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انتاج الداي مثيل ايثر
انتاج الداي مثيل ايثر
انتاج الداي مثيل ايثر
AL MAHDI ABDULKAREEM
IBRAHIM ASSAD
MUKHELED AHMED
MURTADH SABEEH
SHAMS HASSAN
2016-2017
DECLARATION
I hereby declare that this project report is based on my original work except
for citations and quotations which been duly acknowledge.
Signature :
Date :
ii
APPROVAL FOR SUBMISSION
Approved by
Signature :
Supervisor :
Date :
iii
ACKNOWLEDGEMENTS
My efforts bore fruit with the successful completion of this project. However,
there are many others who share the reward of this effort simply because it
would never have been this good without their help.
I extend my sincere gratitude to my teammates who worked on this project
with me and all other colleagues who have helped me wherever and whenever
I got stuck and for being patient with me even at the toughest hours. Each of
you played a very crucial role in the development of this project.
My special thanks to Dr. Ali N. Khalaf, the supervisor of this project for
trusting that I could do this project and stand up to his expectations. It was all
your trust in me that led me to think beyond what I thought I was capable of
doing.
I express my gratitude to all those who have directly or indirectly helped me
to make this project. I also wish to thank my parents who have always
supported me and appreciated my work wholeheartedly and been my
inspiration.
iv
PRODUCTION OF DIMETHYLETHER
ABSTRACT
v
TABLE OF CONTENTS
DECLARATION ............................................................................................II
ABSTRACT..................................................................................................... V
Chapter
1 INTRODUCTION ...................................................................................... 2
1.1 Historical Background ..................................................................................................... 2
Flowsheet ............................................................................................................................. 18
vi
3 ENERGY BALANCE .............................................................................. 27
Energy Balance on Heat Exchanger 1 ................................................................................. 28
viii
Chapter One
Introduction
Introduction
1.1 Historical Background
Dimethyl ether has been employed since 1966 as propellant in aerosols, painting
areas, cosmetics and agriculture, replacing chlorine and fluorine—based
compounds, which are noxious to the environment. The vast application of DME is
associated with its characteristics, mostly to the fact of being practically harmless to
human health and the environment.
What Is DME?
Dimethyl ether (DME) is the organic compound with the formula CH3OCH3,
simplified to C2H6O and the simplest of all ethers
2
1.2 Chemical and Physical Properties
Vapor pressure
T(C) −20 −10 0 10 20 50
p(MPa)
measured 0.124 0.184 0.266 0.375 0.512 1.149
calculated 0.114 0.185 0.267 0.374 0.512 1.152
3
Density of liquid dimethyl ether
Temperature Density Temperature Density
[K] [kg/m3] [K] [kg/m3]
153 856.247 315.76 687.205
159.26 850.54 322.02 679.417
165.52 844.788 328.28 671.475
171.78 838.989 334.54 663.369
178.04 833.142 340.8 655.085
184.3 827.244 347.06 646.609
190.56 821.295 353.32 637.924
196.82 815.292 359.58 629.011
203.08 809.234 365.84 619.848
209.34 803.117 372.1 610.41
215.6 796.94 378.36 600.666
221.86 790.7 384.62 590.581
228.12 784.395 390.88 580.11
234.38 778.022 397.14 569.201
240.64 771.577 403.4 557.788
246.9 765.058 409.66 545.787
253.16 758.461 415.92 533.088
259.42 751.782 422.18 519.545
265.68 745.018 428.44 504.954
271.94 738.164 434.7 489.017
278.2 731.215 440.96 471.268
284.46 724.166 447.22 450.909
290.72 717.011 453.48 426.343
296.98 709.745 459.74 393.351
303.24 702.36 466 321.795
309.5 694.85
4
Constant pressure heat capacity of gas
Cp,gas Temperature Cp,gas Temperature
(J/mol*K) (K) (J/mol*K) (K)
42.27 100 136.7 1000
48.99 150 142.69 1100
54.47 200 147.89 1200
62.56 273.15 152.41 1300
65.57 ± 0.08 298.15 156.35 1400
65.8 300 159.77 1500
78.68 400 166.57 1750
91.36 500 171.5 2000
102.86 600 175.15 2250
113.03 700 177.91 2500
121.99 800 180.03 2750
129.84 900 181.7 3000
Cp,liquid Temperature
(J/mol*K) (K)
102.3 14-240
Enthalpy of vaporization
ΔvapH Temperature
(kJ/mol) (K)
22.6 183. - 265.
22.8 180. - 249.
21.2 293. - 360.
21.1 349. - 400.
22.2 241. - 303.
log10(P) = A − (B / (T + C))
P = vapor pressure (bar)
T = temperature (K)
Temperature (K) A B C
194.93 - 248.24 4.11475 894.669 -30.604
5
6
1.3 Type of Manufacturing Process
1.3.1- Direct and Indirect production process
A- One a step process:
In the one-step process (direct production process), DME is produced directly from
the syngas in one single reactor where a bifunctional catalyst supports both the
methanol formation and the methanol dehydration according to the following
reactions scheme
7
B- Two-steps process
In the two steps (indirect) process, either use pure methanol or formation of
methanol from syngas, then DME production from methanol. The figure illustrates
the block diagram of this architecture.
8
The hydrogen stream in the syngas mixture can be generated by an electrolyze
supplied by electricity produced from renewable power plants as photovoltaics and
wind farms and then mixed with CO/CO2. By this way, the renewable energy is
“stored” in the DME, which, being a liquid fuel, can be easily distributed, stored
and used, differently from the hydrogen itself which has a series of unsolved
issues related to the distribution and storage. The following scheme shows a
conceptual layout of the DME production from solar/biomass energy.
• CO2-rich feedstock influences the active state of the catalyst for methanol
synthesis, reducing the rate of formation of methanol.
• CO2 promotes the reverse Water Gas shift reaction, thus producing H2O
and inhibiting the methanol dehydration.
The research is focused mainly on the development of new catalyst, tailored for
CO2-rich mixture conversion, and of selective membranes able to remove water
from the reaction environment, promoting the methanol dehydration reaction and
the DME production.
9
1.4 Choose the method of manufacture
The method of choice is indirect method and that because total investment needed
for putting up the direct plant is more expensive than indirect plant and that strongly
indicate that the indirect plant is more profitable than the direct plant.
1.4.1 Basis
The block diagram for DME production from methanol is shown in the in Figure
below. The raw material is methanol. Methanol arrives at the plant at 25°C and 1bar.
Methanol dehydration takes place in the fixed-bed reactor and then DME as final
product is purified in separation unit. Producing 3000 metric tons per day of 99.5%
purity DME is the target of our project. The other consideration in this project is
maximizing the energy recovery by using partial heat integration in the plant.
Block diagram
10
1.4.2 Process description
1.4.2.1 Flowsheet
A PFD of the process is shown in Figure below and the belonging stream pressure are given
in table page 13. The essential operations in the process are the preheating of the raw
material (nearly pure methanol), dehydration of methanol to form DME, product separation
and methanol separation and recycle.
Methanol as a liquid pumped up to 15.5 bar. The stream 2 preheated with streams 14 and 7.
After preheating the stream 4 combined with Stream 17, methanol recycle stream. Stream 5
is then sent into heat exchanger E-03 where it is heated to a temperature of 250°C before
sending to the fixed-bed reactor, R-01, to form DME. The reaction is slightly exothermic and
the reaction products are heated to approximately 375°C before leaving the reactor. The
reactor effluent is cooled in E-02 and then throttled to 10.4 bar before entering T-01. Here,
the dimethyl ether is separated from the other components as distillate, Stream DME. The
bottom product, Stream 10, is throttled to 7.4 bar and sent to T-02 where the methanol are
separated from the waste components. The waste components exit as the bottoms stream,
Stream 14. Methanol exits the column as a distillate, Stream 13. This stream is then pumped
up to 15.5 bar and recycled back to mix with methanol, Stream 16 in mixer MIX-01.
11
1.4.2.2 Process Concepts
The reaction is equilibrium limited. Based on the catalyst and reaction kinetics,
the reactor must operate at 15 bar. The reactor operates adiabatically, and, since
the reaction is exothermic, the reactor effluent temperature will be above 250°C.
T Kp
200°C 34.1
300°C 12.4
400°C 6.21
The corresponding equilibrium conversions for pure methanol feed over the
above temperature range are greater than 83%. This reaction is kinetically
controlled at the conditions used in this process.
In the temperature range of normal operation, there are no significant side
reactions. The reactor is kinetically controlled in the temperature range of normal
operation. Above 250°C, the rate equation is given below (Bondiera and
Naccache, 1991):
12
Where
k0 = 1.21×106 kmol/(m3reactor.h.kPa)
Ea = 80.48 kJ/mol
Pmethanol = partial pressure of methanol (kPa)
13
1.4.3 Stream Pressure
Conditions Methanol 2 3 4 5 6 7
Pressure (bar) 1 15.5 15.2 14.9 14.9 14.7 14.7
Conditions 8 9 10 11 12 13 14
Pressure (bar) 14.4 10.4 10.4 7.4 7.4 7.3 7.3
14
1.5 General Uses
Industry Uses
Consumer Uses
1. Extremely Flammable
2. Behavior in Fire: Containers may explode. Vapors are heavier than air and may
travel long distance to a source of ignition and flash back.
3. Mixture of gas & air are explosion.
1.6.3 Environmental
16
Chapter Two
Material Balance
17
Basis
Feed Methanol 99% purity
Product DME 99.5% purity
Flowsheet
18
Material Balance on Reactor
Reactor
species symbols initial change
effluence
Methanol M FM0 -FMO X FM=FMO(1-X)
H2O H FH0 +1/2 FMO X FH=FMO(θH+1/2X)
DME D ─ +1/2 FMO X FD=FMO(θD+1/2X)
𝑦𝐻0 0.01
𝜃𝐻 = = = 0.0101
𝑦𝑀0 0.99
θD=0
𝐾𝑚𝑜𝑙
𝐹𝐷 = 2717.3913
ℎ𝑟
19
𝐹𝐷 2717.3913 𝐾𝑚𝑜𝑙
𝐹𝑀0 = = = 6793.4783
1 0.4 ℎ𝑟
𝑥
2
𝐹𝐻0
𝜃𝐻 = ⟹ 𝐹𝐻0 = 𝜃𝐻 ∗ 𝐹𝑀0
𝐹𝑀0
𝐾𝑚𝑜𝑙
𝐹𝐻0 = 0.0101 ∗ 6793.4783 = 68.6141
ℎ𝑟
𝐾𝑚𝑜𝑙
𝐹𝐻 = 6793.4783 (0.0101 + 0.4) = 2786.0054
ℎ𝑟
𝐾𝑚𝑜𝑙
𝐹𝑀 = 6793.4783 (1 − 0.8) = 1358.6957
ℎ𝑟
In 6 Out 7
Compound Molar flow Mass flow Molar flow Mass flow
Composition Composition
(Kmol/hr) (Kg/hr) (Kmol/hr) (Kg/hr)
Methanol 0.99 6793.4783 217391.3056 0.198 1358.6957 43478.2624
Water 0.01 68.6141 1235.0538 0.405 2786.0054 50148.0972
DME 0 0 0 0.396 2717.3913 124999.9998
Total 1 6862.0924 218626.3594 1 6862.0924 218626.3594
20
Material Balance on Distillation 1
𝐾𝑚𝑜𝑙
𝑏𝐷 = 2.717 ∗ 10−4 (Neglected in bottom)
ℎ𝑟
21
𝑛𝐿𝑘(1 − ℎ𝑛𝑘)
𝐿𝑛 [ ]
𝑛ℎ𝑘(1 − 𝑛𝐿𝑘)
𝑁𝑚 =
𝐿𝑛 𝛼𝐿𝑘
0.999(1 − 0.01)
𝐿𝑛 [ ]
0.01(1 − 0.999)
=
𝐿𝑛(5.096)
Nm= 7.063
𝑛𝑚
(𝛼𝑤/𝑚 ∗ ŋ𝑚)
ŋ𝑤 = 𝑛𝑚
(1 + (𝛼𝑤/𝑚 − 1) ∗ ŋ𝑚
(0.3515)7.063 ∗ 0.01
=
1 + [(0.3515)7.063 − 1] ∗ 0.01
𝐾𝑚𝑜𝑙
𝑑𝐷 = 2717.3913
ℎ𝑟
𝐾𝑚𝑜𝑙
𝑑𝑚 = 0.01 ∗ 1358.6957 = 13.5869
ℎ𝑟
𝐾𝑚𝑜𝑙
∑𝑑𝑖 = 2730.9782
ℎ𝑟
22
𝑑𝐷
𝑋𝐷 = = 0.995
𝑓𝐷
𝑥𝑚
𝑋𝑚 = = 0.05
𝑓𝑚
𝐾𝑚𝑜𝑙
𝑏𝑚 = 𝑓𝑚 − 𝑑𝑚 = 1358.6957 − 13.5869 = 1345.1088
ℎ𝑟
𝑏𝑤 = 𝑓𝑤 − 𝑑𝑤 = 2786.0054
𝐾𝑚𝑜𝑙
∑𝑏𝑖 = 4131.1142
ℎ𝑟
𝑋𝑚 = 0.3256
𝑋𝑤 = 0.6744
23
Material Balance on Distillation 2
O.M.B
𝐹 = 𝐷 + 𝑊 ⟹ 𝐷 = 4131.1141 − 𝑊
𝑀. 𝐵 𝑜𝑛 𝐻2𝑂
𝐹 𝑥𝑓 = 𝐷 𝑥𝑑 + 𝑊 𝑥𝑤
4131.1141 ∗ 0.6744 = (4131.1141 − 𝑤) ∗ 0.01 + 0.95𝑤
𝐾𝑚𝑜𝑙
𝑊 = 2919.9066
ℎ𝑟
𝐾𝑚𝑜𝑙
𝐷 = 1211.2074
ℎ𝑟
24
Material Balance on Mixer
𝑛16 + 𝑛4 = 𝑛5
𝑛4 = 6862.0924 − 1211.2074
𝐾𝑚𝑜𝑙
𝑛4 = 5650.885
ℎ𝑟
25
Overall Process Material Balance
𝒌𝒎𝒐𝒍 𝑲𝒈 𝒌𝒎𝒐𝒍 𝑲𝒈
Stream Molar In ( ) Mass In ( ) Stream Molar In ( ) Mass In ( )
𝒉𝒓 𝒉𝒓 𝒉𝒓 𝒉𝒓
26
Stream Conditions
Conditions Methanol 2 3 4 5 6 7
Composition
DME 0 0 0 0 0 0 0.396
Conditions 8 9 10 11 12 13 14
Composition
Composition
DME 0 0 0.995 0
27
Chapter Three
Energy Balance
Energy Balance on Heat Exchanger 1
(Stream 2-3)
Conditions 2 3
Temperature (C) 25 50
Pressure (bar) 15.5 15.2
𝑲𝒎𝒐𝒍𝒆 5650.885 5650.885
Molar Flow ( 𝒉
)
𝑲𝒈 180037.1961 180037.1961
Mass Flow ( 𝒉 )
Composition
Methanol 0.99 0.99
H2O 0.01 0.01
DME 0 0
323.15
𝑄=n ∫ Cp𝑚𝑖𝑥 dT
298.15
Cp Eq. for liquid from Perry's Chemical Engineers’ Handbook page 170
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) liquid page 163
𝐾𝑚𝑜𝑙.𝐾
Compound C1 C2 C3 C4 C5
Methanol 105800 -362.23 0.9379 0 0
Water 276370 -2090.1 8.125 -0.01412 9.3701*10-6
28
323.15
2093676.744 𝐾𝑗
∫ Cp𝑚𝑖𝑥 dT = = 2093.677
1000 𝐾𝑚𝑜𝑙. 𝐾
298.15
𝑄 = 5650.885 ∗ 2093.677
𝐾𝑗
Q = 11831126.51
ℎ𝑟
(Stream 14-Water)
From Energy Balance on Distillation 2 page 52
Temperature for Stream 14 = 163.52 C
Conditions 14 Water
Temperature (C) 163.52 ?
