-12
0
-3.593e-12
-8.694e-12
-2.871e-12
1.311e-12
-0.8698e-12
P= 1 atm
T = 25 0C
n2 = 85.54
T =??
n 3,w = 1.31 , x 3, w =0.0132
n 3,m = 97.79 , x 3, m =0.9868
METHANOL IS
LIQUID AT THIS
POINT
Ein = Eout
T = 31.13 0 C
36
At 30 0C
37
[
[
= 4155051.3+6231729=4217368.59
38
Cv =20.78
Where
n= coprocessor efficiency,
Where
Assumption:
1.
2.
3.
4.
N=0.75
Adiabatic.
Constant heat capacities.
Ideal gas.
39
2.1.7. Reactor
Species
nin(mole)
in
nout(mole)
out
CH3OH
97790
H1
12320
H5
O2
38460
H2
H6
N2
144700
H3
144700
H7
HCHO
85470
H8
H2
8480
H9
H2o
1.31
H4
78230
H10
40
Where,
iHf
i,out i, in
Also, these are the enthalpies at the end of the reactor and cooling
section.
42
,
,
Q=
ii,out ii, in
= [(12320 X 9.0940) + (144700 X 5.13238)+(85470 X 6.8358)
[(12320 X 18.2296) +
1727035.182 KJ/hr.
So, this is the heat required to be removed from the system using cold
water.
2.1.9. Throttle
Throttle is used to reduce the temperature; its calculation depends on
the difference in pressure (P) of the inlet and outlet of the reactor. This
leads to the need for the reactors dimensions. In order to fully evaluate
the energy balance around the throttle, it will be done in design section
of the project. The temperature after the throttle was decided to be
chosen 165 oC(from literature reference) in orderto continue the energy
balance around the absorber.
43
2.1.10.
Absorber
Since there is a throttle, the temperature of the stream coming from the
reactor will be reduced further to less than 200 oC. Since calculating the
temperature after the throttle needs additional design specifications
such as the reactor length and diameter, this will be done afterwards in
the design section. The temperature is chosen through an educated
decision based upon stream load and literature reference of the same
plant to be less than 200 oC because the throttle is serving the
temperature decrease service. The chosen temperature is 165 oC.
We have four streams, the temperature of the two inlets streams are 20
and 164 oC for reaction product and water stream respectively. The
outlet temperature has calculated as follow:
Reference temperature is 25 oC
Heat in at stream n10 : T=(165-25) oC
Qn10=(nCpT)n10m + (nCpT)n10w + (nCpT)n10f
(nCpT)n10N2 = 4080729.58 kJ/hr.
Heat in at stream n11 : T=(25-25) oC
Qn11 = (nCpT)n11w=-126730 kJ/hr.
44
(nCpT)n10H2
2.1.11.
Also,
45
Thus,
Q=
ii,out ii, in
= [(12320 X 3.7048)+(131490 X 2.6126)+(84260 X 2.8480)
2.1.12.
Tref =250 C
46
]
]
Assumption :
47
2.1.13.
Pump P-102
At 68.3 0C
48
2.1.14.
Pump P-103
49
At 110 0C
2.1.15.
P= 1 atm
T = 110 0C
N17 = 214.82 kmol/h
n 17,m = 0.04 kmol/h
n 17,f = 84.52 kmol/h
P= 1 atm
T 18 = 30 0C
n 18,w = 109.2 kmol/h
Qin = Qout
50
2.1.16.
[
]=-56.526 335.82 = -392.35
E-101
E-102
607730
E-103
E-104
E-105
E-106
105975.16
Equipment
-392.35
C-101
P-101
P-102
P-103
51
PROCESS SIMULATION
This chapter represents a process simulation of the terms project on
the production of formaldehyde from methanol. The simulation mainly
covers the three major units of the plant; the reactor, the absorber and
the distillation column. The purpose of this simulation is to evaluate the
plants processes under given conditions (temperature, pressure and
composition). Also to compare results obtained from said simulation to
previously determined parameters through manual mass & energy
balances. The effect of varying the Flowrate of the utility water supplied
to the absorber is also to be studied. All process parameters that are
imperative to the reaction system are implemented including
conversion, selectivity, stoichiometric coefficients and reaction kinetics.
The process simulator HYSYS was used to simulate the plants processes
utilizing a modified version of the thermodynamic package NRTL as
the basis of simulation and SI as the unit system. An alternative process
design is to be introduced at the end of this chapter where the
distillation column is replaced by a heat exchanger, and results are
compared to the original design. The following is the original process
flow diagram (PFD) of the formaldehyde plant is the reference for unit
designation and stream numbering.
52
A. PROCESS VALIDATION
This first section of the simulation is set to investigate results obtained
from the previous Mass & Energy balances section by means of
validation of said results with values obtained from the HYSYS
simulation of the plants processes. Percentages of error are to be
reported with these validations along with discussions and justifications
in the case of high errors. The error equation used to validate the results
is as follows:
Errors of calculated values that were found to be 100% are in fact zero
and relatively close to the simulated values, for example:
Another example was calculating the overall mass balance across the
reactor for both the calculated and simulated which were 8439 kg/h
and 8177 kg/h respectively with error percent of 3.2%.
53
1. Flowrate Spreadsheets
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
calculated
0.0000
38.4627
0.0000
0.0000
0.0000
144.6972
183.1599
1
simulated
0
38.4636
0
0
0
144.6963
183.1599
calculated
97.7948
0.0000
0.0000
1.3083
0.0000
0.0000
99.1031
4
simulated
90.0964
0.0009
0.1415
0.0464
0.0007
0.0325
90.3184
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
%Error
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
%Error
8.5446
100.0000
100.0000
2719.6101
100.0000
100.0000
9.7264
calculated
85.5372
0.0000
0.0000
0.0000
0.0000
0.0000
85.5372
2
simulated
85.5372
0
0
0
0
0
85.5372
calculated
0.0000
38.4627
0.0000
0.0000
0.0000
144.6972
183.1599
5
simulated
0
38.4636
0
0
0
144.6963
183.1599
54
%Error
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
%Error
0.0000
0.0023
0.0000
0.0000
0.0000
0.0006
0.0000
calculated
97.7948
0.0000
0.0000
1.3083
0.0000
0.0000
99.1031
3
simulated
90.0964
0.0009
0.1415
0.0464
0.0007
0.0325
90.3184
%Error
8.5446
0.0000
100.0000
2719.6101
0.0000
100.0000
9.7264
calculated
97.7948
0.0000
0.0000
1.3083
0.0000
0.0000
99.1031
6
simulated
90.0964
0.0009
0.1415
0.0464
0.0007
0.0325
90.3184
%Error
8.5446
100.0000
100.0000
2719.6101
100.0000
100.0000
9.7264
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
calculated
0.0000
38.4627
0.0000
0.0000
0.0000
144.6972
183.1599
7
simulated
0
38.4636
0
0
0
144.6963
183.1599
calculated
12.3221
0.0000
85.4727
78.2337
8.4794
144.6972
329.2052
10
simulated
5.241
3.1232
84.9969
70.7289
14.1737
144.7288
322.9925
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
%Error
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
%Error
135.1106
100.0000
0.5598
10.6107
40.1749
0.0218
1.9235
calculated
97.7948
38.4627
0.0000
1.3083
0.0000
144.6972
282.2630
8
simulated
90.0964
38.4645
0.1415
0.0464
0.0007
144.7288
273.4783
calculated
0.0000
0.0000
0.0000
182.6318
0.0000
0.0000
182.6318
11
simulated
0
0
0
182.63
0
0
182.63
55
%Error
8.5446
0.0047
100.0000
2719.6101
100.0000
0.0218
3.2122
%Error
0.0000
0.0000
0.0000
0.0010
0.0000
0.0000
0.0010
calculated
12.3221
0.0000
85.4727
78.2337
8.4794
144.6972
329.2052
9
simulated
5.241
3.1232
84.9969
70.7289
14.1737
144.7288
322.9925
%Error
135.1106
100.0000
0.5598
10.6107
40.1749
0.0218
1.9235
calculated
0.0000
0.0000
0.8547
129.3825
8.4794
144.6972
283.4139
12
simulated
0.0086
3.1223
0.0105
121.1805
14.1729
144.6963
283.1911
%Error
100.0000
0.0000
0.0000
6.7685
40.1715
0.0006
0.0787
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
calculated
12.3221
0.0000
84.6179
131.4851
0.0000
0.0000
228.4252
13
simulated
5.2325
0.0009
84.9864
132.1784
0.0007
0.0325
222.4314
calculated
0.0372
0.0000
84.5192
130.2598
0.0000
0.0000
214.8161
16
simulated
0.6533
0
84.8443
132.1318
0
0
217.6294
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
%Error
135.4925
0.0000
0.4335
0.5245
100.0000
100.0000
2.6947
%Error
94.3116
0.0000
0.3832
1.4168
0.0000
0.0000
1.2927
calculated
12.3221
0.0000
84.6179
131.4851
0.0000
0.0000
228.4252
14
simulated
5.2325
0.0009
84.9864
132.1784
0.0007
0.0325
222.4314
calculated
0.0372
0.0000
84.5192
130.2598
0.0000
0.0000
214.8161
17
simulated
0.6533
0
84.8443
132.1318
0
0
217.6294
56
%Error
135.4925
100.0000
0.4335
0.5245
100.0000
100.0000
2.6947
%Error
94.3116
0.0000
0.3832
1.4168
0.0000
0.0000
1.2927
calculated
12.2982
0.0000
0.0000
1.3157
0.0000
0.0000
13.6139
15
simulated
4.5792
0.0009
0.1421
0.0466
0.0007
0.0325
4.802
%Error
168.5663
100.0000
100.0000
2723.4582
100.0000
100.0000
183.5052
calculated
0.0000
0.0000
0.0000
109.2042
0.0000
0.0000
109.2042
18
simulated
0
0
0
107
0
0
107
%Error
0.0000
0.0000
0.0000
2.0600
0.0000
0.0000
2.0600
stream number
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
summation kmol/hr
calculated
0.0372
0.0000
84.5192
239.4640
0.0000
0.0000
324.0203
19
simulated
0.6533
0
84.8443
239.1318
0
0
324.6294
%Error
94.3116
0.0000
0.3832
0.1389
0.0000
0.0000
0.1876
calculated
0.0372
0.0000
84.5192
239.4640
0.0000
0.0000
324.0203
20
simulated
0.6533
0
84.8443
239.1318
0
0
324.6294
%Error
94.3116
0.0000
0.3832
0.1389
0.0000
0.0000
0.1876
2. Energy Spreadsheet:
Results
E-101
E-102
E-103
E-104
E-105
E-106
C-101
P-101
P-103
Hand Calculations
4217368.59
607730
105975.16
-509157.15
571017.54
-392.35
1215098.58
1033.025
1856.6
Simulation
3801000
-103900
387400
-10850000
19900000
905400
780444
1020
1785
57
Error %
10.95418548
684.9181906
72.64451213
95.30730737
97.13056513
100.0433344
55.69324385
1.276960784
4.011204482
Stream 9, 10, 13 and 14: Since the product was produced from one
desired and one undesired reactions, which were hand-calculated using
the conversion given by the problem statement. These conversions
were 78.66 and 8.74 for the desired and undesired reactions
respectively. However, the simulated version of the process has
conversions of 78.45 and 15.73 for the desired and undesired reactions
respectively. As a result, larger amount of methanol was consumed
from the undesired reaction. And the amount of methanol remaining
became lesser in simulation. This makes high error in the methanol
amount.