Pressure (bar) 7.4 7.4
𝑲𝒎𝒐𝒍𝒆 2919.9067 2919.9067
Molar Flow ( 𝒉
)
𝑲𝒈 54602.5092 54602.5092
Mass Flow ( )
𝒉
Composition
Methanol 0.05 0.05
H2O 0.95 0.95
DME 0 0
𝑇𝑊𝑎𝑡𝑒𝑟
𝑄=n ∫ Cp𝑚𝑖𝑥 dT
436.67
𝑇𝑊𝑎𝑡𝑒𝑟
29
Energy Balance on Heat Exchanger 2
(Stream 7-8)
Conditions 7 8 9
Temperature (C) 357.08 ? ?
Pressure (bar) 14.7 14.4 10.4
𝑲𝒎𝒐𝒍𝒆 6862.0924 6862.0924 6862.0924
Molar Flow ( 𝒉
)
𝑲𝒈 218626.3594 218626.3594 218626.3594
Mass Flow ( 𝒉 )
Composition
Methanol 0.198 0.198 0.198
H2O 0.405 0.405 0.405
DME 0.396 0.396 0.396
10.4 ∗ 760
𝑃𝑡𝑜𝑡𝑎𝑙 = = 7800.642 𝑚𝑚ℎ𝑔
1.01325
Antoine Equation
𝑃𝑖
𝐾𝑖 =
𝑃𝑡𝑜𝑡𝑎𝑙
30
At T=153.78 C
compound y PT K Y/K
Methanol 0.198 7800.642 1.429132 0.138546
Water 0.405 7800.642 0.502357 0.8062
DME 0.396 7800.642 7.282536 0.054377
sum= 0.999122
T9=153.78 C
To find T8
𝑛 ∫ Cp 𝑚𝑖𝑥 dT = 𝑛 ∫ Cp 𝑚𝑖𝑥 dT
298.15 298.15
𝐾𝐽
𝐶𝑝(14.4 𝑏𝑎𝑟)𝑚𝑖𝑥 = ∑ 𝑥𝑖 ∗ 𝐶𝑝𝑖 = 0.08057
𝑚𝑜𝑙𝑒. 𝐾
31
𝐾𝐽
𝐶𝑝(160 𝐶,10.4 𝑏𝑎𝑟)𝑚𝑖𝑥 = ∑ 𝑥𝑖 ∗ 𝐶𝑝𝑖 = 0.08249
𝑚𝑜𝑙𝑒. 𝐾
𝑄=n ∫ Cp𝑚𝑖𝑥 dT
650.40
Cp Eq. for gas from Perry's Chemical Engineers’ Handbook page 181
𝑇2
𝐶3 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + 𝐶2 ∗ 𝐶3 [coth ( ) − coth ( )] + 𝐶4
𝑇1 𝑇2 𝑇1
𝐶5 𝐶5
∗ 𝐶5 [tanh ( ) − tanh ( )]
𝑇2 𝑇1
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) gas page 176
𝐾𝑚𝑜𝑙.𝐾
Compound C1 C2 C3 C4 C5
Methanol 39250 87900 1916.5 53650 896.7
Water 33363 26790 2610.5 8896 1169
DME 51480 144200 1603.4 77400 725.4
440.95
𝐾𝑗
∫ Cp𝑚𝑖𝑥 dT = −6631.299
𝐾𝑚𝑜𝑙. 𝐾
630.23
𝑄 = 6862.0924 ∗ −6631.299
𝐾𝑗
𝑄 = −45504590.91
ℎ𝑟
32
(Stream 3-4)
Conditions 3 4
Temperature (C) 50 ?
Pressure (bar) 15.2 14.9
𝑲𝒎𝒐𝒍𝒆 5650.885 5650.885
Molar Flow ( 𝒉
)
𝑲𝒈 180037.1961 180037.1961
Mass Flow ( 𝒉 )
Composition
Methanol 0.99 0.99
H2O 0.01 0.01
DME 0 0
𝑇4
𝑄=n ∫ Cp𝑚𝑖𝑥 dT
323.15
Cp Eq. for liquid from Perry's Chemical Engineers’ Handbook page 170
Cpi = C1 + C2T + C3T2 + C4T3 + C5T4
𝑇2
𝐶2 2 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + (𝑇2 − 𝑇12 ) + (𝑇23 − 𝑇13 )
𝑇1 2 3
𝐶4 4 𝐶5
+ (𝑇2 − 𝑇14 ) + (𝑇25 − 𝑇15 )
4 5
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) liquid page
𝐾𝑚𝑜𝑙.𝐾
163
Compound C1 C2 C3 C4 C5
Methanol 105800 -362.23 0.9379 0 0
Water 276370 -2090.1 8.125 -0.01412 9.3701*10-6
𝑇4
33
Energy Balance on Heat Exchanger 3
Conditions 5 6
Temperature (C) ? 250
Pressure (bar) 14.9 14.7
𝑲𝒎𝒐𝒍𝒆 8275.645 8275.645
Molar Flow ( 𝒉
)
𝑲𝒈 244070.288 244070.288
Mass Flow ( 𝒉 )
Composition
Methanol 0.8209 0.8209
H2O 0.1791 0.1791
DME 0 0
𝑄 − 𝑊 = ∆𝐻 + ∆𝐾𝑒 + ∆𝐸𝑒
For adiabatic, no work, no kinetic or potential energy
∆𝐻 = 0
𝐻𝑜𝑢𝑡 = 𝐻𝑖𝑛
Final Temperature of Mixed Fluids
Component cp l J/(mol K)
Methanol 79.5
Water 75.46
T5= 130 C
Back to heat exchanger
Using Clausius-Clapeyron Equation to find boiling point for mixture
Then
421.64 523.15
35
𝐶𝑝𝑚𝑖𝑥 = ∑ 𝑥𝑖 𝐶𝑝𝑖 = (0.99 ∗ 𝐶𝑝𝑚 ) + (0.01 ∗ 𝐶𝑝𝑤 )
Cp Eq. for liquid from Perry's Chemical Engineers’ Handbook page 170
Cpi = C1 + C2T + C3T2 + C4T3 + C5T4
𝑇2
𝐶2 2 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + (𝑇2 − 𝑇12 ) + (𝑇23 − 𝑇13 )
𝑇1 2 3
𝐶4 4 𝐶5
+ (𝑇2 − 𝑇14 ) + (𝑇25 − 𝑇15 )
4 5
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) liquid page 163
𝐾𝑚𝑜𝑙.𝐾
Compound C1 C2 C3 C4 C5
Methanol 105800 -362.23 0.9379 0 0
Water 276370 -2090.1 8.125 -0.01412 9.3701*10-6
421.64
𝐾𝑗
∫ Cp (𝐿)𝑚𝑖𝑥 dT = 2157.431
𝐾𝑚𝑜𝑙. 𝐾
402.97
𝐾𝑗
Δ𝐻𝑣𝑎𝑝 𝑓𝑜𝑟 𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 27769.984
𝐾𝑚𝑜𝑙
𝐾𝑗
Δ𝐻𝑣𝑎𝑝 𝑓𝑜𝑟 𝑊𝑎𝑡𝑒𝑟 = 38319.749
𝐾𝑚𝑜𝑙
36
Cp Eq. for gas from Perry's Chemical Engineers’ Handbook page 181
𝑇2
𝐶3 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + 𝐶2 ∗ 𝐶3 [coth ( ) − coth ( )] + 𝐶4
𝑇1 𝑇2 𝑇1
𝐶5 𝐶5
∗ 𝐶5 [tanh ( ) − tanh ( )]
𝑇2 𝑇1
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) gas page 176
𝐾𝑚𝑜𝑙.𝐾
Compound C1 C2 C3 C4 C5
Methanol 39250 87900 1916.5 53650 896.7
Water 33363 26790 2610.5 8896 1169
523.15
𝐾𝑗
∫ Cp (𝑉)𝑚𝑖𝑥 dT = 2500.1039
𝐾𝑚𝑜𝑙
421.64
𝐾𝑗
𝑄 = 223244568.7
ℎ𝑟
𝑀𝑗
= 223244.569
ℎ𝑟
37
Energy Balance on Reactor
Conditions 6 7
Temperature (C) 250 ?
Pressure (bar) 14.7 14.7
𝑲𝒎𝒐𝒍𝒆 6862.0924 6862.0924
Molar Flow ( 𝒉
)
𝑲𝒈 218626.3594 218626.3594
Mass Flow ( )
𝒉
Composition
Methanol 0.99 0.198
H2O 0.01 0.405
DME 0 0.396
𝑘𝐽
𝛥𝐻𝑟𝜊 = −11770
𝑘𝑚𝑜𝑙
𝑇𝑖𝑛
∑ 𝑛𝑖𝑖𝑛 ∗ 𝐻𝑖𝑖𝑛 = ∑ 𝑛𝑖𝑖𝑛 ∗ ∫ 𝐶𝑝𝑖 𝑑𝑇
𝑇𝑟𝑒𝑓
38
Cp Eq. for gas from Perry's Chemical Engineers’ Handbook page 181
𝑇2
𝐶3 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + 𝐶2 ∗ 𝐶3 [coth ( ) − coth ( )] + 𝐶4
𝑇1 𝑇2 𝑇1
𝐶5 𝐶5
∗ 𝐶5 [tanh ( ) − tanh ( )]
𝑇2 𝑇1
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) gas page 176
𝐾𝑚𝑜𝑙.𝐾
Compound C1 C2 C3 C4 C5
Methanol 39250 87900 1916.5 53650 896.7
Water 33363 26790 2610.5 8896 1169
DME 51480 144200 1603.4 77400 725.4
523.15
𝑗
∑ 𝑛𝑖𝑖𝑛 ∗ ∫ 𝐶𝑝𝑖 𝑑𝑇 = 75026360466
298 ℎ𝑟
𝑗
𝜉 ∗ 𝛥𝐻𝑟𝜊 = 2717.391 ∗ (−11770 ∗ 103 ) = −31983692070
ℎ𝑟
𝑇𝑜𝑢𝑡
∑ 𝑛𝑖𝑜𝑢𝑡 ∗ 𝐻𝑖𝑜𝑢𝑡 = ∑ 𝑛𝑖𝑜𝑢𝑡 ∫ 𝐶𝑝𝑖𝑝𝑜𝑢𝑡 𝑑𝑇
𝑇𝑟𝑒𝑓
39
Energy Balance on Distillation 1
Conditions 9 10 DME
Temperature (C) 160.1 ? ?