58
B. SIMULATION
This part of the chapter is concerned with virtually simulating the
process of the formaldehyde production from methanol.
60
61
62
63
64
65
Discussion of results:
One part of simulation is comparing the amount of formaldehyde in the
liquid stream product in the absorber, temperature of the off-gas and
re-boils energy of the bottom in the distillation column with the amount
of water that fed to the absorber. The water fed was varied from 150
kmol/hr to 310 kmol/hr. We noticed as the water increases, the off-gas
temperature, amount of the formaldehyde in the liquid product stream
and the re-boil energy in the bottom of the distillation column will
decrease.
In another comparison, the effect of the feed temperature to the
absorber on the amount of the formaldehyde and methanol in the liquid
product stream was studied. The study was taken between 300 and
120 oC . It is noticed as the temperature increases, the amount of the
formaldehyde and methanol increase in the liquid product stream.
C. ALTERNATIVE PROCESS
This last part of the chapter is aimed to study an alternative modern
process of the production of formaldehyde from methanol. The goal of
this study is to achieve a 98% conversion of methanol by means of
removing the distillation column and replacing it with a higher duty
cooler to bring the product to 37 wt. % of formaldehyde. A comparison
is to be done between the original design and the alternative and their
efficiencies. Below are screenshots of the simulated plant using HYSYS:
66
67
68
3. Reactors Volume:
One of the downsides of the alternative design is that, when simulated,
it requires a much higher net volume for the reactor in order to achieve
the specified conversion (98%). While the aternative reactor is 70000
m3 in volume, the original processs reactor has a net volume of just
4000 m3. More details and evaluations are to be presented when
performing the design of the plant later.
69
EQUIPMENT SIZING
This chapter covers the equipment design and sizing of the
formaldehyde production plant. The main units to be designed are the
reactor, absorber, distillation column, heat exchangers, pumps and the
compressor. The reactor design covered mainly the volume of the
reactor, the weight of the silver catalyst with its distribution along the
packed bed reactor, the temperature inlet and outlet of the reactor, the
pressure drop across the reactor. The absorber design is concerned
with determining the height of the packed tower, the diameter and the
type of packing. The design of the distillation tray column covered the
minimum reflux ratio, the minimum and actual number of stages, the
diameter and height of the column, the efficiency of the trays, and the
detailed layout of the sieve tray dimensions for the rectifying and
stripping sections. The heat exchangers design covered the
determination of the shell side and tube side diameter and the length of
the tubes. A detailed pinch analysis was done on all heat exchangers to
optimize the heating cooling Q to a minimum and ultimately lower the
fixed capital cost. The compressor and the pumps were designed by
determining the work of the shaft according to the pressure drop across
the unit. The design pipes were done by taking into account the
mechanical limits of the flowing fluids and the pressure drop across the
pipe.
70
Designation
R-101
T-101
T-102
E-101
E-102
E-103
E-104
E-105
E-106
C-101
P-101
P-103
stream 1
stream 2
stream 3
stream 4
stream 5
stream 6
stream 7
stream 8
stream 9
stream 10
stream 11
stream 12
stream 13
stream 14
stream 15
stream 16
stream 17
stream 18
stream 19
stream 20
REACTOR DESIGN
In this section, designing a plug flow reactor for multi reaction and nonisothermal condition has been done. this reactor is supported with a
heat exchange to remove the heat generated from the exothermic
reaction. in this designing section, mole balances were considered to be
in the form of the final mole which is the remaining at the end of the
reaction period. Since the reaction is parallel, taking in mind the
reaction rates is too important by combining all these rates for each
material. Then evaluating the rest of these rate using the stoichiometric
coefficients. Evaluating the concentration of each material were done in
which all the pressure and temperature effect was considered. Here one
assumption was used which is the ideality of the gas introduced to the
reactor. By the end of this step, combination all previous steps can be
done to reduce the number of equations. Using Ergun equation,
pressure drop across the reactor was evaluated. In energy balance, to
increase the accuracy of the results, we use the integrated heat capacity
instead of assuming it constant. This is also has been done for
calculation of viscosity.
(Desired Reaction)
(Undesired Reaction)
(Desired Reaction)
A C+ E
(Undesired Reaction)
72
Where:
A is methanol
B is Oxygen.
C is formaldehyde.
D is Water.
E is hydrogen
I is Nitrogen inert gas
2- MOLE BALANCE
The basic mole balances of all components involved in the main
reaction are:
Methanol(A):
Oxygen (B):
Formaldehyde (C):
Water (D):
Hydrogen (E):
Where:
Fi is the molar flow rate in (mol/s).
W is the weight of the catalyst in (Kg)
r'i is the reaction rate in (mole i reacted/ (Kg cat. hr))
73
4- RATE LAWS
The reaction rate expressions are:
where:
Where:
- CA is the molar concentration of methanol in (kmol/m3)
- T is in (K)
- R is the gas constant= 0.082 (atm.m3/kmol.K)
And so the reaction rate expressions will be:
75
5- STOICHIOMETRY
In this design problem, the calculation will be done in case there is a
variation in both temperature and pressure. So for gas phase, the
concentration can be found as follow:
(
) ( ) ( )
Therefore,
( ) ( )
( ) ( )
( ) ( )
( ) ( )
( ) ( )
( ) ( )
)
(
)
(
6- COMBINATION
Mole balances, rate equation and stoichiometric relations are combined
together to form the main design equation. Note, the temperature
Methanol(A):
(
(
(
)
)
(
77
(1)
Oxygen (B):
(
(2)
Formaldehyde (C):
(
(
)
)
(
(3)
Water (D):
(
(4)
Hydrogen (E):
(
)
(
(5)
Conversion equation:
(6)
7- PRESSURE DROP
Pressure drop can be calculated using the differential equation of Ergun
equation:
(7)
Where:
78
- Po1=820.732.5kPa
- To =500 (K)
- FTo =282.26 (kmol/hr)
- FT = FA+FB+FC+FD +FE +FF +FI (kmol/hr)
- FI= FBo*(0.79/0.21)
-
(8)
(9)
79
8- ENERGY BALANCES
Using the energy balance design equation of a PBR with heat exchange:
Reactor:
for to reaction :
(
(10)
For variable coolant temperature, Ta, the energy balance equation is:
Coolant:
2)
by simplification:
1)
(11)
2)
(12)
80
Methanol(A):
Oxygen (B):
HoB=0
Formaldehyde (C):
Water (D):
is:
Hydrogen (E):
HoE=0
Nitrogen (I):
HoI=0
To calculate
COOLANT FLOWRATE:
In our design system, saturated water is used to cool the reactor.
This stream is designed to be at medium pressure steam where the
pressure range has to be between 10 to 18 atm. We chose the pressure
82
(13)
difference is:
TC1=480 K
TC2=480 K
Th1=500 K
Th2=616 K
(
(
(14)
)
)
Therefore,
So
83
The procedure used to solve this cooling system is same as normal heat
exchanger. First of all, the length of the tube and the diameter of the
inside tubes were chosen. It is assumed that stainless steel is the
material of construction. Since our aim for cooling is just converting the
water of cooling to steam at same temperature. So correction factor is 1.
overall heat transfer was assumed at the first time to be 700 kJ/hr.m2.K.
Using this guessed overall heat transfer, the provisional area was
determined:
(15)
Where Q is gotten from our last calculation in mass and energy balance.
Based on the assumption of the length and the diameter of the tubes,
number of tubes needed is calculated:
(16)
Then, tube pitch and the bundle diameter were calculated:
pitch:
(17)
( )
(18)
Where K1 and n1 are constant and they were chosen from the following
table to be 0.215 and 2.207 respectively.
84
from information derived above, the shell diameter , baffle space, cross
sectional area, shell side mass velocity and the equivalent diameter
were calculated:
(19)
(20)
85
(21)
(22)
(23)
To find the heat transfer coefficient of the shell side , Reynolds, Prandtle
and Nauseate number are needed.
(24)
(25)
(
86
(26)
(27)
Pressure drop in the shell can be calculated from the following relation:
( )( )(
)(
(28)
for tube side calculation, tube-side mass velocity, tube side velocity,
Reynolds, Nauseate and Prandtle numbers were calculated:
(29)
(30)
(31)
87
(32)
Since the Reynolds number is in the range of the turbulent flow, heat
transfer coefficient was calculated from the following relation:
( )
)
(33)
( ) (
(34)
) (
By the end of this step we will get the calculated result of the overall
heat transfer coefficient. Since this value is neither equal nor close to
the guessed one. So this value was looped several time until the prober
overall transfer coefficient was obtained.
Sp
Sn
88
89
12- RESULTS
12.1.