Pressure (bar) 10.4 10.4 10.3
𝑲𝒎𝒐𝒍𝒆 8275.645 5544.598 2731.046
Molar Flow ( )
𝒉
𝑲𝒈 244070.288 118635.708 125436.945
Mass Flow ( 𝒉 )
Composition
Methanol 0.1642 0.2426 0.005
H 2O 0.5075 0.7574 0
DME 0.3283 0 0.995
10.4 ∗ 760
𝑃𝑡𝑜𝑡𝑎𝑙 = = 7800.642 𝑚𝑚ℎ𝑔
1.01325
Antoine Equation
40
From Introduction to Chemical Engineering Thermodynamics 7th Edition
page 682 Antoine Equation Parameters (P in mmHg, T in °C)
Compound A B C
Methanol 8.08097 1582.27 239.7
Water 8.14019 1810.94 244.485
DME 7.10736 946.89 248.645
𝑿
∑ =𝟏
𝑲
Let T=46.1 C
1582.27
𝑃𝑚 = 108.08097−239.7+46.1 = 350.249 𝑚𝑚ℎ𝑔
𝑃𝑚
𝐾𝑚 = = 0.0449
𝑃𝑡𝑜𝑡𝑎𝑙
𝑃𝐷𝑀𝐸
𝐾𝐷𝑀𝐸 = = 1.0057
𝑃𝑡𝑜𝑡𝑎𝑙
41
compound x P K K*X
Methanol 0.005 350.2492 0.0449 0.000225
DME 0.995 7845.357 1.005732 1.000704
Sum= 1.000928
⸫ Tbub=46.1 C
∑𝑿 ∗ 𝑲 = 𝟏
Let T=49.68 C
compound y P K y/K
Methanol 0.005 410.3837218 7800.6415 0.052608971
DME 0.995 8577.206979 7800.6415 1.099551489
Sum= 0.999955247
⸫ Tdew=49.68 C
42
The Bottom
Tbub Calculation for liquid product in Bottom
Let T=162.86 C
compound x P K K*X
Methanol 0.3256 13708.14 1.75731 0.57218
Water 0.6744 4949.076 0.634445 0.42787
Sum= 1.000049
⸫ Tbub=162.86 C
Let T= 172 C
compound y P K y/K
Methanol 0.3256 16723.63 2.143879 0.151874
Water 0.6744 6196.611 0.794372 0.848973
sum= 1.000504892
⸫ Tdew=172 C
⸫ TDME=46.1 C
T10=162.86 C
43
Condenser and Reboiler duty Calculation
To calculate condenser duty first must Find Reflux ratio by use
Underwood method
𝛼𝑖 𝑥𝐹𝑖
∑ =1−𝑞
𝛼𝑖 − 𝜙
q At saturated vapor = 0
𝛼𝑖 𝑥𝐹𝑖
∑ =1
𝛼𝑖 − 𝜙
𝐾𝑖
Compound K (153.78 C) 𝛼𝑖 =
𝐾𝑀
LK Methanol 1.429132 1
Water 0.502357 0.358
HK DME 7.282536 4.795
𝛼𝑖 𝑥𝐹𝑖
∑ , 𝜙= 3.1365
Compound xfi 𝛼 𝛼𝑖 −𝜙
𝛼𝑖 𝑥𝑑𝑖
𝑅𝑚𝑖𝑛 + 1 = ∑
𝛼𝑖 − 𝜙
1 ∗ 0.005 4.795 ∗ 0.995
𝑅𝑚𝑖𝑛 = + −1
0.005 − 3.1365 0.995 − 3.1365
𝑅𝑚𝑖𝑛 = 1.87
𝑅𝑎𝑡𝑢𝑎𝑙 = 1.5𝑅𝑚𝑖𝑛 = 2.812
𝐿
𝑅= ⇒𝐿 =𝑅∗𝐷
𝐷
kmol
𝐿 = 7678.5782
hr
𝑘𝑚𝑜𝑙
𝑉 = 𝐿 + 𝐷 = 10409.5564
ℎ𝑟
44
For total condenser
𝑇𝑏𝑢𝑏
For liquid
𝑇2
𝐶2 2 𝐶3 𝐶4
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + (𝑇2 − 𝑇12 ) + (𝑇23 − 𝑇13 ) + (𝑇24 − 𝑇14 )
𝑇1 2 3 4
𝐶5 5
+ (𝑇2 − 𝑇15 )
5
45
For gas
𝑇2
𝐶3 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + 𝐶2 ∗ 𝐶3 [coth ( ) − coth ( )] + 𝐶4
𝑇1 𝑇2 𝑇1
𝐶5 𝐶5
∗ 𝐶5 [tanh ( ) − tanh ( )]
𝑇2 𝑇1
𝑇2
∫ Cp 𝑚𝑖𝑥 dT = ∑ 𝑥𝑖 𝐶𝑝𝑖
𝑇1
319.23
𝑘𝑗
∫ Cp 𝑚𝑖𝑥 dT = −126.862 − 320.479 = −447.34
𝐾𝑚𝑜𝑙
322.83
𝐾𝑗
𝜆𝑚𝑖𝑥 = ∑ 𝑥𝑖 𝜆𝑖 = −177013682.8
𝐾𝑚𝑜𝑙
𝐾𝑗
𝑄𝑐𝑜𝑛𝑑𝑒𝑛𝑐𝑒𝑟 = −181670304.9
ℎ𝑟
𝑀𝑗
𝑄𝑐𝑜𝑛𝑑𝑒𝑛𝑐𝑒𝑟 = −181670.305
ℎ𝑟
46
Reboiler Heat Duty Calculation
Reboiler Heat Duty can be calculate from Energy balance on Distillation
Column
The kinetic and potential energy of the process streams will be small and
can be neglected.
𝑄𝑟 + 𝐻𝑓 = 𝐻𝑑 + 𝐻𝑤 + 𝑄𝑐
392.985 426.93
𝑀𝑗
𝐻𝑓 = 285384.074
ℎ𝑟
47
436.01
𝑀𝑗
𝐻𝑑 = 2730.9783 [ ∫ Cp 𝑚𝑖𝑥 dT] = 13705.625
ℎ𝑟
273.15
319.23
𝑀𝑗
𝐻𝑤 = 4131.1141 [ ∫ Cp 𝑚𝑖𝑥 dT] = 55852.374
ℎ𝑟
273.15
𝑄𝑟 = 𝐻𝑑 + 𝐻𝑤 + 𝑄𝑐 − 𝐻𝑓
𝑀𝑗
𝑄𝑟 = 34155.770
ℎ𝑟
48
Energy Balance on Heat Exchanger 4
Conditions 10 11 12
Temperature (C) 162.86 ? 139
Pressure (bar) 10.4 7.4 7.4
𝑲𝒎𝒐𝒍𝒆 5544.598 5544.598 5544.598
Molar Flow ( 𝒉
)
𝑲𝒈 118635.708 118635.708 118635.708
Mass Flow ( 𝒉 )
Composition
Methanol 0.2426 0.2426 0.2426
H 2O 0.7574 0.7574 0.7574
DME 0 0 0
𝑛 ∫ Cp 𝑚𝑖𝑥 dT = 𝑛 ∫ Cp 𝑚𝑖𝑥 dT
298.15 298.15
49
From Perry's Chemical Engineers’ Handbook page 298, 413
Cp (162C, 10.4 bar) Cp (7.4 bar)
Compound
KJ/(mole.K) KJ/(mole.K)
Methanol 0.27588 0.29260
Water 0.13319 0.14127
𝐾𝐽
𝐶𝑝(167.04𝐶,10.4 𝑏𝑎𝑟)𝑚𝑖𝑥 = ∑ 𝑥𝑖 ∗ 𝐶𝑝𝑖 = 0.08982
𝑚𝑜𝑙𝑒. 𝐾
𝐾𝐽
𝐶𝑝(7.4 𝑏𝑎𝑟)𝑚𝑖𝑥 = ∑ 𝑥𝑖 ∗ 𝐶𝑝𝑖 = 0.09527
𝑚𝑜𝑙𝑒. 𝐾
𝑄=n ∫ Cp𝑚𝑖𝑥 dT
428.13
Cp Eq. for liquid from Perry's Chemical Engineers’ Handbook page 170
50
𝑇2
𝐶2 2 𝐶3 𝐶4
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + (𝑇2 − 𝑇12 ) + (𝑇23 − 𝑇13 ) + (𝑇24 − 𝑇14 )
𝑇1 2 3 4
𝐶5 5
+ (𝑇2 − 𝑇15 )
5
𝑗
From Perry's Chemical Engineers’ Handbook Cp ( ) liquid page
𝐾𝑚𝑜𝑙.𝐾
163
Compound C1 C2 C3 C4 C5
Methanol 105800 -362.23 0.9379 0 0
Water 276370 -2090.1 8.125 -0.01412 9.3701*10-6
412.15
𝐾𝑗
∫ Cp𝑚𝑖𝑥 dT = −1455.957
𝐾𝑚𝑜𝑙. 𝐾
428.13
𝑄 = 4131.1141 ∗ −1455.957
𝐾𝑗
Q = −6014726.334
ℎ𝑟
51
Energy Balance on Distillation 2
Conditions 12 13 14
Temperature (C) 139 ? ?
Pressure (bar) 7.4 7.3 7.3
𝑲𝒎𝒐𝒍𝒆 4131.1141 1211.2074 2919.9067
Molar Flow ( 𝒉
)
𝑲𝒈 93191.5770 38589.0678 54602.5092
Mass Flow ( 𝒉 )
Composition
Methanol 0.3256 0.99 0.05
H 2O 0.6744 0.01 0.95
DME 0 0 0
52
From Introduction to Chemical Engineering Thermodynamics 7th Edition
page 682 Antoine Equation Parameters (P in mmHg, T in °C)
Compound A B C
Methanol 7.9701 1521.23 234
Water 8.14019 1810.94 244.485
DME 7.10736 946.89 248.645
Let T= 125.75C
compound x P K K*X
Methanol 0.99 5514.299 1.007095 0.997024
DME 0.01 1773.478 0.323896 0.003239
sum= 1.000263
⸫ Tbub=125.75C
⸫ Tdew=126.25 C
53
The Bottom
Tbub Calculation for liquid product in Bottom
Let T=163.52 C
compound x P K K*X
Methanol 0.05 13909.88472 2.540409281 0.127020464
Water 0.95 5031.458236 0.918912231 0.872966619
sum= 0.999987
⸫ Tbub=163.52 C
⸫ Tdew=165.6 C
⸫ T13=142.95 C
T14=163.52 C
54
Condenser and Reboiler duty Calculation
To calculate condenser duty first must Find Reflux ratio by use
Underwood and Fenske equation
𝐾𝑖
Compound K (139 C) 𝛼𝑖 =
𝐾𝑤
Methanol 1.423363 2.977613
Water 0.478021 1
1 𝑥𝑑 𝛼(1 − 𝑥𝑑)
𝑅𝑚𝑖𝑛 = [ − ]
𝛼 − 1 𝑥𝑓 1 − 𝑥𝑓
1 0.99 2.978(0.01)
𝑅𝑚𝑖𝑛 = [ − ]
2.978 − 1 0.3256 0.6744
𝑅𝑚𝑖𝑛 = 1.515
𝐿
𝑅= ⇒𝐿 =𝑅∗𝐷
𝐷
kmol
𝐿 = 2752.748
hr
𝑘𝑚𝑜𝑙
𝑉 = 𝐿 + 𝐷 = 3963.958
ℎ𝑟
55
For total condenser
𝑇𝑏𝑢𝑏
𝐾𝑗
𝜆 = ∑ 𝑥𝑖 𝜆𝑖 = −36433.254
𝐾𝑚𝑜𝑙
𝑇𝑏𝑢𝑏
𝑄𝑐𝑜𝑛𝑑𝑒𝑛𝑐𝑒𝑟 = 𝑉 𝜆
𝑀𝑗
𝑄𝑐𝑜𝑛𝑑𝑒𝑛𝑐𝑒𝑟 = −144558.638
ℎ𝑟
56
From Perry's Chemical Engineers’ Handbook Cp page 163, 176
Cp Liquid (j/Kmol.K)
Compound C1 C2 C3 C4 C5
Methanol 105800 -362.23 0.9379 0 0
Water 276370 -2090.1 8.125 -0.01412 9.37E-06
DME 110100 -157.47 0.51853 0 0
Cp Gas (j/Kmol.K)
Compound C1 C2 C3 C4 C5
Methanol 39250 87900 1916.5 53650 896.7
Water 33363 26790 2610.5 8896 1169
DME 51480 144200 1603.4 77400 725.4
For liquid
𝑇2
𝐶2 2 𝐶3 𝐶4
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + (𝑇2 − 𝑇12 ) + (𝑇23 − 𝑇13 ) + (𝑇24 − 𝑇14 )
𝑇1 2 3 4
𝐶5 5
+ (𝑇2 − 𝑇15 )
5
For gas
𝑇2
𝐶3 𝐶3
∫ Cp dT = 𝐶1 (𝑇2 − 𝑇1 ) + 𝐶2 ∗ 𝐶3 [coth ( ) − coth ( )] + 𝐶4
𝑇1 𝑇2 𝑇1
𝐶5 𝐶5
∗ 𝐶5 [tanh ( ) − tanh ( )]
𝑇2 𝑇1
57
Reboiler Heat Duty Calculation
From Energy balance on Distillation Column
𝑄𝑟 + 𝐻𝑓 = 𝐻𝑑 + 𝐻𝑤 + 𝑄𝑐
412.15
𝑀𝑗
𝐻𝑓 = 4131.1141 [ ∫ Cp 𝑚𝑖𝑥 dT] = 18648.394
ℎ𝑟
273.15
398.89
𝑀𝑗
𝐻𝑑 = 1211.2074 [ ∫ Cp 𝑚𝑖𝑥 dT] = 13869.388
ℎ𝑟
273.15
436.67
𝑀𝑗
𝐻𝑤 = 2919.9067 [ ∫ Cp 𝑚𝑖𝑥 dT] = 36845.083
ℎ𝑟
273.15
𝑄𝑟 = 𝐻𝑑 + 𝐻𝑤 + 𝑄𝑐 − 𝐻𝑓
𝑀𝑗
𝑄𝑟 = 112492.560
ℎ𝑟
58
Overall Process Energy Balance
59
Stream Conditions
Conditions Methanol 2 3 4 5 6 7
Composition
DME 0 0 0 0 0 0 0.396
Conditions 8 9 10 11 12 13 14
Composition
Composition
DME 0 0 0.995 0
60
Chapter Four
Process Design
61
Design Heat Exchanger 1
Shell Steam Tube
163.5 Temp. in, °C 25
114.5 Temp. out, °C 50
15.2 Pressure (bar) 15.2
𝐾𝑔
180037.196 Mass Flow ( ℎ𝑟 ) 54602.5
3286.424 Q, kW 3286.424
Composition
0 Methanol 0.99
1 H2O 0.01
0 DME 0
54602.5 𝑘𝑔
𝑚𝑤 = 101.578
3600 𝑠
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 ) (49.68 − 37) − (46.1 − 25)
∆𝑇𝑚 = =
(𝑇1 − 𝑡2 ) (49.68 − 37)
(𝑇2 − 𝑡1 ) (46.1 − 25)
(𝑇ℎ𝑜𝑡 𝑖𝑛 − 𝑇ℎ𝑜𝑡 𝑜𝑢𝑡 ) (49.68 − 46.1)
𝑅= = = 0.298
(𝑇𝑐𝑜𝑙𝑑 𝑜𝑢𝑡 − 𝑇𝑐𝑜𝑙𝑑 𝑖𝑛 ) (37 − 25)
To calculate corrected logarithmic mean temperature (Ft) for 1 shell, 2
passes, from Figure 12.19 page 657 Chemical Engineering Vol 6
62
From Figure 12.19 Ft = 0.99
𝑊
𝐴𝑠𝑠𝑢𝑚𝑒 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 700
𝑚2 𝐶
Choose standard dimension for stainless steel tube of heat exchanger
From Table 12.3 page 645 Chemical Engineering Vol 6
𝑄 3286.424
𝐴= = = 46.942 𝑚2
𝐹𝑡 𝑈 ∆𝑇𝑚 0.99 ∗ 700 ∗ 101.02
46.942
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = = 327
0.1436
63
Tube-Side Coefficient
25 + 50
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = = 37.5 °𝐶
2
180037.196 𝑚³
Q= = 0.0645
3600 ∗ 778 𝑆
𝜋
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = (23 ∗ 10−3 )² = 0.000145 𝑚2
4
327
number of tube for 2 passes = = 163.5
2
area per pass=163.5*0.000145=0.06785
𝑄 0.0645 𝑚
𝑇𝑢𝑏𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 0.95
𝐴 0.06785 𝑠
64
from Figure 12.30 page 674 Chemical engineering Vol 6
𝑗𝑓 = 0.0034
-0.14
𝜇
N𝑢𝑑 = 𝑗ℎ 𝑅𝑒 𝑝𝑟⅓ ( )
𝜇𝑤
Fouling factors: as neither fluid is heavily fouling, use 5000 W/m2 ºC for
mixture in tube side and use 3000 W/m2 ºC for water in shell side
Kw=45 W/m °C for stainless steel
65
Shell-Side Coefficient
Use pull-through floating head, no need for close clearance.
Select baffle spacing (lB) = shell diameter, 45 per cent cut.
From Figure 12.10 page 646, clearance = 94 mm.
Ds= 704+94= 798 mm
𝐷𝑠 798
lB= = = 159.6𝑚𝑚
5 5
114.5 + 163.5
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = = 139 °𝐶
2
Physical properties at 139 °𝐶 From Perry's Chemical Engineers’
Handbook
Cross-flow Area
(31.25 − 25)
𝐴𝑠 = ∗ 798 ∗ 159.5 ∗ 10−6 = 0.0318 𝑚2
31.25
Mass flow-rate, based on inlet conditions
54602.509 𝑘𝑔
𝐺𝑠 = = 476.3535
3600 ∗ 0.0318 𝑠 𝑚2
𝐺𝑠 476.3535 𝑚
𝑢𝑠 = = = 0.5134
𝜌𝑤 928 𝑠
66
𝐺𝑠 𝑑𝑒 476.3535 ∗ 17.75 ∗ 10−3
𝑅𝑒 = = = 43369.09
𝜇 0.000195
𝐶𝑝∗𝜇 4.2∗1000∗0.000195
𝑃𝑟 = = = 1.193
𝐾 0.686
67
Overall Coefficient
25
1 1 1 25 ∗ 10−3 ∗ ( ) 25 1 25 1
= + + 23 + ∗ + ∗
𝑈0 3553.244 5000 2 ∗ 45 23 3000 23 1976
𝑊
𝑈0 = 705
𝑚2 °𝐶
Same as assumed, firm up design
Shell-side pressure drop
Take pressure drop as 50 per cent of that calculated using the inlet flow;
neglect viscosity correction.
68
Summary
69
Design Heat Exchanger 2
Shell Steam Tube
377 Temp. in, °C 50
160.1 Temp. out, °C 131.7
14.7 Pressure (bar) 14.4
𝐾𝑔
218626.36 Mass Flow ( ) 180037.196
ℎ𝑟
12640 Q, kW 12640
Composition
0.198 Methanol 0.99
0.396 H2O 0.01
0.405 DME 0
70
From Figure 12.19 Ft = 0.92
𝑊
𝐴𝑠𝑠𝑢𝑚𝑒 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 670
𝑚2 𝐶
Choose standard dimension for stainless steel tube of heat exchanger
From Table 12.3 page 645 Chemical Engineering Vol 6
𝑄 12640.16 ∗ 1000
𝐴= = = 121.5𝑚2
𝐹𝑡 𝑈 ∆𝑇𝑚 0.92 ∗ 670 ∗ 168.76
121.5
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = = 1057
0.114924
71
Tube-Side Coefficient
131.7 + 50
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = = 90.85 °𝐶
2
180037.196 𝑚³
Q= = 0.0693
3600 ∗ 721.367 𝑆
𝜋
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = (18 ∗ 10−3 )² = 0.00025434 𝑚2
4
1057
number of tube for 2 passes = = 529
2
area per pass=529*0.00025434=0.1344
𝑄 0.0693 𝑚
𝑇𝑢𝑏𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 0.5156
𝐴 0.1344 𝑠
72
from Figure 12.30 page 674 Chemical engineering Vol 6
𝑗𝑓 = 0.0038
-0.14
𝜇
N𝑢𝑑 = 𝑗ℎ 𝑅𝑒 𝑝𝑟⅓ ( )
𝜇𝑤
Fouling factors: as neither fluid is heavily fouling, use 5000 W/m2 ºC for
mixture in tube side and use 3000 W/m2 ºC for water in shell side
Kw=45 W/m °C for stainless steel
73
Shell-Side Coefficient
Use pull-through floating head, no need for close clearance.
Select baffle spacing (lB) = shell diameter, 45 per cent cut.
From Figure 12.10 page 646, clearance = 94 mm.
Ds= 895+95= 990 mm
𝐷𝑠 1035
lB= = = 207𝑚𝑚
5 5
377 + 160.1
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = = 268.55 °𝐶
2
Physical properties at 268.55 °𝐶 From Perry's Chemical Engineers’
Handbook
Cross-flow Area
(25 − 20)
𝐴𝑠 = ∗ 1035 ∗ 207 ∗ 10−6 = 0.04287 𝑚2
25
Mass flow-rate, based on inlet conditions
218626.36 𝑘𝑔
𝐺𝑠 = = 1416.56
3600 ∗ 0.04287 𝑠 𝑚2
𝐺𝑠 1416.56 𝑚
𝑢𝑠 = = = 2.158
𝜌 656 𝑠
74
𝐺𝑠 𝑑𝑒 1416.56 ∗ 14.2 ∗ 10−3
𝑅𝑒 = = = 15458
𝜇 0.00013
𝐶𝑝∗𝜇 0.959∗1000∗0.00013
𝑃𝑟 = = = 0.47
𝐾 0.264
75
Overall Coefficient
20
1 1 1 25 ∗ 10−3 ∗ ( ) 20 1 20
= + + 18 + ∗ +
𝑈0 5390.49 5000 2 ∗ 45 18 3000 18
1
∗
1575.74
𝑊
𝑈0 = 673
𝑚2 °𝐶
Same as assumed, firm up design
Shell-side pressure drop
Take pressure drop as 50 per cent of that calculated using the inlet flow;
neglect viscosity correction.
76
Summary
77
Design Heat Exchanger 3
Select kettle type. Physical properties of Methanol and Water at pressure
14.7 bar:
Q(w)= 62012380.19
TBP M(°c)= 154.303
TBP W(°c)= 198
XW= 0.01
XM= 0.99
Mwt= 32.04
Mwt(w)= 18
P in(bar)= 14.7
Pcw(bar)= 220.8885
P cM(bar)= 79.54013
From table 12.1 page 637, assume over all heat transfer = 1182 (W/m2
°C)
𝑄 62012380.19
Area (outside) required (A) = =
∆Tm∗U 95.26003∗1182
=702.23 m²
78
𝐴
Number of tube =
𝜋∗Length of Tube∗Outside diameter
702.23
= = 1205.99 ≅1206
𝜋∗0.03∗4.88
𝑄 62012380.2
= =88.3 kw/m²
𝐴 702.23
79
14.7 0.17 14.7 1.2
hnb =104(80.95)0.69 (88308)0.7 [1.8( ) + 4( ) +
80.95 80.95
14.7 10
10( ) [
80.95
= 11646.04 W/m² °C
38
1 1 1 38 ∗ 10−3 ∗ ( ) 38 1 38 1
= + + 36 + ∗ + ∗
𝑈0 111646.04 2500 2 ∗ 59 36 5000 36 8000
𝑈0 = 1181.92 W/m² °C
Check maximum allowable heat flux, use Mostinski’s method
Layout
From tube sheet layout Db =2176.533 mm
Take shell diameter as twice bundle diameter
Ds= 2 *1778.2 = 3556.664 mm
80
From sketch, width at liquid level = 3330 mm
Maximum velocity:
Find density of Methanol from J. Phys Chem. Ref. Data, vol 16 No. 4,
1987 page 801
a 54.566 c 513.16
b 0.233211 d 0.2088175
81
𝑎 54.466
ρM = 𝑑
= 0.2088175
𝑏1+(1−𝑇/𝑐) 0.2332111+(1−403/513.6)
𝑘𝑔
= 665.7 3
𝑚
Summary
82
Design Reactor
Conditions 6 7
Temperature (C) 250 373
Pressure (bar) 14.7 14.7
𝑲𝒎𝒐𝒍𝒆 6862.0924 6862.0924
Molar Flow ( 𝒉
)
Other information
Type of reactor Packed bed reactor
Working Condition Adiabatic reactor
𝑱
E( ) 80400
𝒎𝒐𝒍
𝒌𝒈
Density of catalyst (𝒎𝟑) 1770
1 1
𝐴↔ 𝐵 + 𝐶
2 2
−80400
( )
𝐾1 = 5.26 ∗ 109 𝑒 𝑅𝑇 (𝟔)
83
𝐾𝑝523 ∆𝐻𝑟 1 1
𝐿𝑛 ( ) = (− )∗( − )
𝐾𝑝473 𝑅 473 523
𝐾𝑝523 11770 1 1
𝐿𝑛 ( ) = (− )∗ ( − )
34.1 8314 473 523
𝐾𝑝523 = 34.09
𝑘1
𝐾2 = (𝟕)
𝑘𝑝
−∆𝐻𝑟. 𝑋
𝑇 = 𝑇𝑜 +
∑ᶲ𝐶𝑝𝑖
substance ᶲ 𝐶𝑝𝑖
A 1 19.038 + 0.09146𝑇 − 1.218 ∗ 10−5 𝑇 2 −
8.034 ∗ 10−9 𝑇 3
B 0.01 29.163 + 0.01449𝑇 − 0.202 ∗ 10−5 𝑇 2
C 0 17.01 + 0.179𝑇 − 5.2 ∗ 10−5 𝑇 2 − 1.9 ∗
10−9 𝑇 3
−(−11770) 𝑋
𝑇 = 650 +
62.3906
𝑇 = 650 + 188.65 𝑋 (𝟖)
Substation (8) in (6) , Substation in (7)
−9.6704
𝐾2 = 154297447.9 𝑒 (𝟗)
650 + 188.65𝑥
Substation (9)(6)(3)(4)(5) in (2) then (2) in (1)
0.8
w dx
=∫ 9.6704
FAo
0 e−650+188.65x ∗ [(381.18 − 38.18x)2 − (6.2507 ∗ 10−9 𝑥 + 3.1253 ∗ 10−7 𝑥 2 )]
0.8
ℎ
∫ fx= ∗ (𝐹0 + 𝐹6 + 4(𝐹1 + 𝐹3 + 𝐹5) + 2(𝐹2 + 𝐹4))
0 3
0.1333
=
3
∗ (6.985 ∗ 10−6 + 8.2324 ∗ 10−6
+ 4(7.1719 ∗ 10−6 + 7.5691 ∗ 10−6 + 8.0016 ∗ 10−6 )
+ 2( 17.3663 ∗ 10−6 + 7.7807 ∗ 10−6 )) = 6.4
Volume of catalyst
𝑤
𝑉= = 24.85 𝑚3
𝑝
Volume of Reactor
𝑊 44123
𝑉𝑅 = = = 49.85 𝑚3
𝑝(1 − 𝑒) 1770 ∗ (1 − 0.5)
3.14 2
𝑉= 𝑑 𝐿
4
𝐿 3
=
𝐷 2
𝐿 = 5.25𝑚 𝑑 = 3.5𝑚
85
Summary
86
Design Distillation 1
From Material and Energy balance
Rmin 1.87
Nmin 7.063
R 2.812
Ln, Kmol/hr 7678.578
Vn, Kmol/hr 10409.556
Lm, Kmol/hr 14540.6704
Vm, Kmol/hr 10409.5563
𝑅 2.813
= = 0.7377
𝑅 + 1 3.813
𝑅𝑚 1.87
= = 0.65156
𝑅𝑚 + 1 2.87
From Figure 11.11 Chemical engineering vol. 6 page 524
7.063
𝑁= = 11.578 ≈ 12 𝑃𝑙𝑎𝑡𝑒
0.61
87
Column Efficiency
𝐸 = 51 − 32.5 𝐿𝑜𝑔(𝛼𝑎 𝜇𝑎 )
𝜇𝑎 = mixture viscosity
From Perry’s Chemical Engineers Handbook, 8th Edition
𝜇𝑎 = 7.38 ∗ 10−5 𝑝𝑎. 𝑠
𝛼𝑎 = volatility of Light Key component
𝛼𝑎 = 5.096 From M.B chapter 2 page 20