POLYMATH REASULTS:
2 d(FB)/d(W) = 0.5*rA1
kmoleA/(kg cat. hr)
3 d(FC)/d(W) = -rA1-rA2
kmoleA/(kg cat. hr)
4 d(FD)/d(W) = -rA1
kmoleA/(kg cat. hr)
5 d(FE)/d(W) = -rA2
kmoleA/(kg cat. hr)
d(T)/d(W) = ((306.495*4/1500/0.0092456)*(480T)+(rA1*DHrxn1)+(rA2*DHrxn2))/(sumFiCPi)
7 d(y)/d(W) = (-alpha)*(FT/FTo)*(T/To)/2/y
8 d(V)/d(W) = 1/1500
2 FI = 144.693
kmol/hr
3
4
5
k1 = exp(12.5-(8774/T))
k2 = exp(-17.29+(7439/T))
k3 = exp(16.9-(12500/T))
6 k4 = exp(25-(15724/T))
7 CTo = 8.2/(0.082*To)
kmole/m3
8 FT = FA+FB+FC+FD+FE+FI
90
kmole/hr
9 CA = CTo*(FA/FT)*(To/T)*y
kmole/m3
10 Pa = 0.082*CA*T
atm
11
12
rA1 = -((Pa*k1)/(1+Pa*k2))
rA2 = -((Pa^0.5*k3)/(1+Pa^0.5*k4))
13 CB = CTo*(FB/FT)*(To/T) *y
kmole/m3
14 CC = CTo*(FC/FT)*(To/T) *y
kmole/m3
15
CD = CTo*(FD/FT)*(To/T) *y
kmole/m3
16 CE = CTo*(FE/FT)*(To/T) *y
kmole/m3
17 FTo = 282.26
kmol/hr
18
CI = CTo*(FI/FT)*(To/T) *y
kmole/m3
19 CAo = 0.3465*CTo
kmole/m3
20 Conversion = (97.79-FA)/97.79
21 Si = rA1/rA2
alpha = 2*(((8439.419/(3600*(3.14*(1/2)^2)))*(1-0.5)/(1.858*1*0.001*0.5^3)*((150*(122 0.5)*4.894e5/0.001)+(1.75*(8439.419/(3600*(3.14*(1/2)^2)))))))/((3.14*(1/2)^2)*3000*(10.5)*101.325*8.2)/1000
DHrxn1 = 1000*(((-115.9+(34.28E-3*((T-273.15)-(To-273.15))+2.134e-5*((T-273.15)^223 (To-273.15)^2)-2.1735e-12*((T-273.15)^4-(To-273.15)^4)))+(-241.83+(33.46E-3*((T273.15)-(To-273.15))+3.44e-6*((T-273.15)^2-(To-273.15)^2)+2.535e-9*((T-273.15)^3(To-273.15)^3)-8.9825e-13*((T-273.15)^4-(To-273.15)^4)))-(-201.2+(42.93E-3*((T-
91
273.15)-(To-273.15))+4.1505e-5*((T-273.15)^2-(To-273.15)^2)-6.233e-9*((T-273.15)^3(To-273.15)^3)-2.0075e-12*((T-273.15)^4-(To-273.15)^4)))-(0+0.5*((29.1E-3*((T273.15)-(To-273.15))+5.79e-6*((T-273.15)^2-(To-273.15)^2)-2.0253e-9*((T-273.15)^3(To-273.15)^3)+3.2775e-13*((T-273.15)^4-(To-273.15)^4))))))
kJ/kmol
25 CPIg = 29e-3+0.2199e-5*(T-273.15)+0.5723e-8*(T-273.15)^2-8.69e-12*(T-273.15)^3
26 CPAg = 42.93e-3+8.301e-5*(T-273.15)-1.87e-8*(T-273.15)^2-8.03e-12*(T-273.15)^3
27 CPBg = 29.1e-3+1.158e-5*(T-273.15)-0.6076e-8*(T-273.15)^2+1.311e-12*(T-273.15)^3
28 CPCg = 34.28e-3+4.268e-5*(T-273.15)-8.69e-12*(T-273.15)^3
29 CPDg = 33.46e-3+0.688e-5*(T-273.15)+0.7604e-8*(T-273.15)^2-3.593e-12*(T-273.15)^3
30 CPEg = 28.84e-3+0.00765e-5*(T-273.15)+0.3288e-8*(T-273.15)^2-0.8698e-12*(T273.15)^3
31
sumFiCPi = (FA*CPAg+FB*CPBg+FC*CPCg+FD*CPDg+FE*CPEg+FI*CPIg)*1000
kJ/h
32 Q = 58.8527*305.2868*60.514
kJ/hr
33 mc = Q/(1910)
kg/hr
34
35
36
37
38
XA = FA/FT
XB = FB/FT
XC = FC/FT
XD = FD/FT
XE = FE/FT
92
39 XI = FI/FT
12.1.3. The result of solving these differential and explicit equations were:
Variable
1 alpha
0.0001169
0.0001169
0.0001169
0.0001169
2 CA
0.0679586
0.0046567
0.0679586
0.0046567
3 CAo
0.0693
0.0693
0.0693
0.0693
4 CB
0.0305775
0.0020098
0.0305775
0.0020098
5 CC
0.0364541
0.0364541
6 CD
0.0009104
0.0009104
0.0335263
0.0335263
7 CE
0.0034786
0.0034786
8 CI
0.1005535
0.0598285
0.1005535
0.0608288
9 Conversion 0
0.8867272
0.8867272
10 CPAg
0.0607048
0.0607048
0.0701898
0.0688707
11 CPBg
0.0314296
0.0314296
0.0325628
0.0324091
12 CPCg
0.0438605
0.0438605
0.0493426
0.0485641
13 CPDg
0.0353701
0.0353701
0.0367835
0.0365682
14 CPEg
0.0290164
0.0290164
0.0292586
0.0292177
15 CPIg
0.0296919
0.0296919
0.0301356
0.0300765
16 CTo
0.2
0.2
0.2
0.2
17 DHrxn1
-1.565E+05
-1.565E+05
-1.564E+05
-1.564E+05
18 DHrxn2
8.53E+04
8.53E+04
8.669E+04
8.652E+04
19 FA
97.79
11.07695
97.79
11.07695
20 FB
44.
4.780681
44.
4.780681
21 FC
86.71305
86.71305
22 FD
1.31
1.31
79.74864
79.74864
23 FE
8.274411
8.274411
24 FI
144.693
144.693
144.693
144.693
25 FT
287.793
287.793
335.2867
335.2867
26 FTo
282.26
282.26
282.26
282.26
27 k1
0.0064222
0.0064222
0.2724181
0.1750521
28 k2
0.0896358
0.0037374
0.0896358
0.0054376
29 k3
0.0003035
0.0003035
0.0632314
0.0336744
30 k4
0.0015837
0.0015837
1.307468
0.5918646
31 mc
569.242
569.242
569.242
569.242
32 Pa
2.786301
0.2352352
2.786301
0.2352352
93
33 Q
1.087E+06
1.087E+06
1.087E+06
1.087E+06
34 rA1
-0.0143181
-0.1176075
-0.0143181
-0.0411258
35 rA2
-0.0005053
-0.0217943
-0.0005053
-0.0126897
36 Si
28.3337
3.240879
28.3337
3.240879
37 sumFiCPi
1.166E+04
1.166E+04
1.274E+04
1.264E+04
38 T
500.
500.
635.7779
616.0361
39 To
500.
500.
500.
500.
40 V
1.198667
1.198667
41 W
1798.
1798.
42 XA
0.3397928
0.0330373
0.3397928
0.0330373
43 XB
0.1528877
0.0142585
0.1528877
0.0142585
44 XC
0.2586236
0.2586236
45 XD
0.0045519
0.0045519
0.2378521
0.2378521
46 XE
0.0246786
0.0246786
47 XI
0.5027676
0.43155
0.5027676
0.43155
48 y
1.
0.8683294
1.
0.8683294
As it is clear in the result of the polymath, we need 1798 kg of catalyst with diameter of 0.001 m
and porosity of 0.5 to achieve this reaction. this amount lead to 88.67% conversion of methanol
to formaldehyde.
12.1.4. Graphs:
94
95
12.2.
Heat exchanger was calculated as the procedure mentioned above. the results are shown below:
Q (kJ/hr)
1087245.768
K1
n1
A m2
n
Bundle diameter m
BDC
DS
BS
pt
As m2
GS (kg/hr/m2)
equivalent dia. m
Re s
pr
Nu shell
ho
0.215
2.207
58.8527
910.5372
0.6034
0.0380
0.6414
0.2565
0.0171
0.0329
16354.9775
0.0135
562.5432
0.0057
0.4652
82.2360
dPs (kPa)
0.0000
GM kg/hr/m2
Velocity m/s
Ret
Prt
138032.6281
74259.9563
7243.2726
0.0009
hi
732.6217
96
UTILITY PROPERTIES
kf (kJ/(hr.m.K))
2.394
Viscosity kg /(m.hr)
Density kg/m3
0.393754633
936.76
Cpc kJ/kg K
1.833333333
mc(kg/hr)
538.1871933
REACTION PROPERTIES
Viscosity kg /(m.hr)
0.176190312
Density kg/m3
1.858776048
Cph kJ/kg K mix
0.667622394
mh (kg/hr)
8438
TUBES PROPERTIES
k (kJ/(hr.mK))
126
di (m)
do (m)
Ai (m)
Ao (m)
guess L (m)
0.0092456
0.013716
6.71367E-05
0.000147756
1.5
Guess U (kJ/hrm2 k)
305.2868
UO calculated
error%
307.8752222
0.840737431
L/D
2.228554938
97
Product
Methanol
Water
Formaldehyde
Hydrogen
Mass balance
12.32
78.23
85.47
8.48
Design
11.07695
79.74
86.713
8.27
Tin ( C)
Tout (oC)
P (atm)
Totall weight of catalyst (kg)
Weight of catalyst per tube
(kg)
Volume (m3)
Diameter (m)
Height (m)
Length of the tube (m)
Number of tubes
MOC
Orientation
227
343
7.12
1798
1.976
1.199
0.8414
1.875
1.5
910
stainless Steel
Vertical
98
%error
10.08969
1.930206
1.454311
2.476415
ABSORBER DESIGN
One of the most common unit operations in the industry is the
absorption process. Absorption is the mechanism of transporting
molecules or components of gases into liquid phase. The component
that is absorbed is called the solute and the liquid that absorbs the
solute is called the solvent. Actually, the absorption can be either
physical where the gas is removed due to its high solubility in the
solvent, or chemical where the removed gas reacts with the solvent and
remains in solution.
1- Packed-Bed Absorber
The packed-bed absorbers are the most common absorbers used for gas
removal. The absorbing liquid is dispersed over the packing material,
which provides a large surface area for gas-liquid contact. Packed beds
are classified according to the relative direction of gas-to-liquid flow
into two types. The first one is co-current while the second one the
counter current packed bed absorber. The most common packed-bed
absorber is the countercurrent-flow tower. The gas stream enters the
bottom of the tower and flows upward through the packing material
and exits from the top after passing through a mist eliminator. Liquid is
introduced at the top of the packed bed by sprays or weirs and flows
downward over the packing. In this manner, the most dilute gas
contacts the least saturated absorbing liquid and the concentration
difference between the liquid and gas phases, which is necessary or
mass transfer, is reasonably constant through the column length. The
maximum (L/G) in countercurrent flow is limited by flooding, which
occurs when the upward force exerted by the gas is sufficient to prevent
the liquid from flowing downward. The minimum (L/G) is fixed to
ensure that a thin liquid film covered all the packing materials.
99
Packing material
The main purpose of the packing material is to give a large surface area
for mass transfer. However, the specific packing selected depends on
the corrosiveness of the contaminants and scrubbing liquid, the size of
the absorber, the static pressure drop, and the cost. There are three
common types of packing material: Mesh, Ring, and Saddles. In our
project Ceramic Berl Saddles packed was selected since it is good liquid
distribution ratio, good corrosion resistance, most common with
aqueous corrosive fluids and Saddles are beast for redistributing liquids
low cost. Also we use 2 inches diameter packing.
100
= 8873.33
= 3291.2
Where:
101
= 1.620
= 995.65
= 150 m-1
= 0.797
=
-3
G' = mass flow rate of gas per unit cross-sectional area of column, g/sm2
= density of the gas stream (
= density of the absorbing liquid (
54
15]
Area of packing =
Area =
= 0.469
D packing = 0.77 M
PACKING HEIGHT:
Equilibrium data table:
Y
0.128131 0.020408
0.256075 0.041667
0.383319
0.06383
0.509738 0.086957
0.63521
0.111111
0.759703 0.136364
0.883187 0.162791
1.005826 0.190476
1.128138 0.219512
1.250327
0.25
103
= 0.469
Y vs X
0.7
y = 5.8413x
0.6
0.5
y = 7.481x + 0.0073
0.4
0.3
0.2
0.1
0
0
0.02
Calculating
0.04
X 0.06
0.08
0.1
0.12
and Z :
Z= HOG
= number of transfer units based on an overall gas-film coefficient.
HOG = height of a transfer unit based on an overall gas-film coefficient, m
= mole fraction of solute in entering gas
= mole fraction of solute in exiting gas
[
]
[
HOG was obtained from table 15-4 in Separation Process Engineering. For
ceramic packing with size 2 in, HOG = 3 ft = 0.9 m
Z = HOG
104
105
4- Design Summary
Absorber Summary Table
Diameter (m)
Height (m)
Orientation
Vertical
Internals
2 Ceramic, saddles
106
A. PRELIMINARY CALCULATIONS
This first section of the design is set to present the initial calculations
needed in the design and sizing of the distillation column. These
calculations include material balance, physical properties of the system
and the relative volatilities of the participating components.
1. Material Balance
This initial mass balance around the distillation column gives an
indication of the accuracy of the simulated parameters that are to be
used in the upcoming calculations on a kmol/hr. basis.
107
Assumptions:
9- Light Key : methanol
10Heavy key: H20
11Non-heavy key: formaldehyde
12Constant Molal Overflow (CMO)
n14 = D + B . (1)
DxM= frac.1 * n14 * xM,n14 = 0.997 * 23.458 * 0.054 = 1.25755
BxM= (1 frac.1) * n14 * xM,n14 = 0.003784
BxH2O = frac.2 * n14 * xwater,n14 = 0.99 * 23.358 * 0.576 = 13.3197
DxH2O = (1 frac.2) * n14 * xwater,n14 = (1 -0.99) * 23.358 * 0.576 = 0.13454
xH2O, D = 0.0.0966
Component
Methanol
Formaldehyde
Water
Mol
fraction
(yi)
0.00173
0.39345
0.60637
xH2O, B= 0.60637
nj = yi * ntot
Molecular
weight
mi = ni * M
0.0038
8.6425
13.3194
32.042
30.026
18
0.12176
259.5
239.73
108
Mass
fraction xi
= mi/Mtot
0.006244
0.51965
0.4801
2. Physical Properties
The physical parameters to be included are the molecular weight and
average density on the basis of mole fractions of the components in
both the rectifying and stripping section.
Molecular Weight
Rectifying Section:
= 31.57g/mol
Stripping Section:
= 22.63 g/mol
Average Density
Rectifying Section:
Stripping Section:
109
3. Relative Volatilities
The volatility of each component is to be calculated for the rectifying
and stripping sections and their average relative to an reference
component with is methanol in our case.
Rectifying Section
Stripping Section
78547
110
B. MINIMUM REFLUX
This is concerned with the determination of the minimum external and
internal reflux ratios for the distillation column T-101. The application
is done by utilizing underwoods shortcut method. To facilitate the
underwoods approach, we use the following assumptions:
-
.43 (1-1) = 0
Solving for
= 0.8758
111
Minimum refluxes
External Reflux:
Internal Reflux:
External Reflux:
Internal Reflux:
112
C. COLUMN DIAMETER
Sieve tray column is decided to be used in the design. This decision is
based upon the compatibility of this tray type with our methanolformaldehyde-water separation process. Also depends on the many
features that serve the upcoming economical evaluation of the column.
These features include high capacity, relatively high efficiency, low cost,
low fouling tendency and low maintenance requirements. We are to use
Fairs (1963) approach to calculating the diameter of the column
starting with determining the vapor flooding velocity, then the
operating velocity and finally sizing the actual diameter of the column.
This approach is to be applied to the rectifying section and extended to
the stripping section of the column.
114
()
1.145 *
7.9039
( )
115
D. TRAY SPECIFICATIONS
This section is aimed to investigate the design specifications of the
column in relation to the tray instillation. These specifications include
the minimum number of stages, the theoretical number of stages, the
optimum feed stage, the tray efficiency and the actual construction
stages.
[(
116
( )
Abscissa =
( ) ( )
Ordinate = 0.62
( )
117
[(
)(
)]
[(
)(
)]
Since,
( )
( )
( )
( )
118
= 0.8573 85.7%
Actual Number of stages in top side NTOP =
119
= 0.841 84.1%
Actual Number of stages in bottom side NTOP =
COLUMN HEIGHT
The column height is heavily dependent upon the spacing between the
sieve trays. In our design, 18 inches were chosen for spacing to provide
a reasonable space to ease the accessibility for manual workers to crawl
between the plates for maintenance. According to Turtons Distillation
Column Design Heuristics (1955), a safety factor of 10% is to be added to
the final design height. The column height is determined as follows:
1 stage of partial condenser is to be added to the total height.
Total Actual number of stages= 4+15 = 19 stages
Safety Factor = 19*(0.1) = 1.9 stage
Total Construction stages = 1.9+19+1 22 STAGE including
reboiler
Column Height = Tray Spacing * (Num. of stages + safety factor)
= 18 * (20+1.9) (
10.06 m
120
1. Tray Dimensions
Diatop = 8.115 ft.
ENTRAINMENT AT A FLOODING POINT OF 75%:
FP= 0.03993 from below chart: fractional entrainment () = 0.07
121
( )
ENTRAINED LIQUID:
(e) =
AMOUNT ENTRAINED ON TOP:
L+e=
COLUMN CROSS-SECTIONAL AREA:
Atot =
DOWNCOMER AREA:
Ad =
Atot =
WEIR LENGTH:
= (Dia)* 0.726 = 8.115*0.726 = 5.8915 ft.
ACTIVE AREA OF THE TRAY:
Since a non-fouling operation is aimed, the tray holes are punched from
the bottom down to provide safer maintenance of personnel.
VAPOR VELOCITY THROUGH THE TRAY HOLES:
ORIFICE COEFFICIENT:
Determined through a correlation by Hughmark and OConnell (1957)
in the following fit equation:
(
The chosen weir height is h weir = 2 inch. This optimum height is enough
to retain the down flowing liquid and provide the downcomer with
enough head to remain sealed. It also provides a reasonable residence
time of the liquid in the sieve tray.
123
The abscissa =
The
124
With a gap between the downcomer apron and the lower tray is chosen
to be 1 inch as a standard. The fractional loss of the liquid head is
encountered during down flow through the downcomer and the lower
tray and is estimated by the empirical equation by Ludwig (1997):
(
Since the aerated liquid head is much less than the tray
spacing which is 18 inch, there would be no operational problem and
the liquid flooding is regulated.
125
WEEPING CHECK
An analysis is done to check for the operation to be above the weeping
and dumping points and avoid excessive weeping. An approximate
estimation given by Kessler and Wankat (1987) provides an indication
of the state of operation by utilizing the surface tension head as follows:
Correlation parameter:
X=
Correlation term:
(X=
: 0.10392+0.25199X-0.021675X2 = 0.66241
Condition:
0.10392+0.25199X-0.021675X2
0.66241
126
3. Design Schematics
127
1. Tray Dimensions
Dia bot = 9.244 ft.
Atot =
Ad =
= 6.7111 ft.
A hole = 5.37
= 773.28 in2
0.83118
0.365
128
Since the aerated liquid head is much less than the tray
spacing which is 18 inch, there would be no operational problem and
the liquid flooding is regulated.
WEEPING CHECK
X=
(X=
: 0.10392+0.25199X-0.021675X2 = 0.303
Condition:
0.10392+0.25199X-0.021675X2
0.303
G. DESIGN FLOWSHEET
This following is a detailed design flow sheet of the distillation column
based upon the previously determined parameters. Due to the corrosive
nature of concentrated formaldehyde at relatively elevated
temperatures, a stainless steel Material of Construction (MOC) is
decided to be chosen for the column interior walls and sieve trays.
DESIGN ITEM
Material of Construction
Tray Type
Flow Type
Number of Trays
Reflux Ratio
Feed Tray
Number of Tray Passes
Downcomer Type
Top Downcomer Area
Bottom Downcomer Area
Top Tray Efficiency
Bottom Tray Efficiency
Tray Spacing
Tray Thickness
Top Weir Height
Bottom Weir Height
Top Weir Length
Bottom Weir Length
Top Hole Area
Bottom Hole Area
Hole Diameter
Hole Hole Spacing
Hole Wall Spacing
Hole Weir Spacing
Top Column Diameter
Bottom Column Diameter
Column Height
SPECIFICATION
Stainless Steel
SS Sieve Trays
Gas-liquid Counter-flow
20 plus a Reboiler
7.05
13 from top
Single
Vertical Straight Segment
5.17
6.71
85%
84%
18 inch
0.078 in
2 inch
0.5 inch
5.89 ft.
6.71 ft.
4.14
5.37
3/16 in
0.1725 in
2.5 in
4 in
8.115 ft.
9.244 ft.
33 ft.
130
H. DESIGN SIMULATION
As a measure of accuracy and consistency, this final part of the design is
set to present a simulated version of the design as a reference and a
comparison to the actual design parameters obtained through rigorous
calculations previously. A snapshot of the simulated column is the
following:
rigorous solution
0.8697
7
16
simulated solution
0.8601
9.031
10.28
131
and
oC
4. Assuming Tshell, in =
= 155 oC.
w
[
]
= 4155051.3+6231729 = 4217368.59
133
= 1171491.275 W.
134
LMTD = 66.197 oC
6. for one shell pass and two tube passes:
So, Ft = 0.83
( )
135
For square pitch and two tubes passes, k1 and n1 can be found by:
( )
= 0.489 m
12. For fixed and U-tube heat exchanger with bundle diameter 0.50 m
=
136
( )
137
So, jh =2.7E-3
( )
( )
Where,
,
and
Thus, jf = 2.8E-2
(
)(
138
25.
Because the composition of methanol is very high (0.987);
139
So,
Also,
26. Because
( )
)
(
, assuming that
)
])
, assuming that
])
28. Overall heat transfer factors based on inside and outside tube flow:
Because the assumed overall heat transfer coefficient (U=1000 W/m2.oC) is not in
the range (between Ui and Uo), use the calculated value in step 8 and do loop using
Excel sheet until the difference between the calculated U in the two consecutive
iterations is small.