𝐸 = 51 − 32.5 𝐿𝑜𝑔(7.38 ∗ 10−5 ∗ 5.096)
Overall efficiency E =0.63
𝑁𝑜. 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠
𝐸=
𝑁𝑜. 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠
12 − 1
0.63 = ⇒ 𝑁𝑜. 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠 = 17.46
𝑁𝑜. 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠
𝑁 ≈ 18 𝑝𝑙𝑎𝑡𝑒
𝐿𝑛 𝜌𝑣
𝐹𝐿 = √
𝑉𝑛 𝜌𝐿
T, K 319.1
R 8.314
P, bar 10.3
ρL, Kg/m3 682.869
𝑃 𝑀𝑤𝑡𝑚𝑖𝑥
𝜌𝑣 =
𝑅𝑇
𝑘𝑔
𝑀𝑤𝑡𝑚𝑖𝑥 = (32 ∗ 0.005) + (46.07 ∗ 0.995) = 45.999 ∗ 10−3
𝑚𝑜𝑙
10.3 ∗ 105 ∗ 45.999 ∗ 10−3 𝑘𝑔
𝜌𝑣 = = 17.808 3
8.314 ∗ 319.1 𝑚
88
7678.578 17.808
𝐹𝐿 = √ = 0.1191
10409.556 682.869
𝜌𝑙 − 𝜌𝑣
𝑈𝑚𝑎𝑥 = (−0.171 𝐿𝑡 2 + 0.27 𝐿𝑡 − 0.047)√
𝜌𝑣
𝜌𝑙 − 𝜌𝑣
𝑈𝑓 = 𝐾1 √
𝜌𝑣
𝐾1 = 0.082
𝑚
𝑈𝑓 = 0.5011
𝑠
89
𝑈𝑓 𝑚𝑎𝑥 = 0.85 ∗ 𝑈𝑓
𝑚
𝑈𝑓 𝑚𝑎𝑥 = 0.425
𝑠𝑒𝑐
4 𝑢𝑓𝑚𝑎𝑥
𝐷𝑐𝑜𝑙𝑢𝑚 = √
𝜋 ∗ 𝜌𝑣 ∗ 𝑢𝑚𝑎𝑥
4 ∗ 0.452
𝐷𝑐𝑜𝑙𝑢𝑚 = √
𝜋 ∗ 17.808 ∗ 0.2768
𝐷𝑐𝑜𝑙𝑢𝑚𝑛 = 0.604 𝑚
𝐿𝑚 𝜌𝑣
𝐹𝐿 = √
𝑉𝑚 𝜌𝐿
T, K 435.86
R 8.314
P, bar 10.3
ρL, Kg/m3 813.98
𝑃 𝑀𝑤𝑡𝑚𝑖𝑥
𝜌𝑣 =
𝑅𝑇
𝑘𝑔
𝑀𝑤𝑡𝑚𝑖𝑥 = (32 ∗ 0.3356) + (16 ∗ 0.6744) = 21.209 ∗ 10−3
𝑚𝑜𝑙
10.3 ∗ 105 ∗ 21.209 ∗ 10−3 𝑘𝑔
𝜌𝑣 = = 6.087 3
8.314 ∗ 435.86 𝑚
𝐹𝐿 = 0.12079
Take spacing plate (Lt) = 0.5 m
90
𝜌𝑙 − 𝜌𝑣
𝑈𝑚𝑎𝑥 = (−0.171 (0.5)2 + 0.27(0.5) − 0.047) ∗ √
𝜌𝑣
𝑚
= 0.5213
𝑠𝑒𝑐
𝜌𝑙 − 𝜌𝑣
𝑈𝑓 = 𝐾1 √
𝜌𝑣
𝐾1 = 0.082
𝑚
𝑈𝑓 = 0.9792
𝑠
𝑚
𝑈𝑓 𝑚𝑎𝑥 = 0.85 ∗ 𝑈𝑓 = 0.83232
𝑠𝑒𝑐
4 𝑢𝑓𝑚𝑎𝑥 4 ∗ 0.452
𝐷𝑐𝑜𝑙𝑢𝑚 = √ =√ = 0.7 𝑚
𝜋 ∗ 𝜌𝑣 ∗ 𝑢𝑚𝑎𝑥 𝜋 ∗ 17.808 ∗ 0.2768
91
Column Height
1. Actual No. of stage N=18
2. Safety factor = 0.1 ∗ 18 = 1.8
3. 1 plate for reboiler = 2
Total stage 18 + 2 + 1 = 21 𝑝𝑙𝑎𝑡𝑒𝑠
𝐾𝑚𝑜𝑙
𝑉𝑚 = 𝐷(1 + 𝑅) = 47699
ℎ𝑟
At 12 percent of Area
𝐴 𝑑𝑜𝑤𝑛 𝑐𝑜𝑚𝑒𝑟 = 0.12 ∗ 0.4 = 0.048 𝑚2 = 𝐴𝑑
𝑁𝑒𝑡 𝐴𝑟𝑒𝑎 = 𝐴𝑐 − 𝐴𝑑 = 0.352 𝑚2 = 𝐴𝑁
𝐴𝑐𝑡𝑖𝑣𝑒 𝐴𝑟𝑒𝑎 = 𝐴𝑐 − 2𝐴𝑑 = 0.304 𝑚2 = 𝐴𝑎
Hole Area Ah ⇒ take 10 percent from Aa as first trial
𝐴ℎ = 0.1 ∗ 0.304 = 0.0304 𝑚2
92
Weir Length
From figure 11.31 from Chemical engineering vol. 6 page 573
𝐴𝑑
∗ 100% = 12
𝐴𝑐
𝐿𝑤
From the figure ⇒ = 0.77 ⟹ 𝐿𝑤 = 0.539 𝑚
𝐷𝑐
Plate thickness = 55 mm
Hole diameter = 5 mm =dh
The weir height = 50 mm = hw
93
Check Weeping
𝐿𝑚 ×𝑀𝑤𝑡 𝑚𝑖𝑥
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 𝑟𝑎𝑡𝑒 (𝐿𝑤) =
3600
14540.6704 ∗ 21.209 ∗ 10−3 𝑘𝑔
= = 0.08566
3600 𝑠
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 𝑟𝑎𝑡𝑒 (𝑙𝑤) = 70 𝑝𝑒𝑟𝑐𝑒𝑛𝑡 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 𝑟𝑎𝑡𝑒
𝑘𝑔
= 0.7 ∗ 0.08566 = 0.059
𝑠𝑒𝑐
2 2
𝐿𝑤 3 0.08566 3
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = 750 [ ] = 750 [ ]
𝜌𝑙 × 𝑙𝑤 813.98 ∗ 0.059
= 2.524 𝑚𝑚 𝐿𝑖𝑞𝑢𝑖𝑑
2 2
𝑙𝑤 3 0.059 3
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = 750 [ ] = 750 [ ]
𝜌𝑙 × 𝐿𝑤 813.98 ∗ 0.08566
= 1.968 𝑚𝑚 𝐿𝑖𝑞𝑢𝑖𝑑
At minimum rate
ℎ𝑤 + ℎ𝑜𝑤 = 50 + 1.968 = 51.968 𝑚𝑚
From figure. (11.30) From chemical engineering vol. 6 page 571
94
𝐾2 = 30.1
𝑀𝑖𝑛. 𝑉𝑎𝑝𝑜𝑟𝑅𝑎𝑡𝑒
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
𝐴𝑎
0.6 ×0.4612 𝑚
= = 9.55
0.0304 𝑠
0.461 𝑚
𝑈ℎ^ = = 15.17
0.0304 𝑠
95
𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘 5 𝑚𝑚
= = 1 𝑚𝑚
𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 5 𝑚𝑚
𝐴ℎ 𝐴ℎ 0.0304
≈ 𝑎𝑡 100 𝑝𝑒𝑐𝑒𝑛𝑡 = = 10
𝐴𝑝 𝐴𝑎 0.304
𝐶𝑜 = 0.84
96
pressure drop through dry plate
2
𝑈ℎ^ 𝜌𝑣 15.17 2 6.087
ℎ𝑑 = 51 [ ] . = 51 [ ] = 124.38 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝐶0 𝜌𝑙 0.84 813.98
Residual head
97
Back up in down comer
Perforated Area
𝐿𝑤
= 0.77 ⟹ Ө𝑐 = 99˚
𝐷𝑐
98
Angle subtended at plate edge by imperforated strip = 180-99 = 81˚
81
𝑚𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑒𝑑𝑔𝑒 𝑠𝑡𝑟𝑖𝑝𝑠 = (0.7– 50×10−3 )𝜋
180
= 0.91 𝑚
Ө𝑐
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = (𝐷𝑐 − ℎ𝑤) sin ( )
2
99
= (0.7 − 50 ∗ 10^ − 3 ) sin ( ) = 0.494 𝑚
2
𝐴ℎ 0.0304
= = 0.148
𝐴𝑝 0.205
99
𝐿𝑝
= 2.61 satisfacory
𝑑ℎ
Total plate 21
Column diameter 0.7 m
Column Height 11 m
Hole size 5 mm
Hole pitch 12.5 mm
Active holes 1548
Turn down 70% max rate
Plate material Mild steel
Down comer material Mild steel
Plate spacing 0.5 m
Plate pressure drop 124.38 mm liq.
Plate thickness 55 mm
100
Design Condenser for Distillation 1
Shell Steam Tube
49.68 Temp. in, °C 25
46.1 Temp. out, °C 37
10.4 Pressure (bar) 10.4
𝑲𝒈
478110.9267 Mass Flow ( ) 478110.9267
𝒔
5046.397358 Q, kW 5046.397358
Composition
0.005 Methanol 0
0 H2O 1
0.995 DME 0
𝑄 = 𝑚𝑤 𝑐𝑝 𝑤 ∆𝑇
5046.397 𝑘𝑔
𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 = = 101.578
(37 − 25) ∗ 4.18 𝑠
𝑊
𝐴𝑠𝑠𝑢𝑚𝑒 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 538
𝑚2 𝐶
Choose horizontal Heat Exchanger 1 shell, 4 tube passes.
To calculate corrected logarithmic mean temperature (Ft) for 1 shell, 4
passes, from Figure 12.19 page 657 Chemical Engineering Vol 6
101
(𝑇ℎ𝑜𝑡 𝑖𝑛 − 𝑇ℎ𝑜𝑡 𝑜𝑢𝑡 ) (49.68 − 46.1)
𝑅= = = 0.298
(𝑇𝑐𝑜𝑙𝑑 𝑜𝑢𝑡 − 𝑇𝑐𝑜𝑙𝑑 𝑖𝑛 ) (37 − 25)
583.12
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = = 1015
0.5746
102
1
1015 2.263
𝐷𝑏 = 50 ( ) = 2408 𝑚𝑚
0.158
Shell-Side Coefficient
Estimate tube wall temperature Tw:
𝑊
assume condensing coefficient of 1704
𝑚2 °𝐶
Mean temperature
49.68 + 46.1
𝑆ℎ𝑒𝑙𝑙 − 𝑠𝑖𝑑𝑒 (𝑇𝑠 ) = = 47.89 °𝐶
2
25 + 37
𝑇𝑢𝑏𝑒 − 𝑠𝑖𝑑𝑒 (𝑇𝑡 ) = = 31 °𝐶
2
(𝑇𝑠 − 𝑇𝑤 ) 𝑈𝑐𝑜𝑛𝑑 = (𝑇𝑠 − 𝑇𝑡 ) 𝑈𝑜𝑣𝑒𝑟𝑎𝑙𝑙
(47.89 − 𝑇𝑤 ) 1704 = (47.89 − 31) 538
𝑇𝑤 = 42.56 °𝐶
42.56 + 47.89
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒 = = 45.2 °𝐶
2
Physical properties at 45.2 °𝐶 From Perry's Chemical Engineers’
Handbook
103
𝐶𝑜𝑛𝑑𝑒𝑛𝑠𝑒 𝑓𝑙𝑜𝑤 478110.9267 𝑘𝑔
𝛤ℎ = = = 0.0358
𝐿 𝑁𝑡 3.66 ∗ 1015 𝑠𝑚
2
Average number of tubes in a vertical tube row, 𝑁𝑟 = ∗ 39 = 26
3
1
620.82(620.82 − 18.4) 3
−
1
ℎ𝑐 = 0.95 ∗ 0.581 ∗ [ ] ∗ 26 6
0.000674 ∗ 0.0358
𝑊
ℎ𝑐 = 1704.42
𝑚2 °𝐶
Same as assumed so no need to correction
Tube-Side Coefficient
𝜋 1015
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = (48 ∗ 10−3 ) ∗ = 0.459 𝑚2
4 4
Density of water at 31ºC =992.48 kg/m3
𝐺 101.578 𝑚
𝑇𝑢𝑏𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 0.223
𝜌 𝐴 992.48 ∗ 0.459 𝑠
Tube-side heat transfer coefficient
Fouling factors: as neither fluid is heavily fouling, use 6000 W/m2 ºC for
each side
Kw=45 W/m °C for stainless steel
104
Overall Coefficient
50
1 1 1 50 ∗ 10−3 ∗ ( ) 50 1 50
= + + 48 + ∗ +
𝑈0 1704.42 6000 2 ∗ 45 48 6000 48
1
∗
1148.66
𝑊
𝑈0 = 538.64 2
𝑚 °𝐶
Same as assumed, firm up design
Cross-flow Area
(62.5 − 50)
𝐴𝑠 = ∗ 2518 ∗ 2518 ∗ 10−6 = 1.27 𝑚2
62.5
Mass flow-rate, based on inlet conditions
478110.9267 𝑘𝑔
𝐺𝑠 = = 104.767
3600 ∗ 1.27 𝑠 𝑚2
𝑗𝑓 = 0.018
𝐺𝑠 104.767 𝑚
𝑢𝑠 = = = 3.49
𝜌𝑣 30.1 𝑠
Take pressure drop as 50 per cent of that calculated using the inlet flow;
neglect viscosity correction.