140
Design of E-101
TUBE-SIDE CLACULATION
SHELL-SIDE CLACULATION
0.011
364
0.357
0.001
Tube Pitch (m )
0.015
0.143
1.10
0.012
2000
0.344
0.013
182
2o
2000
0.877
31.13
50.666
T stream 6 ( C)
150
0.065
8147
45
Prandtle Number
6.577
Prandtle Number
5.140
T shell in (oC)
180
Reynolds Number
1066
2054
T shell in (oC)
155
140
2o
hdo (W/m . C)
hdi (W/m . C)
T stream 4 ( C)
LMTD ( C)
Ft
66.197
15453
0.90
DTm
2o
2o
59.578
306
491
303
U (W/m . C)
q (W)
267138
14.653
2o
141
116
0.854
0.010
1105398.773
5.527
2
542.967
0.011
0.546
7940
Design of E-102
TUBE-SIDE CLACULATION
SHELL-SIDE CLACULATION
0.011
550
0.422
0.001
Tube Pitch (m )
0.015
0.169
1.30
0.012
2000
0.412
0.010
275
2o
2000
1.467
37.300
56.087
150
47.693
710
45
Prandtle Number
0.694
Prandtle Number
4.505
T shell in (oC)
180
Reynolds Number
33170
276
T shell in (oC)
155
2o
hdo (W/m . C)
hdi (W/m . C)
T stream 5 ( C)
o
T stream 7 ( C)
2o
LMTD ( C)
Ft
64.158
208
26244879
0.87
DTm
2o
2o
55.817
114
U (W/m . C)
q (W)
166512
26.168
2o
2o
109
118
113
0.770
0.014
119425.290
0.597
2
41.978
0.011
0.042
68
Design of E-103
TUBE-SIDE CLACULATION
SHELL-SIDE CLACULATION
0.011
151
0.244
0.001
Tube Pitch (m )
0.015
0.098
1.00
0.012
2000
0.234
0.010
76
2o
2000
1.473
788.966
T stream 13 ( C)
89.31
T stream 14 (oC)
102
0.332
27902
45
Prandtle Number
1.693
Prandtle Number
2.019
T shell in ( C)
120
Reynolds Number
12331
T shell in (oC)
105
2119
2o
hdo (W/m . C)
hdi (W/m . C)
2o
16.819
LMTD ( C)
Ft
205.053
149011
0.90
DTm
2o
U (W/m . C)
q (W)
15.137
727
60836
2
Provisional Area (m )
5.528
2o
2o
648
807
727
0.338
0.005
752408.330
3.762
2
0.011
2o
10164
0.817
19622
Design of E-106
TUBE-SIDE CLACULATION
SHELL-SIDE CLACULATION
0.011
635
0.455
0.001
Tube Pitch (m )
0.015
0.182
1.40
0.012
2000
0.438
0.017
318
2000
1.903
2o
hdo (W/m . C)
2o
hdi (W/m . C)
0.017
1200796
6.004
2
362.380
63.060
30
0.084
7411
45
Prandtle Number
3.014
Prandtle Number
3.643
T shell in ( C)
25
Reynolds Number
1808
T shell in (oC)
35
303
T stream 19 ( C)
48
T stream 20 (oC)
2o
LMTD ( C)
8.372
Ft
0.90
DTm
7.535
490
2o
U (W/m . C)
q (W)
120050
2
Provisional Area (m )
32.514
83315
2o
2o
227
752
489
0.541
0.011
2o
7028
0.366
7280
[
Because
g = 9.8 m/s
Tg : Vapor temperature at the edge of the film (saturation temperature).
Tw : Wall temperature.
hfg : Latent heat of vaporization.
For tube-side:
hfg =
In the case of film-boiling inside the reboiler and all the tubes are arranged
horizontally, the tube-side heat transfer coefficient can be calculated by the
following equation:
[
Because
;
145
SHELL-SIDE CLACULATION
0.011
397
0.371
0.001
Tube Pitch (m )
0.015
0.148
1.20
0.012
2000
0.357
0.014
199
2o
2000
0.328
T Tube in ( C)
100
17.348
68
0.025
18574
45
Prandtle Number
3.710
Prandtle Number
5.140
T shell in ( C)
30
Reynolds Number
830
T shell in (oC)
40
1604
3245
45.924
596
713
833
2o
714
2o
hdo (W/m . C)
hdi (W/m . C)
2o
48.341
LMTD ( C)
Ft
0.95
DTm
2o
U (W/m . C)
q (W)
571018
2
Provisional Area (m )
17.439
2o
146
0.156
1.101E-02
2726344
13.632
2
1237.863
0.011
2o
12490
1.244
64314
SHELL-SIDE CLACULATION
0.011
132
0.231
0.001
Tube Pitch (m )
0.015
0.092
1.00
0.012
2000
0.221
0.010
66
2o
2000
0.233
T Tube in ( C)
110
37.037
120
0.061
642
45
Prandtle Number
1.392
Prandtle Number
5.140
T shell in ( C)
140
Reynolds Number
2589
T shell in (oC)
125
204
4138
14.773
104
107
7640
2o
hdo (W/m . C)
hdi (W/m . C)
2o
17.380
LMTD ( C)
Ft
0.85
DTm
2o
U (W/m . C)
q (W)
2
Provisional Area (m )
4.833
2o
2o
147
109
106
0.725
4.262E-03
36478
0.182
2
42.799
0.011
2o
252
0.043
53
10 C
3. Select appropriate units for the input data from the drop down lists below (E15/F15).
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams).
SI-based (kW/K)
Mass Flowrate
kg/s
0.877
5.527
148
Specific Heat
Stream
Heat Flow
Capacity
Type
kJ/kgK
kW
2.5625
267.138
COLD
4.174
576.7425
HOT
Supply
Shift
C
41.1
170.0
Target
Shift
C
160.0
145.0
10 C
3. Select appropriate units for the input data from the drop down lists below (E15/F15).
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams).
5. Select desired output unit set:
SI-based (kW/K)
Stream Supply
Target
dT Min
Specific Heat
Stream
Mass Flowrate
Heat Flow
Name Temperature Temperature Contrib
Capacity
Type
C
C
C
kg/s
kJ/kgK
kW
1
37.3
150
10
1.467
1.007
166.4882 COLD
2
180
155
10
0.597
4.174
62.297
HOT
149
Supply
Shift
C
47.3
170.0
Target
Shift
C
160.0
145.0
10 C
3. Select appropriate units for the input data from the drop down lists below (E15/F15).
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams).
SI-based (kW/K)
Stream
Supply
Target
dT Min
Specific Heat
Stream
Mass Flowrate
Heat Flow
Name Temperature Temperature Contrib
Capacity
Type
C
C
C
kg/s
kJ/kgK
kW
1
89.3
102
10
1.473
3.2546
60.8841
COLD
2
120
105
10
3.762
4.2
237.006
HOT
150
Supply
Shift
C
99.3
110.0
Target
Shift
C
112.0
95.0
10 C
3. Select appropriate units for the input data from the drop down lists below (E15/F15).
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams).
SI-based (kW/K)
Mass Flowrate
kg/s
1.903
6.004
151
Specific Heat
Stream
Heat Flow
Capacity
Type
kJ/kgK
kW
3.5047
120.05
HOT
4.174
250.607
COLD
Supply
Shift
C
38.0
35.0
Target
Shift
C
20.0
45.0
10 C
3. Select appropriate units for the input data from the drop down lists below (E15/F15).
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams).
SI-based (kW/K)
Mass Flowrate
kg/s
0.328
13.632
152
Specific Heat
Heat Flow
Capacity
kJ/kgK
kW
3.1934
33.5179
4.174
568.9997
Stream
Type
HOT
COLD
Supply
Shift
C
90.0
40.0
Target
Shift
C
58.0
50.0
10 C
3. Select appropriate units for the input data from the drop down lists below (E15/F15).
4. Input data: Stream Name, Temperatures & Heat/Flow Data (max 50 streams).
SI-based (kW/K)
Mass Flowrate
kg/s
0.233
1.113
153
Specific Heat
Heat Flow
Capacity
kJ/kgK
kW
3.2846
7.6531
4.174
69.6849
Stream
Type
COLD
HOT
Supply
Shift
C
120.0
130.0
Target
Shift
C
130.0
115.0
PUMP P-101
At 30 0C
154
PUMP P-102
Volumetric Flow Rate:
At 68.3 0C
155
PUMP P-103
Volumetric Flow Rate:
At 110 0C
156
COMPRESSOR C-101
For Air
Cp=29.1
Cv =20.78
Where
n= coprocessor efficiency,
Where
Assumption:
5.
6.
7.
8.
N=0.75
Adiabatic.
Constant heat capacities.
Ideal gas.
157
VISCOSITY ESTIMATION
methanol
-25.317
1789.2
2.069
0
0
C1
C2
C3
C4
C5
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
water
-52.843
3703.6
5.866
-5.88E-29
10
formaldehyde
-11.24
751.69
-0.024579
0
0
hydrogen
-11.661
24.7
-0.261
-4.10E-16
10
nitrogen
16.004
-181.61
-5.1551
0
0
oxygen
-4.1476
94.04
-1.207
0
0
20
89.31
89.31
102
68.3
293.15
362.46
362.46
375.15
341.45
1
1
1.2
1.2
1.2
composition viscosity composition viscosity composition viscosity composition viscosity composition viscosity
0.000
5.75E-04
0.000
2.78E-04
0.054
2.78E-04
0.054
2.53E-04
0.903
3.33E-04
0.000
2.29E-05
0.000
1.67E-05
0.000
1.67E-05
0.000
1.59E-05
0.000
1.82E-05
0.000
1.48E-04
0.003
9.04E-05
0.370
9.04E-05
0.370
8.42E-05
0.000
1.03E-04
1.000
1.02E-03
0.457
3.16E-04
0.576
3.16E-04
0.576
2.73E-04
0.097
4.18E-04
0.000
0.00E+00
0.030
0.00E+00
0.000
0.00E+00
0.000
0.00E+00
0.000
0.00E+00
0.000
9.19E-07
0.511
3.46E-07
0.000
3.46E-07
0.000
2.95E-07
0.000
4.57E-07
1
1.02E-03
1.000
1.45E-04
1.000
2.30E-04
1.000
2.02E-04
1.000
3.41E-04
158
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
10
110
110
30
48
30
383.15
383.15
303.15
321.15
303.15
1
3
3
3
3
composition viscosity composition viscosity composition viscosity composition viscosity composition viscosity
0.000
2.39E-04
0.000
2.39E-04
0.000
5.04E-04
0.000
4.08E-04
0.000
5.04E-04
0.000
1.54E-05
0.000
1.54E-05
0.000
2.18E-05
0.000
2.00E-05
0.000
2.18E-05
0.393
8.07E-05
0.393
8.07E-05
0.000
1.36E-04
0.261
1.18E-04
0.261
1.36E-04
0.606
2.52E-04
0.606
2.52E-04
1.000
8.20E-04
0.739
5.79E-04
0.739
8.20E-04
0.000
0.00E+00
0.000
0.00E+00
0.000
0.00E+00
0.000
0.00E+00
0.000
0.00E+00
0.000
2.67E-07
0.000
2.67E-07
0.000
7.89E-07
0.000
6.06E-07
0.000
7.89E-07
1.000
1.84E-04
1.000
1.84E-04
1.000
8.20E-04
1.000
4.59E-04
1.000
6.41E-04
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
1
11
12
13
14
15
25
298.15
1
5.38E-04
2.23E-05
1.42E-04
9.13E-04
0.00E+00
8.51E-07
5.36E-06
1.0000
0.0000
0.0000
0.0000
0.0000
0.0000
1
25
298.15
1
5.38E-04
2.23E-05
1.42E-04
9.13E-04
0.00E+00
8.51E-07
5.38E-04
0.9868
0.0000
0.0000
0.0132
0.0000
0.0000
1
159
31.13
304.28
1
4.97E-04
2.17E-05
1.35E-04
8.01E-04
0.00E+00
7.76E-07
5.01E-04
0.9868
0.0000
0.0000
0.0132
0.0000
0.0000
1
31.13
304.28
3
4.97E-04
2.17E-05
1.35E-04
8.01E-04
0.00E+00
7.76E-07
5.01E-04
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
1
37.3
310.45
3
4.61E-04
2.10E-05
1.28E-04
7.07E-04
0.00E+00
7.08E-07
4.97E-06
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
0.9868
0.0000
0.0000
0.0132
0.0000
0.0000
1
16
17
18
19
20
150
423.15
3
1.89E-04
1.33E-05
6.69E-05
1.79E-04
0.00E+00
1.68E-07
1.88E-04
0.0000
0.2100
0.0000
0.0000
0.0000
0.7900
1
150
423.15
3
1.89E-04
1.33E-05
6.69E-05
1.79E-04
0.00E+00
1.68E-07
2.93E-06
0.3465
0.1363
0.0000
0.0046
0.0000
0.5126
1
150
423.15
3
1.89E-04
1.33E-05
6.69E-05
1.79E-04
0.00E+00
1.68E-07
6.81E-05
0.0374
0.0000
0.2596
0.2376
0.0258
0.4395
1
343
616.15
3
1.09E-04
7.90E-06
3.80E-05
6.67E-05
0.00E+00
2.76E-08
2.98E-05
0.0374
0.0000
0.2596
0.2376
0.0258
0.4395
1
DENSITY ESTIMATION
(
C1
C2
C3
C4
C5
methanol
2.3267
0.27073
512.5
0.24713
water
17.863
58.616
-95.396
2.14E+02
-141.26
formaldehyde
1.9415
0.22309
408
0.28571
160
hydrogen
5.414
0.34893
33.19
2.71E-01
nitrogen
3.2091
0.2861
126.2
0.2966
oxygen
3.9143
0.28772
154.58
0.2924
165
438.15
3
1.75E-04
1.27E-05
6.29E-05
1.62E-04
0.00E+00
1.42E-07
6.16E-05
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
25
298.15
1
0.000
0.210
0.000
0.000
0.000
0.790
1.000
788.577
1.308
732.164
993.996
0.082
1.145
1.175
25
298.15
1
1.000
0.000
0.000
0.000
0.000
0.000
1.000
6
g
150
423.15
3
0.987
0.000
0.000
0.013
0.000
0.000
1.000
788.577
1015.182
732.164
993.996
0.082
1.145
788.577
31.13
304.28
1
0.987
0.000
0.000
0.013
0.000
0.000
1.000
7
g
2.765
2.765
2.592
1.555
0.173
2.419
2.737
150
423.15
3
0.000
0.210
0.000
0.000
0.000
0.790
1.000
782.664
1.282
719.981
991.694
0.080
1.121
784.848
31.13
304.28
3
0.987
0.000
0.000
0.013
0.000
0.000
1.000
8
g
2.765
2.765
2.592
1.555
0.173
2.419
2.485
150
423.15
3
0.346
0.136
0.000
0.005
0.000
0.513
1.000
161
782.664
3.845
719.981
991.694
0.240
3.364
784.848
37.3
310.45
3
0.000
0.210
0.000
0.000
0.000
0.790
1.000
9
g
2.765
2.765
2.592
1.555
0.173
2.419
2.568
343
616.15
3
0.037
0.000
0.260
0.238
0.026
0.440
1.000
3.769
3.769
3.533
2.120
0.236
3.298
3.386
10
g
1.899
1.899
1.780
1.068
0.119
1.661
1.150
165
438.15
3
0.037
0.000
0.260
0.238
0.026
0.440
1.000
2.670
2.670
2.503
1.502
0.167
2.336
1.617
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
stream number
material
condition
temperature C
temperature K
Pressure (atm)
methanol
oxygen
formaldehyde
water
hydrogen
nitrogen
Summation
11
l
20
293.15
1
0.000
0.000
0.000
1.000
0.000
0.000
1.000
12
g
793.339
1.330
741.891
995.773
0.083
1.164
995.773
89.31
362.46
1
0.000
0.000
0.003
0.457
0.030
0.511
1.000
16
l
110
383.15
1
0.000
0.000
0.393
0.606
0.000
0.000
1.000
13
l
1.076
1.076
1.009
0.605
0.067
0.941
0.573
89.31
362.46
1.2
0.054
0.000
0.370
0.576
0.000
0.000
1.000
17
l
696.882
1.018
512.462
949.208
0.064
0.891
710.815
110
383.15
3
0.000
0.000
0.393
0.606
0.000
0.000
1.000
14
l
721.509
1.291
582.103
962.786
0.081
1.130
763.935
102
375.15
1.2
0.054
0.000
0.370
0.576
0.000
0.000
1.000
18
l
696.882
3.054
512.462
949.208
0.191
2.672
710.815
30
303.15
3
0.000
0.000
0.000
1.000
0.000
0.000
1.000
162
15
l
706.631
1.247
541.967
954.676
0.078
1.092
733.787
68.3
341.45
1.2
0.903
0.000
0.000
0.097
0.000
0.000
1.000
19
l
783.761
3.859
722.250
992.129
0.241
3.377
992.129
48
321.15
3
0.000
0.000
0.261
0.739
0.000
0.000
1.000
744.784
1.371
638.064
974.749
0.086
1.199
762.162
20
l
765.931
3.643
684.755
984.651
0.228
3.188
883.671
30
303.15
3
0.000
0.000
0.261
0.739
0.000
0.000
1.000
783.761
3.859
722.250
992.129
0.241
3.377
903.990
PIPING SCHEMATICS
The plant piping layout is designed to accommodate all process units in the PFD inside a confined
rectangular space of 80 meters by 40 meters. The plant area is divided into three sections as follows:
The first section includes the feed areas of methanol and air, the reactor feed mixing, the reactor and the
absorber. The second section accommodates the the distillation tower and its reflux area. The third and final
section side of the plant is where the product is mixed with deionized water and pumped for storage
loading. The following are pipes sizing and dimensions tables for each section in the formaldehyde
production plant.
163
SECTION 1
164
STREAM
#
1
2
3
4
5
PIPE CODE
10 in,
Sche.40
6 in, Sche.40
6 in, Sche.40
6 in, Sche.40
10 in,
Sche.40
6
7
8
9
10
11
12
10 in,
Sche.40
10 in,
Sche.40
10 in,
Sche.40
6 in, Sche.40
weight
kg/hr
density
kg/m3
D1
A m2
velocity 1
m/s
5282.328
1.175390216
4494.105811
0.24765
0.04816888
25.91637448
2740.783
3158.5247
3158.5247
788.5773877
784.8484078
784.8484078
3.475604351
4.024375496
4.024375496
0.154054
0.4
0.154054
0.018639568
0.125663706
0.018639568
0.051795495
0.008895823
0.059973605
5282.328
1.175390216
4494.105811
0.24765
0.04816888
25.91637448
3158.5247
2.736824764
1154.083645
0.24765
0.04816888
6.65530924
5282.328
1.175390216
4494.105811
0.24765
0.04816888
25.91637448
8440.8527
2.56763335
3287.405773
0.254508
0.050873634
17.94973557
8440.8527
8440.8527
1.149918745
1.149918745
7340.39056
7340.39056
1.4
0.254508
1.5393804
0.050873634
1.32455719
40.079649
3287.373
6423.166
995.7732285
0.573238289
3.301326955
11205.05403
0.154054
0.77
0.018639568
0.465662571
0.049198311
6.684056658
165
STREAM
#
1
2
3
4
5
6
7
8
9
10
11
12
STREAM
#
1
2
3
4
5
6
7
8
9
10
11
12
/D
viscosity
Re
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.001025641
0.001648773
0.000635
0.001648773
0.001025641
0.001025641
0.001025641
0.000998004
0.000181429
0.000998004
0.001648773
0.00032987
5.36336E-06
0.000537992
0.000501236
0.000501236
4.97133E-06
0.000188464
2.93309E-06
6.80734E-05
2.98101E-05
2.98101E-05
0.001021406
0.000144745
1406558.519
11695.8874
5571.728029
14466.94803
1517476.457
23934.52002
2571986.956
172311.7307
71532.41049
393486.1564
7388.99484
20382.71052
profile of
flow
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
A1
D2
A2
velocity 2
LOSS PIPE
0.04816888
0.018639568
0.125663706
0.018639568
0.04816888
0.04816888
0.04816888
0.050873634
1.5393804
0.050873634
0.018639568
0.465662571
0.254508
0.4
0.154054
0.154054
0.254508
0.254508
0.254508
1
0.254508
0.254508
0.77
0.15405
0.050873634
0.125663706
0.018639568
0.018639568
0.050873634
0.050873634
0.050873634
0.785398163
0.050873634
0.050873634
0.465662571
0.0186386
24.53850133
0.007682772
0.059973605
0.059973605
24.53850133
6.301472251
24.53850133
1.162681953
40.079649
40.079649
0.001969313
166.9929618
0.201494044
0.836974048
0.092525
0.300971348
0.241778316
0.464728447
0.25286493
0.421695978
0.021606
0.080041492
4.992518403
0.050803636
166
0.00499
0.0080587
0.0092525
0.00772764
0.0049897
0.00677
0.00497
0.0053
0.0050414
0.0050928
0.00871225
0.0065198
5
8
2
3
6
8.5
6.3
10.125
3
2
44.14
3
LOSS
expand
0
32.96793914
0
0
0
0.003152989
0.003152989
208.4620923
0.934995931
0
575.1591911
0
m constant
0
0
1.109
0
0
0
0
0.044
0
0
0
1.0105
STREAM
#
1
2
3
4
5
6
7
8
9
10
11
12
LOSS
contra
0
0
0.42915279
0
0
0
0
841.9473529
0
0
0
0.882082046
# of elbow
0
4
0
0
0
1
1
3
2
3
2
0
loss 90
elbow
0
3
0
0
0
0.75
0.75
2.25
1.5
2.25
1.5
0
SECTION 2
167
lv (m2/s2)
Po (Pa)
Pf (Pa)
121.3272302
0.00217241
0.001876388
0.001082544
145.5839232
48.36030898
605.7616654
1423.585967
42499.31029
3742.928007
0.002255758
26015.05587
101325
101325
111457.5
303975
303975
303975
303975
303975
303302
254201
101325
120000
101192.6074
101323.5455
111455.6822
303974.1504
303814.0963
303844.2147
303273.2079