106
Tube-side pressure drop
Viscosity of water= 0.0008 pa.s
𝜌𝑢𝑑 992.48 ∗ 0.223 ∗ 48 ∗ 10−3
𝑅𝑒 = = = 13196.69
𝜇 0.0008
𝑗𝑓 = 0.0045
Neglect viscosity correction
107
Summary
108
Design Reboiler for Distillation 1
Q(w)= 9487714
TBP M(°c)= 139
TBP W(°c)= 198
XW= 0.7574
XM= 0.2426
Mwt= 32.04
Mwt(w)= 18
P in(bar)= 10.7
Pcw(bar)= 220.8885
P cM(bar)= 79.54013
The boiling point of mixture = TBP
M(°C) * XM + TBP (°C)*XW
=139*0.2426 + 198*0.7574
= 170.81°C
=109.61m ²
109
Inside diameter(di) 26.4 mm
Outside diameter(do) 30 mm
Length of Tube 4.88 m
𝐴
Number of tube =
𝜋∗Length of Tube∗Outside diameter
109.61
=𝜋∗0.03∗4.88 = 237.45 ≅238
Use Mostinski’s equation ; heat flux, based on estimated area,
𝑄 9487714
= =86.5538 kw/m²
𝐴 109.61
Pc of mix = Pc M *XM + Pc W * XW = 79.5403 * 0.2426 + 220.88 *
0.7574=186.6 bar
= 12935.59 W/m² °C
110
30
1 1 1 30 ∗ 10−3 ∗ ( ) 30 1 30
= + + 26.4 + ∗ +
𝑈0 12935.59 2500 2 ∗ 59.9 26.4 3000 26.4
1
∗
8000
𝑈0 =1095.308 W/m² °C
Check maximum allowable heat flux, use Mostinski’s method
10.4 10.4
𝑞𝑐 = 3.67 * 104 (186.5974)( )0.35 [1 − ( )]0.9
186.5974 186.5974
=236.7559 kw/m²
Applying a factor of 0.7, maximum flux should not exceed 236.7559 ∗
kW
0.7 = 165.7299 . Actual flux of 86.81762 kW/m² is well below
m2
maximum allowable.
Layout
Use square pitch arrangement, pitch = 1.5 * do
=1.5 * 30 = 45 mm
Tube bundle diameter
1
𝑁𝑡 𝑛1
𝐷𝑏 = 𝑑0 ( )
𝐾1
From Table 12.4 page 649 Chemical Engineering Vol 6
For 1 passes:
K1= 0.215
n1=2.027
111
1
239 2.027
𝐷𝑏 = 30 ( ) = 951.51 mm
0.215
112
Maximum velocity
Find density of Methanol from J. Phys Chem. Ref. Data, vol 16 No. 4,
1987 page 801
a 54.566 c 513.16
b 0.233211 d 0.2088175
𝑎 54.466
ρM=
1+(1−𝑇/𝑐)𝑑
= 0.2088175
𝑏 0.2332111+(1−(435/513.6)
=618.82 kg/m³
From Berry’s chemical Engineering 8th edition page 2-96 ρw=903.6
kg/m³
ρ mix =0.7574* 903.6+ 0.2426*618.82 = 834.5134 kg/m³
Summary
113
Design Heat Exchanger 4
Shell Steam Tube
25 Temp. in, °C 154.98
60 Temp. out, °C 139
7.4 Pressure (bar) 7.4
𝐾𝑔
93191.577 Mass Flow ( ) 40916
ℎ𝑟
1670 Q, kW 1670
Composition
0 Methanol 0.336
1 H2O 0.664
0 DME 0
114
From Figure 12.19 Ft = 0.97
𝑊
𝐴𝑠𝑠𝑢𝑚𝑒 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 755
𝑚2 𝐶
Choose standard dimension for stainless steel tube of heat exchanger
From Table 12.3 page 645 Chemical Engineering Vol 6
𝑄 1670 ∗ 1000
𝐴= = = 21.8𝑚2
𝐹𝑡 𝑈 ∆𝑇𝑚 0.97 ∗ 670 ∗ 168.76
21.8
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = = 127
0.172
2408
93191.577 𝑚³
Q= = 0.0312
3600 ∗ 829 𝑆
𝜋
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = (28 ∗ 10−3 )² = 0.000615 𝑚2
4
127
number of tube for 2 passes = = 64
2
area per pass=54*0.000615=0.039
𝑄 0.0312 𝑚
𝑇𝑢𝑏𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 0.8
𝐴 0.039 𝑠
𝐶𝑝 ∗ 𝜇 4 ∗ 1000 ∗ 0.000168
𝑃𝑟 = = =2
𝐾 0.47798
116
from Figure 12.30 page 674 Chemical engineering Vol 6
𝑗𝑓 = 0.0028
-0.14
𝜇
N𝑢𝑑 = 𝑗ℎ 𝑅𝑒 𝑝𝑟⅓ ( )
𝜇𝑤
Fouling factors: as neither fluid is heavily fouling, use 5000 W/m2 ºC for
mixture in tube side and use 3000 W/m2 ºC for water in shell side
Kw=45 W/m °C for stainless steel
117
Shell-Side Coefficient
Use pull-through floating head, no need for close clearance.
Select baffle spacing (lB) = shell diameter, 45 per cent cut.
From Figure 12.10 page 646, clearance = 94 mm.
Ds= 559+95= 654 mm
𝐷𝑠 654
lB= = = 131𝑚𝑚
5 5
25 + 60
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = = 42.5 °𝐶
2
Physical properties at 268.55 °𝐶 From Perry's Chemical Engineers’
Handbook
Cross-flow Area
(37.5 − 30)
𝐴𝑠 = ∗ 654 ∗ 131 ∗ 10−6 = 0.02568 𝑚2
30
Mass flow-rate, based on inlet conditions
40916 𝑘𝑔
𝐺𝑠 = = 442.57
3600 ∗ 0.02568 𝑠 𝑚2
𝐺𝑠 442.57 𝑚
𝑢𝑠 = = = 0.449
𝜌 987 𝑠
119
Overall Coefficient
30
1 1 1 30 ∗ 10−3 ∗ ( ) 30 1 30 1
= + + 28 + ∗ + ∗
𝑈0 1822 5000 2 ∗ 45 28 3000 28 5515.597
𝑊
𝑈0 = 755.7
𝑚2 °𝐶
Same as assumed, firm up design
Shell-side pressure drop
Take pressure drop as 50 per cent of that calculated using the inlet flow;
neglect viscosity correction.
120
Summary
121
Design Distillation 2
From Material and Energy balance
Rmin 1.515
Nmin 7.6314
R 2.72
Ln, Kmol/hr 2752.784
Vn, Kmol/hr 3963.958
Lm, Kmol/hr 6883.8981
Vm, Kmol/hr 3963.9915
𝑅 2.27
= = 0.6941
𝑅 + 1 3.27
𝑅𝑚 1.515
= = 0.6023
𝑅𝑚 + 1 2.515
From Figure 11.11 Chemical engineering vol. 6 page 524
6.3124
𝑁= = 10.69 ≈ 11 𝑃𝑙𝑎𝑡𝑒
0.5.9
122
Column Efficiency
𝐸 = 51 − 32.5 𝐿𝑜𝑔(𝛼𝑎 𝜇𝑎 )
𝜇𝑎 = mixture viscosity
From Perry’s Chemical Engineers Handbook, 8th Edition
𝜇𝑎 = 1.97 ∗ 10−4 𝑝𝑎. 𝑠
𝛼𝑎 = volatility of Light Key component
𝛼𝑎 = 2.977613 From M.B chapter 2 page 20
𝐸 = 51 − 32.5 𝐿𝑜𝑔(1.97 ∗ 10−4 ∗ 2.977613)
Overall efficiency E =0.61
𝑁𝑜. 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠
𝐸=
𝑁𝑜. 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠
11 − 1
0.63 = ⇒ 𝑁𝑜. 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠 = 16.39
𝑁𝑜. 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑝𝑙𝑎𝑡𝑒𝑠
𝑁 ≈ 17 𝑝𝑙𝑎𝑡𝑒
𝐿𝑛 𝜌𝑣
𝐹𝐿 = √
𝑉𝑛 𝜌𝐿
T, K 398.7
R 8.314
P, bar 7.3
ρL, Kg/m3 678.64
𝑃 𝑀𝑤𝑡𝑚𝑖𝑥
𝜌𝑣 =
𝑅𝑇
𝑘𝑔
𝑀𝑤𝑡𝑚𝑖𝑥 = (32 ∗ 0.99) + (18 ∗ 0.01) = 31.86 ∗ 10−3
𝑚𝑜𝑙
7.3 ∗ 105 ∗ 31.86 ∗ 10−3 𝑘𝑔
𝜌𝑣 = = 7.0163 3
8.314 ∗ 398.7 𝑚
123
2752.784 7.0163
𝐹𝐿 = √ = 0.0706
3963.958 678.64
𝜌𝑙 − 𝜌𝑣
𝑈𝑚𝑎𝑥 = (−0.171 𝐿𝑡 2 + 0.27 𝐿𝑡 − 0.047)√
𝜌𝑣
𝑚
𝑈𝑚𝑎𝑥 = (−0.171 (0.5)2 + 0.27(0.5) − 0.047) ∗ 9.7838 = 0.2765
𝑠𝑒𝑐
𝜌𝑙 − 𝜌𝑣
𝑈𝑓 = 𝐾1 √
𝜌𝑣
𝐾1 = 0.073
𝑚
𝑈𝑓 = 0.7142
𝑠
124
𝑈𝑓 𝑚𝑎𝑥 = 0.85 ∗ 𝑈𝑓
𝑚
𝑈𝑓 𝑚𝑎𝑥 = 0.6070
𝑠𝑒𝑐
4 𝑢𝑓𝑚𝑎𝑥
𝐷𝑐𝑜𝑙𝑢𝑚 = √
𝜋 ∗ 𝜌𝑣 ∗ 𝑢𝑚𝑎𝑥
4 ∗ 0.6070
𝐷𝑐𝑜𝑙𝑢𝑚 = √
𝜋 ∗ 7.0163 ∗ 0.4427
𝐷𝑐𝑜𝑙𝑢𝑚𝑛 = 0.693 𝑚
𝐿𝑚 𝜌𝑣
𝐹𝐿 = √
𝑉𝑚 𝜌𝐿
T, K 436.52
R 8.314
P, bar 7.3
ρL, Kg/m3 881.45
𝑃 𝑀𝑤𝑡𝑚𝑖𝑥
𝜌𝑣 =
𝑅𝑇
𝑘𝑔
𝑀𝑤𝑡𝑚𝑖𝑥 = (32 ∗ 0.05) + (18 ∗ 0.95) = 18.7 ∗ 10−3
𝑚𝑜𝑙
7.3 ∗ 105 ∗ 18.7 ∗ 10−3 𝑘𝑔
𝜌𝑣 = = 3.7614 3
8.314 ∗ 436.52 𝑚
𝐹𝐿 = 0.1134
Take spacing plate (Lt) = 0.5 m
125
𝜌𝑙 − 𝜌𝑣
𝑈𝑚𝑎𝑥 = (−0.171 (0.5)2 + 0.27(0.5) − 0.047) ∗ √
𝜌𝑣
𝑚
= 0.6912
𝑠𝑒𝑐
𝜌𝑙 − 𝜌𝑣
𝑈𝑓 = 𝐾1 √
𝜌𝑣
𝐾1 = 0.083
𝑚
𝑈𝑓 = 1.261
𝑠
𝑚
𝑈𝑓 𝑚𝑎𝑥 = 0.85 ∗ 𝑈𝑓 = 1.0718
𝑠𝑒𝑐
4 𝑢𝑓𝑚𝑎𝑥 4 ∗ 1.0618
𝐷𝑐𝑜𝑙𝑢𝑚 = √ =√ = 0.72 𝑚
𝜋 ∗ 𝜌𝑣 ∗ 𝑢𝑚𝑎𝑥 𝜋 ∗ 3.7614 ∗ 0.6912
126
Column Height
1. Actual No. of stage N=17
2. Safety factor = 0.1 ∗ 18 = 1.7 = 2
3. 1 plate for reboiler = 2
Total stage 17 + 2 + 1 = 20 𝑝𝑙𝑎𝑡𝑒𝑠
𝐾𝑚𝑜𝑙
𝑉𝑚 = 𝐷(1 + 𝑅) = 3960.6481
ℎ𝑟
At 12 percent of Area
𝐴 𝑑𝑜𝑤𝑛 𝑐𝑜𝑚𝑒𝑟 = 0.12 ∗ 0.407 = 0.0488 𝑚2 = 𝐴𝑑
𝑁𝑒𝑡 𝐴𝑟𝑒𝑎 = 𝐴𝑐 − 𝐴𝑑 = 0.358 𝑚2 = 𝐴𝑁
𝐴𝑐𝑡𝑖𝑣𝑒 𝐴𝑟𝑒𝑎 = 𝐴𝑐 − 2𝐴𝑑 = 0.3094 𝑚2 = 𝐴𝑎
Hole Area Ah ⇒ take 10 percent from Aa as first trial
𝐴ℎ = 0.1 ∗ 0.304 = 0.03094 𝑚2
127
Weir Length
From figure 11.31 from Chemical engineering vol. 6 page 573
𝐴𝑑
∗ 100% = 11.1
𝐴𝑐
𝐿𝑤
From the figure ⇒ = 0.78 ⟹ 𝐿𝑤 = 0.561 𝑚
𝐷𝑐
Plate thickness = 55 mm
Hole diameter = 5 mm =dh
The weir height = 50 mm = hw
Check Weeping
𝐿𝑚 ×𝑀𝑤𝑡 𝑚𝑖𝑥
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 𝑟𝑎𝑡𝑒 (𝐿𝑤) =
3600
6883.89881 ∗ 18.7 ∗ 10−3 𝑘𝑔
= = 0.0357
3600 𝑠
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 𝑟𝑎𝑡𝑒 (𝑙𝑤) = 70 𝑝𝑒𝑟𝑐𝑒𝑛𝑡 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 𝑟𝑎𝑡𝑒
𝑘𝑔
= 0.7 ∗ 0.0357 = 0.0249
𝑠𝑒𝑐
128
2 2
𝐿𝑤 3 0.0357 3
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = 750 [ ] = 750 [ ]
𝜌𝑙 × 𝑙𝑤 881.45 ∗ 0.561
= 1.3 𝑚𝑚 𝐿𝑖𝑞𝑢𝑖𝑑
2 2
𝑙𝑤 3 0.0249 3
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = 750 [ ] = 750 [ ]
𝜌𝑙 × 𝐿𝑤 881.45 ∗ 0.51
= 1.022 𝑚𝑚 𝐿𝑖𝑞𝑢𝑖𝑑
At minimum rate
ℎ𝑤 + ℎ𝑜𝑤 = 50 + 1.022 = 51.022 𝑚𝑚
From figure. (11.30) From chemical engineering vol. 6 page 571
𝐾2 = 30
129
𝑀𝑖𝑛. 𝑉𝑎𝑝𝑜𝑟𝑅𝑎𝑡𝑒
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 =
𝐴𝑎
0.61 ×0.4995 𝑚
= = 9.84
0.03094 𝑠
0.4995 𝑚
𝑈ℎ^ = = 16.14
0.03094 𝑠
130
𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘 5 𝑚𝑚
= = 1 𝑚𝑚
𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 5 𝑚𝑚
𝐴ℎ 𝐴ℎ 0.03094
≈ 𝑎𝑡 100 𝑝𝑒𝑐𝑒𝑛𝑡 = = 10
𝐴𝑝 𝐴𝑎 0.3094
𝐶𝑜 = 0.84
2
𝑈ℎ 𝜌𝑣 16.14 2 3.7614
ℎ𝑑 = 51 [ ] . = 51 [ ] = 80.34 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝐶0 𝜌𝑙 0.84 881.45
Residual head
131
Back up in down comer
Perforated Area
𝐿𝑤
= 0.779 ⟹ Ө𝑐 = 99.1˚
𝐷𝑐
132
Angle subtended at plate edge by imperforated strip = 180-99.1 = 80.9˚
𝑚𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑒𝑑𝑔𝑒 𝑠𝑡𝑟𝑖𝑝𝑠
80.9
= (0.72– 50×10−3 )𝜋 = 0.94 𝑚
180
Ө𝑐
𝑀𝑒𝑎𝑛 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒 = (𝐷𝑐 − ℎ𝑤) sin ( )
2
99.1
= (0.72 − 50 ∗ 10^ − 3 ) sin ( ) = 0.509 𝑚
2
𝐴ℎ 0.03094
= = 0.146
𝐴𝑝 0.2113
133
𝐿𝑝
= 2.58 satisfacory
𝑑ℎ
Total plate 20
Column diameter 0.72 m
Column Height 10 m
Hole size 5 mm
Hole pitch 12.5 mm
Active holes 1576
Turn down 70% max rate
Plate material Mild steel
Down comer material Mild steel
Plate spacing 0.5 m
Plate pressure drop 80.34 mm liq.