300422.7285
254200.5981
249896.9369
101323.0546
103092.1633
STREAM
#
13
14
15
21
22
23
24
25
26
STREAM
#
13
14
15
21
22
23
24
25
26
STREAM
#
13
14
15
21
22
23
24
25
26
PIPE CODE
weight
kg/hr
5302.297
5302.297
417.7417
8139.398333
8139.398333
3255.759333
696.2361667
696.2361667
278.4944667
density
kg/m3
763.9345926
733.7866677
762.1619183
710.8153975
710.8153975
710.8153975
762.1619183
762.1619183
762.1619183
D1
A m2
6.940773532
7.225938046
0.548100987
11.45079069
11.45079069
4.580316275
0.913501646
0.913501646
0.365400658
0.77
0.1281938
0.1281938
0.1281938
0.1281938
0.1281938
0.1281938
0.1281938
0.1281938
0.465662571
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
/D
viscosity
Re
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.000254
0.00032987
0.001981375
0.001981375
0.001981375
0.001981375
0.001981375
0.001981375
0.001981375
0.001981375
0.000230429
0.00020225
0.000340995
0.00018442
0.00018442
0.00018442
0.000340995
0.000340995
0.000340995
10569.24844
72329.75441
3379.875473
121765.7117
121765.7117
48706.28468
5633.125788
5633.125788
2253.250315
profile of
flow
Turbulent
Turbulent
laminar
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
laminar
A1
D2
A2
velocity 2
LOSS PIPE
0.465662571
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.15405
0.4572
0.4
0.1281938
0.1281938
0.1281938
0.4
0.4
0.4
0.0186386
0.164173223
0.125663706
0.012906959
0.012906959
0.012906959
0.125663706
0.125663706
0.125663706
0.103440851
0.012226141
0.001211569
0.246438781
0.246438781
0.098575512
0.002019282
0.002019282
0.000807713
0.650922078
0.918445416
2.85672689
0.096728547
2.031299486
0.31077946
0.599092936
0.149773234
0.177252961
5
5
5
5
5
5
5
5
in,
in,
in,
in,
in,
in,
in,
in,
Sche.40
Sche.40
Sche.40
Sche.40
Sche.40
Sche.40
Sche.40
Sche.40
168
velocity 1
m/s
0.004140321
0.155513397
0.011795984
0.246438781
0.246438781
0.098575512
0.019659973
0.019659973
0.007863989
0.0083535
0.0064128
0.004733902
0.0062
0.0062
0.00664
0.0096
0.0096
0.007100853
30
9.18
38.68
1
21
3
4
1
1.6
LOSS
expand
0
137.35242
76.31980124
0
0
0
76.31980124
76.31980124
76.31980124
m constant
1.0105
0
0
0
0
0
0
0
0
STREAM
#
13
14
15
21
22
23
24
25
26
LOSS
contra
0.882082046
0
0
0
0
0
0
0
0
# of elbow
2
2
3
0
2
1
2
1
0
loss 90
elbow
1.5
1.5
2.25
0
1.5
0.75
1.5
0.75
0
SECTION 3
169
lv (m2/s2)
Po (Pa)
Pf (Pa)
0.032453174
0.020892743
0.000119526
0.005874525
0.214463137
0.010307734
0.000319753
0.000314863
4.99067E-05
101325
101299.1878
121590
101303
101303
101303
121590
121590
121590
101299.1878
101286.0615
121589.922
101298.8243
101150.5563
101295.6731
121589.7927
121589.7965
121589.9678
STREAM
#
16
17
18
19
20
STREAM
#
16
17
18
19
20
PIPE CODE
density
kg/m3
710.8153975
710.8153975
992.1287895
883.6712054
903.990441
D1
A m2
5 in, Sche.40
5 in, Sche.40
5 in, Sche.40
5 in, Sche.40
5 in, Sche.40
weight
kg/hr
4883.639
4883.639
1965.676
6849.315
8814.991
6.870474412
6.870474412
1.981271001
7.750976786
9.751199349
0.1281938
0.1281938
0.1281938
0.1281938
0.1281938
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
velocity 1
m/s
0.147863268
0.147863268
0.042640026
0.166813046
0.209860938
/D
viscosity
Re
0.000254
0.000254
0.000254
0.000254
0.000254
0.001981375
0.001981375
0.001981375
0.001981375
0.001981375
0.00018442
0.00018442
0.000819619
0.000459201
0.000641335
73059.42702
73059.42702
6616.687609
41151.38768
37920.8021
profile of
flow
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
0.00502189
0.006408
0.009248
0.00676
0.00682
3
1
57.04
1
1
STREAM
#
16
17
18
19
20
A1
D2
A2
velocity 2
LOSS PIPE
0.012906959
0.012906959
0.012906959
0.012906959
0.012906959
0.1281938
1
1
0.1281938
0.1281938
0.012906959
0.785398163
0.785398163
0.012906959
0.012906959
0.147863268
0.002429933
0.000700731
0.166813046
0.209860938
STREAM
#
16
17
18
19
20
LOSS
contra
0
813.2432284
813.2432284
0
0
# of elbow
loss 90
elbow
0
0
0
0
0
0
0
0
0
0
170
m constant
0.235045221
0.099973634
8.229819539
0.105465319
0.106401402
LOSS
expand
0
0
0
0
0
lv (m2/s2)
Po (Pa)
Pf (Pa)
0.005138922
0.004802446
0.000403363
0.00293474
0.004686089
101286.0615
101282.4087
101325
101324.8252
101322.2319
101282.4087
101280.9371
101324.8252
101322.2319
101317.9957
0
0.06
0.06
0
0
( )
( )
((
171
HAZOP ANALYSIS
This chapter of the report is aimed to investigate some of the problems during normal production hours. A
troubleshooting sequence is to be presented through the HAZOP (Hazard & Operability) tables with a
contingency protocol to prevent reoccurrence of the problem in the future.
Unit: REACTOR
Node: METHANOL INLET FLOW (STREAM 8)
Parameter: FLOW
Guide Word
No
More
Less
Deviation
Cause
Consequence
Action
Install a micrometer in
the reactor section
Pipe Blockage
Regular inspection of
transferring lines
Increasing unused
Methanol
Leakage in heat
exchanger tubes
Regular inspection of
transferring lines
Plugging of pipelines
Pump Damage
172
Guide Word
No
More
Deviation
Cause
Consequence
Action
Compressor(C- 101)
tripping
No Oxygen inlet to
the Reactor
Install a spare
compressor for
Emergency
Pipe Blockage
Deficient Product
Regular inspection
of transferring lines
Less
Perform Regular
Low quality Product
Maintenance and
provide spare Filters
Low quality Product
Regular inspection
of transferring lines
Plugging of
Compressor Damage
pipelines due to dust
173
Guide Word
Very High
Deviation
Cause
Consequence
Action
Failure in Pump
Control
Unwanted Outlet
Stream Properties
Pressure
Transmitter Faulty
Deficient Control
System
Pump Tripping
Very Low
174
Regular inspection of
Instrumentation
Perform Regular
Maintenance and
provide spare Pump
Pump Damage
Inspect the
Distillation Column
and its Effluent
Guide Word
High
low
Deviation
High pressure
Cause
Consequence
Action
Pressure increased
absorber tank
leakage
Effluent (stream
13) Blocked
Temperature
increase
Regular inspection
of transferring lines
Install pressure
sensor
No absorption take
place
Low pressure
175
Guide Word
No
More
Less
Deviation
No Reflux Flow
Cause
Consequence
Action
Pump(P- 103)
tripping
Desired Product
loss
Install a micrometer
in the reflux section
Pipe Blockage
Accumulation in the
reactor
Regular inspection
of transferring lines
Plugging recycle
stream
Increasing try
flooding
Fluctuation of
pressure drop in the Low quality Product
pump
Regular inspection
of pump
Accumulation in
V-101
Leakage in V-10l
Install a Level
transmitter
Condenser fouling
Regular inspection
of Condenser
176
177
Compressor Type
Power
(kilowatts)
# Spares
MOC
C-101
Centrifugal
183
Carbon Steel
Drives
Drive Type
Power
(kilowatts)
# Spares
D-101
183
Exchangers
Exchanger Type
Shell Pressure
(barg)
E-101
2.02
1.01
13.8
$19,600.00
$64,400.00
E-102
1.01
24.7
$20,900.00
$68,700.00
E-103
2.3
2.71
5.22
$19,300.00
$63,500.00
E-104
11.9
1.22
16.5
$19,900.00
$66,300.00
E-105
0.599
0.972
4.56
$19,300.00
$63,500.00
E-106
9.03
2.21
30.7
$21,700.00
$71,800.00
E-107
Floating Head
10
2.5
140
$37,400.00
$124,000.00
Pumps
(with drives)
Pump Type
Power
(kilowatts)
# Spares
P-101
Centrifugal
0.3
Carbon Steel
$6,170.00
$24,600.00
P-102
Centrifugal
1.7
Stainless Steel
1.5
$6,470.00
$32,200.00
P-103
Centrifugal
0.5
Stainless Steel
3.5
$6,170.00
$30,700.00
Towers
Tower Description
Height
(meters)
Tower MOC
Demister MOC
T-101
12.3
Carbon Steel
2.41
$24,800.00
$67,500.00
T-102
9.6
2.65
Carbon Steel
1.21
$137,000.00
$292,000.00
Vessels
Orientation
V-101
Horizontal
Length/Height
(meters)
4.41
Diameter
(meters)
1.1
$189,000.00
$517,000.00
Purchased
Bare Module
Equipment Cost
Cost
$70,900.00
Tube Pressure
(barg)
Diameter
(meters)
Purchased
Bare Module
Equipment Cost
Cost
Area
Purchased
Bare Module
(square meters) Equipment Cost
Cost
MOC
MOC
MOC
Carbon Steel
Discharge
Pressure (barg)
Demister MOC
Purchased
Bare Module
Equipment Cost
Cost
Pressure
(barg)
Purchased
Bare Module
Equipment Cost
Cost
Pressure
(barg)
Purchased
Bare Module
Equipment Cost
Cost
2
179
$106,000.00
$8,450.00
$25,400.00
$
1,617,600
52.20
52.23%
1.4
Year
0
1
2
3
4
5
6
7
8
9
10
11
12
Investment
1.00
9.34
8.48
dk
1.56
1.56
1.56
1.56
1.56
1.56
1.56
1.56
1.56
1.56
FCIL-Sdk
15.56
15.56
15.56
12.45
10.89
9.34
7.78
6.22
4.67
3.11
1.56
0.00
-
34.20
34.20
34.20
34.20
34.20
34.20
34.20
34.20
34.20
34.20
COMd
12.41
12.41
12.41
12.41
12.41
12.41
12.41
12.41
12.41
12.41
118.26
76.00%
1.2
Cash Flow
(R-COMd-dk )*(1-t)+dk (Non-discounted)
(1.00)
(9.34)
(8.48)
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
13.23
18.04
Cash Flow
(discounted)
Cumulative Cash
Flow (discounted)
(1.00)
(8.49)
(7.01)
9.94
9.03
8.21
7.47
6.79
6.17
5.61
5.10
4.64
5.75
(1.00)
(9.49)
(16.50)
(6.56)
2.47
10.69
18.15
24.94
31.11
36.72
41.82
46.45
52.20
(1.00)
(10.34)
(18.82)
(5.59)
7.63
20.86
34.09
47.31
60.54
73.77
86.99
100.22
118.26
Economic Options
Cost of Land $
1,000,000
Taxation Rate
42%
10%
Salvage Value $
1,556,000
Working Capital $
FCIL $
2,260,000
15,560,000
34,200,000
6,722,144
310,329
1.18
0.50
180
351,232
3- SIMULATION
Bins
0
1
2
3
4
5
6
7
8
9
10
48.6
86.4
Upper Value
48.6
52.4
56.2
59.9
63.7
67.5
71.3
75.1
78.8
82.6
86.4
1000
# points/bin
0
6
38
107
183
225
206
135
66
23
11
Cumulative
0
6
44
151
334
559
765
900
966
989
1000
Low NPV
High NPV
750
500
250
0
0
10
20
30
40
50
60
70
80
90
100
Bins
0
1
2
3
4
5
6
7
8
9
10
Upper
1.09
1.13
1.17
1.21
1.26
1.30
1.34
1.38
1.43
1.47
1.51
#/bin
0
5
30
82
160
203
226
172
81
31
10
Cumulative
0
5
35
117
277
480
706
878
959
990
1000
1000
Low DCFROR
High DCFROR
750
500
250
0
0.00
0.20
0.40
0.60
0.80
DCFROR
181
1.00
1.20
1.40
1.60
182
Compressor Type
Power
(kilowatts)
# Spares
MOC
C-101
Centrifugal
183
Carbon Steel
Drives
Drive Type
Power
(kilowatts)
# Spares
D-101
183
Exchangers
Exchanger Type
E-101
2.02
1.01
13.8
..
19,600
..
64,400
E-102
1.01
24.7
..
20,900
..
68,700
E-103
2.3
2.71
5.22
..
19,300
..
119,000
E-104
11.9
1.22
16.5
..
19,900
.. 125,000
E-105
0.599
0.972
4.56
..
19,300
..
E-106
9.03
2.21
30.7
..
21,700
.. 135,000
E-107
Floating Head
43
..
24,600
.. 152,000
Pumps
(with drives)
Pump Type
Power
(kilowatts)
# Spares
P-101
Centrifugal
0.3
Carbon Steel
6,170
24,600
P-102
Centrifugal
1.7
Stainless Steel
1.5
6,470
32,200
P-103
Centrifugal
0.5
Stainless Steel
3.5
6,170
30,700
Towers
Tower Description
Height
(meters)
Tower MOC
Demister MOC
T-101
12.3
Stainless Steel
2.41
..
24,800
.. 121,000
T-102
9.6
2.65
Stainless Steel
1.21
..
137,000
.. 562,000
Vessels
Orientation
V-101
Horizontal
Shell Pressure
(barg)
Length/Height
(meters)
4.41
Diameter
(meters)
1.1
..
189,000
.. 517,000
Purchased
Bare Module
Equipment Cost
Cost
..
Tube Pressure
(barg)
Diameter
(meters)
Purchased
Bare Module
Equipment Cost
Cost
MOC
Stainles Steel
Discharge
Pressure (barg)
Demister MOC
119,000
Purchased
Bare Module
Equipment Cost
Cost
Pressure
(barg)
Pressure
(barg)
Purchased
Bare Module
Equipment Cost
Cost
Purchased
Bare Module
Equipment Cost
Cost
2 ..
183
.. 106,000
Area
Purchased
Bare Module
(square meters) Equipment Cost
Cost
MOC
MOC
70,900
8,450
..
$
52,500
2,229,100
51.34
50.44%
1.5
Year
0
1
2
3
4
5
6
7
8
9
10
11
12
Investment
1.00
9.76
8.83
dk
1.46
1.46
1.46
1.46
1.46
1.46
1.46
1.46
1.46
1.46
FCIL-Sdk
16.26
16.26
16.26
13.17
11.71
10.24
8.78
7.32
5.85
4.39
2.93
1.46
-
34.20
34.20
34.20
34.20
34.20
34.20
34.20
34.20
34.20
34.20
COMd
12.54
12.54
12.54
12.54
12.54
12.54
12.54
12.54
12.54
12.54
117.17
72.06%
1.2
Cash Flow
(R-COMd-dk )*(1-t)+dk (Non-discounted)
(1.00)
(9.76)
(8.83)
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
13.18
18.14
Cash Flow
(discounted)
Cumulative Cash
Flow (discounted)
(1.00)
(8.87)
(7.30)
9.90
9.00
8.18
7.44
6.76
6.15
5.59
5.08
4.62
5.78
(1.00)
(9.87)
(17.17)
(7.27)
1.73
9.92
17.36
24.12
30.27
35.86
40.94
45.56
51.34
(1.00)
(10.76)
(19.59)
(6.41)
6.77
19.95
33.13
46.31
59.49
72.67
85.85
99.03
117.17
Economic Options
Cost of Land $
1,000,000
Taxation Rate
42%
10%
Salvage Value $
1,626,000
Working Capital $
FCIL $
2,330,000
16,260,000
34,200,000
6,722,144
310,329
1.18
0.50
184
351,232
3- SIMULATION
Bins
0
1
2
3
4
5
6
7
8
9
10
-172.9
186.4
Upper Value
-172.9
-137.0
-101.0
-65.1
-29.2
6.7
42.7
78.6
114.5
150.5
186.4
1000
# points/bin
0
5
22
74
156
232
235
156
99
19
2
Cumulative
0
5
27
101
257
489
724
880
979
998
1000
Low NPV
High NPV
750
500
250
0
-200
-150
-100
-50
50
100
150
200
250
Bins
0
1
2
3
4
5
6
7
8
9
10
Upper
0.00
0.03
0.05
0.08
0.11
0.13
0.16
0.19
0.21
0.24
0.27
#/bin
0
63
68
126
140
169
159
108
68
29
3
Cumulative
0
63
131
257
397
566
725
833
901
930
933
1000
Low DCFROR
High DCFROR
750
500
250
0
0.00
0.05
0.10
0.15
DCFROR
185
0.20
0.25
0.30
186
By CAPCOST
$ 1617600
By CAPCOST
$ 1908768
By CAPCOST
$ 15560000
Contingency Cost
0.15 CBM
$ 242640
Fees Cost
0.03 CBM
$ 48528
$ 12409606
Cost Item
Value ($)
1.
a.
Raw Materials
CRM
6722144
b.
Waste Treatment
CWT
c.
Utilities
CUT
310329
d.
Operating Labor
COL
351232
e.
0.18 COL
63222
f.
0.06 FCI
933600
g.
Operating Supplies
0.009 FCI
140040
h.
Laboratory Charges
0.15 COL
52684.8
i.
0.03 COM
418968
2.
a.
Depreciation
0.1 FCI
1556000
b.
0.032 FCI
497920
c.
808832
3.
a.
Administration Costs
202208
b.
0.11 COM
1536217
c.
0.05 COM
698280
187
By CAPCOST
$ 2229100
By CAPCOST
$ 2630338
By CAPCOST
$ 16260000
Contingency Cost
0.15 CBM
$ 334365
Fees Cost
0.03 CBM
$ 66873
$ 12535606
Cost Item
Value ($)
1.
a.
Raw Materials
CRM
6722144
b.
Waste Treatment
CWT
c.
Utilities
CUT
310329
d.
Operating Labor
COL
351232
e.
0.18 COL
63222
f.
0.06 FCI
975600
g.
Operating Supplies
0.009 FCI
146340
h.
Laboratory Charges
0.15 COL
52684.8
i.
0.03 COM
424848
2.
a.
Depreciation
0.1 FCI
1626000
b.
0.032 FCI
520320
c.
834032
3.
a.
Administration Costs
208508
b.
0.11 COM
1557777
c.
0.05 COM
708080
188
Salvage Value:
Carbon steel has a moderate resistance to corrosion by formaldehyde at
elevated temperatures. This requires regular maintenance and reduces the
life time of the equipment. Stainless steel is much more durable to corrosion
and increases the life time of the plant. This has an impact on the salvage
value at the end of the plants lifetime. The increase of Stainless Steel salvage
value over the carbon steel adds to the strong suits of the SS model to be
chosen for the material of construction.
189
CONCLUSION
Our Chemical Engineering senior project design was aimed to bring forth an
integrated detailed design for the PRODUCTION OF FORMALDEHYDE FROM
METHANOL. This project covered several aspects of the plants design
including firstly a literature background on the production of formaldehyde
through different routes. Rigorous comprehensive mass and energy balances
were done throughout the plant including the reaction area. The third task
was set to simulate the process to obtain an optimized view of the plants
operations. The fourth task was the detailed design and sizing of the plants
equipment including the three major units in the plant; the reactor, the
absorber and the distillation column. The final task was to estimate the
economical feasibly of the formaldehyde manufacturing process.
The
guidance and support from our mentor prof. Shawabkeh is much
appreciated, and the knowledge he passed on to us is something to
cherished, so for that we express our deep gratitude.
187
REFERENCES
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<http://www.alibaba.com/>.
188
9- Guidelines for Facility Siting and Layout. New York: Center for Chemical
Process Safety of the American Institute of Chemical Engineers, 2003. Print.
10- Holland, Charles Donald. Fundamentals of Multicomponent Distillation.
New York: McGraw-Hill, 1981. Print.
11- Holman, J. P. Heat Transfer. New York: McGraw-Hill, 2010. Print.
12- Kirk, Raymond E., Donald F. Othmer, Jacqueline I. Kroschwitz, and Mary
Howe-Grant. Encyclopedia of Chemical Technology. New York: Wiley, 1991.
Print.
15- Perry, Robert H., and Don W. Green. Perry's Chemical Engineers' Handbook.
8th ed. New York: McGraw-Hill, 1984. Print.
16- Rosaler, Robert C. Standard Handbook of Plant Engineering. New York:
McGraw-Hill, 1995. Print.
17- "ScienceLab: Chemicals & Laboratory Equipment." ScienceLab: Chemicals &
Laboratory Equipment. N.p., n.d. Web. 19 Sept. 2012.
<http://www.sciencelab.com/>.
18- Smith, J. M., Hendrick C. Van. Ness, and Michael M. Abbott. Introduction to
Chemical Engineering Thermodynamics. New York [etc.: McGraw-Hill, 2001.
Print.
189
190