Plate thickness 55 mm
134
Design Condenser for Distillation 2
Shell Steam Tube
126.25 Temp. in, °C 25
125.75 Temp. out, °C 80
7.4 Pressure (bar) 7.4
𝑲𝒈
126291.7019 Mass Flow ( ) 126291.7019
𝒔
40155.17725 Q, kW 40155.17725
Composition
0.01 Methanol 0
0.99 H2O 1
0 DME 0
𝑄 = 𝑚𝑤 𝑐𝑝 𝑤 ∆𝑇
40155.17725 𝑘𝑔
𝐶𝑜𝑜𝑙𝑖𝑛𝑔 𝑊𝑎𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 = = 176.35
(80 − 25) ∗ 4.18 𝑠
𝑊
𝐴𝑠𝑠𝑢𝑚𝑒 𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 = 742
𝑚2 𝐶
Choose horizontal Heat Exchanger 1 shell, 8 tube passes.
To calculate corrected logarithmic mean temperature (Ft) for 1 shell, 4
passes, from Figure 12.19 page 657 Chemical Engineering Vol 6
135
(𝑇ℎ𝑜𝑡 𝑖𝑛 − 𝑇ℎ𝑜𝑡 𝑜𝑢𝑡 )
𝑅= = 0.009
(𝑇𝑐𝑜𝑙𝑑 𝑜𝑢𝑡 − 𝑇𝑐𝑜𝑙𝑑 𝑖𝑛 )
773.86
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = = 1010
0.766
136
1
1010 2.643
𝐷𝑏 = 50 ( ) = 2487 𝑚𝑚
0.0331
Shell-Side Coefficient
Estimate tube wall temperature Tw:
𝑊
assume condensing coefficient of 1403
𝑚2 °𝐶
Mean temperature
126.25 + 125.75
𝑆ℎ𝑒𝑙𝑙 − 𝑠𝑖𝑑𝑒 (𝑇𝑠 ) = = 126 °𝐶
2
25 + 80
𝑇𝑢𝑏𝑒 − 𝑠𝑖𝑑𝑒 (𝑇𝑡 ) = = 52.5 °𝐶
2
(𝑇𝑠 − 𝑇𝑤 ) 𝑈𝑐𝑜𝑛𝑑 = (𝑇𝑠 − 𝑇𝑡 ) 𝑈𝑜𝑣𝑒𝑟𝑎𝑙𝑙
(126 − 𝑇𝑤 ) 1704 = (126 − 52.5) 538
𝑇𝑤 = 87.12 °𝐶
126 + 87.12
𝑀𝑒𝑎𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒 = = 106.56 °𝐶
2
Physical properties at 106.56 °𝐶 From Perry's Chemical Engineers’
Handbook
137
𝐶𝑜𝑛𝑑𝑒𝑛𝑠𝑒 𝑓𝑙𝑜𝑤 126291.7019 𝑘𝑔
𝛤ℎ = = = 0.007
𝐿 𝑁𝑡 4.88 ∗ 1010 𝑠𝑚
2
Average number of tubes in a vertical tube row, 𝑁𝑟 = ∗ 40 = 27
3
1
702.708(702.708 − 7.57) 3
−
1
ℎ𝑐 = 0.95 ∗ 0.182 ∗ [ ] ∗ 27 6
0.000245 ∗ 0.007
𝑊
ℎ𝑐 = 1403.16
𝑚2 °𝐶
Same as assumed so no need to correction
Tube-Side Coefficient
𝜋 1010
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = (48 ∗ 10−3 ) ∗ = 0.228 𝑚2
4 8
Density of water at 31ºC =993.34 kg/m3
𝐺 176.351 𝑚
𝑇𝑢𝑏𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = = = 0.785
𝜌 𝐴 993.34 ∗ 0.228 𝑠
Tube-side heat transfer coefficient
Fouling factors: as neither fluid is heavily fouling, use 6000 W/m2 ºC for
each side
Kw=45 W/m °C for stainless steel
138
Overall Coefficient
50
1 1 1 50 ∗ 10−3 ∗ ( ) 50 1 50 1
= + + 48 + ∗ + ∗
𝑈0 1403.16 6000 2 ∗ 45 48 6000 48 3830.6
𝑊
𝑈0 = 742.0786
𝑚2 °𝐶
Same as assumed, firm up design
Cross-flow Area
(62.5 − 50)
𝐴𝑠 = ∗ 2598 ∗ 2598 ∗ 10−6 = 1.35 𝑚2
62.5
Mass flow-rate, based on inlet conditions
126291.7019 𝑘𝑔
𝐺𝑠 = = 25.98
3600 ∗ 1.35 𝑠 𝑚2
𝑗𝑓 = 0.024
𝐺𝑠 25.98 𝑚
𝑢𝑠 = = = 3.43
𝜌𝑣 7.57 𝑠
Take pressure drop as 50 per cent of that calculated using the inlet flow;
neglect viscosity correction.
140
Tube-side pressure drop
Viscosity of water= 0.00054 pa.s
𝜌𝑢𝑑 993.34 ∗ 0.785 ∗ 48 ∗ 10−3
𝑅𝑒 = = = 68971.406
𝜇 0.00054
𝑗𝑓 = 0.0033
Neglect viscosity correction
141
Summary
142
Design Reboiler for Distillation 2
Q(w)= 31247933
TBP M(°c)= 125.6
TBP W(°c)= 167
XW= 0.95
XM= 0.05
Mwt= 32.04
Mwt(w)= 18
P in(bar)= 7.3
Pcw(bar)= 220.8885
P cM(bar)= 79.54013
=125.6*0.05+ 167*0.95
= 164.93 °C
From table 12.1 page 637, assume over all heat transfer = 1101 (W/m2
°C)
𝑄 31247933
Area (outside) required (A) = =
∆Tm∗U 85.93∗1101
=333.624 m ²
143
Inside diameter(di) 25 mm
Outside diameter(do) 30 mm
Length of Tube 4.88 m
𝐴
Number of tube =
𝜋∗Length of Tube∗Outside diameter
333.624
=𝜋∗0.03∗4.88 = 737.84 ≅ 738
7.3
hnb =104(213.8211 )0.69 (93662.07)0.7 [1.8( )0.17 +
213.8211
7.3 7.3
4( )1.2 + 10( )10 [
213.8211 213.8211
= 13790.81 W/m² °C
30
1 1 1 30 ∗ 10−3 ∗ ( ) 50 1 50 1
= + + 25 + ∗ + ∗
𝑈0 13790.81 2500 2 ∗ 59 38 3000 38 8000
𝑈0 =1101.089 W/m² °C
144
Check maximum allowable heat flux, use Mostinski’s method
7.3 7.3
𝑞𝑐 = 3.67 * 104 (213.8211 )( )0.35 [1 − ( )]0.9
213.8211 213.8211
=233.230 kw/m²
Applying a factor of 0.7, maximum flux should not exceed 233.230 * 0.7
= 163.261 kW/m². Actual flux of 93.66207 kW/m² is well below
maximum allowable.
Layout
Use square pitch arrangement, pitch = 1.5 * do
=1.5 * 30 = 45 mm
Tube bundle diameter
1
𝑁𝑡 𝑛1
𝐷𝑏 = 𝑑0 ( )
𝐾1
From Table 12.4 page 649 Chemical Engineering Vol 6
For 2 passes:
K1= 0.156
n1=2.291
1
738 2.291
𝐷𝑏 = 30 ( ) = 1205.465 mm
0.156
145
Take shell diameter as twice bundle diameter
Ds= 2 * 1205.465 = 2410.931 mm
Take liquid level as 1800 mm from base,
Freeboard = 2410.931 - 1800 = 610.931 mm
218626.4 1 1
Velocity of vapor = ∗ ∗ = 0.0323 𝑚/𝑠
3600 6.432 7.847
146
Maximum velocity
Find density of Methanol from J. Phys Chem. Ref. Data, vol 16 No. 4,
1987 page 801
a 54.566 c 513.16
b 0.233211 d 0.2088175
𝑎 54.466
ρM=
1+(1−𝑇/𝑐)𝑑
= 0.2088175
𝑏 0.2332111+(1−(436.52/513.6)
=616.34 kg/m³
From Berry’s chemical Engineering 8th edition page 2-96 ρw=903.6
kg/m³
ρ mix =0.95* 903.6+ 0.05*616.34 =890.18 kg/m³
Summary
147
Chapter Five
Mechanical Design
148
Mechanical Design Heat Exchanger 1
Condition
Operating Pressure (bar) 15.2
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 163.5-114.5
Tube temperature °C 25 – 50
corrosion allowance mm 2
Shell diameter, mm 798
Tube inside, outside diameter, mm 23, 25
Number of tubes 327
Insulation thickness, mm 75
Design temperature 50 C.
From Table 13.2 Chemical Engineering vol. 6 page 812, typical design
stress = 140 N/mm2
Shell thickness
𝑃𝑖𝐷𝑖 1.672 ∗ 798
𝑒= = = 10.998 𝑚𝑚
2𝑓 − 𝑃𝑖 2 ∗ 140 − 1.672
add corrosion allowance 10.998 + 2 = 12.998
say 13 mm plate
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=798
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
149
𝑅𝑘 = 6% 𝑅𝑐 = 47.88 𝑚𝑚
1 798
𝐶𝑠 = (3 + √ ) = 1.77
4 47.88
Dead weight
Take 𝐶𝑣 = 1.08
798 + 10.358
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 0.810 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.0252 − 0.0232
= 798 ∗ 7800 ∗ 9.81 ∗ 3.14
4
= 18.85612 𝑁
150
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 327 ∗ (0.025)2 = 0.16 𝑚
4
𝑒𝑚𝑝𝑡𝑦 𝐴 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = 𝐴 𝑠ℎ𝑒𝑙𝑙 − 𝐴 𝑡𝑢𝑏𝑒 = 0.399 𝑚
𝑊 = (928 ∗ 0.339 ∗ +778 ∗ 0.16) ∗ 9.81 = 1885.612 𝑁 = 1.8 𝐾𝑁
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 3.66 ∗ 75 ∗ 10−3 =
1.7328 𝑚3
weight = 1.7328 ∗ 130 ∗ 9.81 = 2198.439 𝑁
double this to allow for fittings, etc. = 4397 𝑁 = 4 𝐾𝑁
Total weight:
Shell 6.77
Pipes 1.885
Liquid 4
Insulation 2.198
Total 15 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 0.399 + (75 + 15) ∗ 0.001
= 0.883 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 0.883 = 1134.072
𝑚
151
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.672 ∗ 0.798 ∗ 103 𝑁
𝜎𝐿 = = = 25.67
4𝑡 4 ∗ 15 𝑚𝑚2
Bending stresses:
𝐷0 = 798 + 2 ∗ 15 = 823.986 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (823.9864 − 7984 ) = 1.33 ∗ 109 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 25.67 − 0.45 + 0.138 = 25.422
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 25.67 − 0.45 − 0.138 = 25.1467
𝑚𝑚2
152
As there is no torsional shear stress, the principal stresses will be σz and
σH.
25.422 25.1467
51.343 51.343
153
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 0.798 m choose the design that fit that diameter
from fig 13.26
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
154
Select standard flange design from Figure 13.37 chemical engineering
Vol. 6 page 866
D for shell = 17.75 mm
10 17.75 75 12 28 35 2 4 11 50 26
20 25 90 14 32 50 2 4 11 65 38
155
Summary
Shell thickness 13 mm
Head thickness 11 mm
Total weight 15 KN
Loading fx 1139 N/m
Pressure stress σL 25.67 N/mm2
Pressure stress σH 51.343 N/mm2
Dead weight stress σw 0.45 N/mm2
Bending stresses σb 0.138 N/mm2
The greatest difference 26.197
σz (upwind) 25.422 N/mm2
σz (downwind) 25.1467 N/mm2
156
Mechanical Design Heat Exchanger 2
Condition
Operating Pressure (bar) 14.7
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 377-160.1
Tube temperature °C 50-131.7
corrosion allowance mm 2
Shell diameter, mm 1035
Tube inside, outside diameter, mm 20,18
Number of tubes 1057
Insulation thickness, mm 75
Design temperature 50 C.
From Table 13.2 Chemical Engineering vol. 6 page 812, typical design
stress = 110 N/mm2
Shell thickness
𝑃𝑖𝐷𝑖 1.617 ∗ 1035
𝑒= = = 13.55 𝑚𝑚
2𝑓 − 𝑃𝑖 2 ∗ 110 − 1.617
add corrosion allowance 13.55 + 2 = 15.55
say 16 mm plate
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=1035
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
157
𝑅𝑘 = 6% 𝑅𝑐 = 62.1 𝑚𝑚
1 1035
𝐶𝑠 = (3 + √ ) = 1.77
4 62.1
Dead weight
Take 𝐶𝑣 = 1.08
1035 + 15
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 1.05 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.022 − 0.0182
= 1057 ∗ 7800 ∗ 9.81 ∗ 3.14
4
= 4825.273 𝑁 = 4.825𝐾𝑁
158
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 1057 ∗ (0.02)2 = 0.3318 𝑚²
4
𝑒𝑚𝑝𝑡𝑦 𝐴 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = 𝐴 𝑠ℎ𝑒𝑙𝑙 − 𝐴 𝑡𝑢𝑏𝑒 = 0.509 𝑚²
𝑊 = (656 ∗ 0.509 + 721 ∗ 0.3318) ∗ 9.81 = 5737.974 𝑁 = 5.737 𝐾𝑁
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 3.66 ∗ 75 ∗ 10−3 =
1.7328 𝑚3
weight = 1.7328 ∗ 130 ∗ 9.81 = 2198.439 𝑁
double this to allow for fittings, etc. = 4397 𝑁 = 4 𝐾𝑁
Total weight:
Shell 11.307
Pipes 4.825
Liquid 5.737
Insulation 2.198
Total 24 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 1.035 + (75 + 15) ∗ 10−3 =
1.126 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 1.126 = 1140.7
𝑚
159
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.617 ∗ 1.035 ∗ 103 𝑁
𝜎𝐿 = = = 26.907
4𝑡 4 ∗ 15 𝑚𝑚2
Bending stresses:
𝐷0 = 1035 + 2 ∗ 15 = 1066 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (10664 − 10354 ) = 3.46 ∗ 109 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 26.905 − 0.469 + 0.1405 = 26.577
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 26.905 − 0.469 − 0.1405 = 26.2967
𝑚𝑚2
160
As there is no torsional shear stress, the principal stresses will be σz and
σH.
26.577 26.2967
53.813
53.813
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 2.6 m choose the design that fit that diameter from
fig 13.26
161
1.035 90 0.68 0.15 0.91 0.39 0.31 0.095 11 8 20 25
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
8 14.2 65 12 20 30 2 4 11 45 20
15 20 80 12 28 40 2 4 11 50 26
Summary
Shell thickness 16 mm
Head thickness 16 mm
Total weight 24 KN
Loading 1140.7 N/m
Pressure stress σL 26.906 N/mm2
Pressure stress σH 53.813 N/mm2
Dead weight stress σw 0.469 N/mm2
Bending stresses σb 0.1405 N/mm2
The greater difference 27.516
σz (upwind) 26.577 N/mm2
σz (downwind) 26.2967 N/mm2
163
Mechanical Design Heat Exchanger 3
Condition
Operating Pressure (bar) 14.7
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 250-130
Tube temperature °C 300-155
corrosion allowance mm 2
Shell diameter, mm 4321.7
Tube inside, outside diameter, mm 30,38
Number of tubes 1205
Insulation thickness, mm 75
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=3556
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
164
𝑅𝑘 = 6% 𝑅𝑐 = 216 𝑚𝑚
1 3556
𝐶𝑠 = (3 + √ ) = 1.77
4 216
Dead weight
Take 𝐶𝑣 = 1.08
3556 + 38
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 3.63 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.0382 − 0.0362
= 872 ∗ 7800 ∗ 9.81 ∗ 3.14
4
= 10721.17 𝑁 = 11 𝐾𝑁
165
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 1206 ∗ (0.038)2 = 1.37 𝑚²
4
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 4.88 ∗ 75 ∗ 10−3 = 2 𝑚3
weight = 2.3 ∗ 130 ∗ 9.81 = 2931.25 𝑁
double this to allow for fittings, etc. = 5863𝑁 = 6 𝐾𝑁
Total weight:
Shell 280
Pipes 11
Liquid 58
Insulation 6
Total 354 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 3.556 + (75 + 38) ∗ 10−3 =
3.713 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 3.556 = 4752.8
𝑚
166
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.617 ∗ 3556 𝑁
𝜎𝐿 = = = 29
4𝑡 4 ∗ 38 𝑚𝑚2
Bending stresses:
𝐷0 = 3556 + 2 ∗ 38 = 3676.3 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (3676.34 − 35564 ) = 3.55 ∗ 1011 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 29 − 0.81 + 0.17 = 28.35
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 29 − 0.81 − 0.17 = 28.01
𝑚𝑚2
167
As there is no torsional shear stress, the principal stresses will be σz and
σH.
28.35 28.01
76.3 76.3
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 2.6 m choose the design that fit that diameter from
fig 13.26
168
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
169
D for shell = 107.01 mm
Summary
Shell thickness 38 mm
Head thickness 59 mm
Total weight 514 KN
Loading 5863 N/m
Pressure stress σL 45.8 N/mm2
Pressure stress σH 91.62 N/mm2
Dead weight stress σH 0.98 N/mm2
Bending stresses σb 0.2 N/mm2
longitudinal stress
σz (upwind) 45.03 N/mm2
σz (downwind) 44.63 N/mm2
170
Mechanical Design Reactor
Condition
Operating Pressure (bar) 14.7
Material Carbon Steel
Catalyst weight, kg 44123
Operating Temperature °C 250-377
Diameter, m 3.5
Height, m 5.25
Insulation thickness, mm 75
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 3.5 + 2 ∗ (38.08 + 75) 0.001 =
= 3.7 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 3.7 = 4769.48
𝑚
171
Dead weight
Take 𝐶𝑣 = 1.08
𝐷𝑚 = 𝐷𝑖 + 𝑡 = 2 + 0.038 = 2.038 𝑚
Weight of catalyst:
= 44123 𝐾𝑔 ∗ 9.81 = 432.84 𝐾𝑁
Weight of insulation:
mineral wool density = 130 kg/m3
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 ∗ 𝑣𝑜𝑙𝑢𝑚𝑒 ∗ 9.81
𝑉𝑜𝑙𝑢𝑚𝑒 = 3.14 ∗ 3.5 ∗ 5.25 ∗ 75 ∗ 0.001 = 4.3273 𝑚3
𝑊𝑒𝑖𝑔ℎ𝑡 = 4.3273 ∗ 130 ∗ 9.81 = 5.51 𝐾𝑁 ∗ 2 = 11.02 𝐾𝑁
172
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.502 ∗ 3.5 ∗ 1000 𝑁
𝜎𝐿 = = = 345
4𝑡 4 ∗ 38.084 𝑚𝑚2
Bending stresses:
𝐷0 = 3500 + 2 ∗ 38.084 = 3576.16 𝑚𝑚
𝜋 4 4
4.14(3576.162 − 35002 )
𝐼𝑣 = (𝐷0 − 𝐷𝑖 ) = = 3.486 ∗ 1010 𝑚𝑚4
64 64
3500
𝑀𝑥 𝐷𝑖 387336 ( + 38.084) 𝑁
𝜎𝑏 = ∓ ( + 𝑡) = ∓ 2 = ∓198.6
𝐼𝑣 2 3.486 ∗ 1010 𝑚𝑚2
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 345 + 1.37 + 198.6 = 544.97
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 1.37 + 345 − 198 .6 = 147.74
𝑚𝑚2
173
Check elastic stability (buckling):
𝑡
𝜎 𝑐 = 2 ∗ 10000 ∗ ( )
𝐷𝑜
38.084 𝑁
= 2 ∗ 10000 ( ) == 366.86
2076.16 𝑚𝑚2
𝑁
𝑃𝑚𝑎𝑥 = 𝜎 𝑤 + 𝜎 𝑏 = 1.37 + 198.6 = 199.97
𝑚𝑚2
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
174
Summary
175
Mechanical Design Distillation 1
Condition
Operating Pressure (bar) 10.4
Material Stainless steel
Density of material, kg/m3 7800
Diameter, m 0.7
Length of column, m 11
Insulation thickness, mm 75
corrosion allowance mm 2
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
𝑅𝑘 = 6% 𝑅𝑐 = 0.042 𝑚
1 0.07
𝐶𝑠 = (3 + √ ) = 1.77
4 0.042
176
add corrosion allowance 5.21 + 2 ≈ 7 𝑚𝑚
Dead weight
Take 𝐶𝑣 = 1.15 for distillation column
𝐷𝑚 = 𝐷𝑖 + 𝑡 = 0.7 + 14 ∗ 10−3 = 0.714 𝑚
177
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 0.7 + 2(18.2 + 75) ∗ 10−3 =
0.793 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 0.793 = 1124
𝑚
Analysis of stresses
As a first trial, divide the column into five sections (courses), with the
thickness
increasing by 2 mm per section. Try 10.2, 12.2, 14.2, 16.2, 18.2 mm
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.14 ∗ 0.7 ∗ 103 𝑁
𝜎𝐿 = = = 11
4𝑡 4 ∗ 18.2 𝑚𝑚2
Bending stresses:
𝐷0 = 700 + 2 ∗ 18.2 = 736.4 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (736.44 − 7004 ) = 1.27 ∗ 109 𝑚𝑚4
64 64
178
𝑀𝑥 𝐷𝑖 61425 ∗ 103 700 𝑁
𝜎𝑏 = ∓ ( + 𝑡) = ∓ ( + 18.2) = ∓17.75
𝐼𝑣 2 1.27 ∗ 109 2 𝑚𝑚2
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 11 − 1.15 + 17.75 = 27.6
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 11 − 1.15 − 17.75 = −7.9
𝑚𝑚2
𝑁
22 + 7.9 = 29.1
𝑚𝑚2
well below the maximum allowable design stress
179
Design of Skirt support
532
𝑀𝑠 (𝑠𝑘𝑖𝑟𝑡 ) = 1.150× = 4614.785 𝐾𝑁. 𝑚
0.7
𝑊
𝜎𝑤𝑠 =
𝜋( 𝐷𝑠 + 𝑡𝑠 )𝑡𝑠
41.52863 × 103 𝑁
𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) = = 1.11
𝜋 (700+18.2)18.2 𝑚𝑚2
47.436 × 103 𝑁
𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) = = 1.15
𝜋 (700+18.2)18.2 𝑚𝑚2
180
Note: the (test) condition is with the vessel full of water for the
hydraulic. The weight of liquid on plates has been counted twice.
𝑡
𝜎𝑠^ (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) > 0.125 E ( 𝑠 ) sin 𝜃
𝐷𝑆
18
598.21 > 0.125 ×200 ,000 ( ) 𝑠𝑖𝑛 90
700
625.615 > 650
Both criteria are satisfied, add 2 mm for Correction, gives a design thick.
181
Base ring and anchor bolts
900𝜋
𝐵𝑜𝑙𝑡 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 = = 4.71
600
𝑁
𝑇𝑎𝑘𝑒 𝑏𝑜𝑙𝑡 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 = 125
𝑚𝑚2
𝑀𝑠 = 4614.785 𝐾𝑁. 𝑚
1 4𝑀𝑠
𝐴𝑏 = [ − 𝑊]
𝑁𝑏 . 𝐹𝑏 𝐷𝑏
1 4 ×4614.785 ×103
= [ − 47.436 × 103 ]
5×125 0.9
= 32740.35
32740.35 ×4
𝐵𝑜𝑙𝑡 𝑟𝑜𝑜𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √ = 102.08 𝑚𝑚
𝜋
182
Taking the bearing pressure at 5 N/mm2
The min. weight of the base ring is
𝐹𝑏 1 1201.86×103
𝐿𝑏 = × 3= = 240.372𝑚𝑚
𝐹𝑐 10 5 × 103
3
Skirt angle 𝜃𝑠 = tan−1 (1 ) = 69.02
(3−0.7)
2
𝑠𝑖𝑛𝜃𝑠 = 𝑠𝑖𝑛 (69.02) = 0.933
1 4 ×4614.785 × 103
𝐴𝑏 = [ − 47.436×103 ] = 5721.045 ×103 𝑚𝑚2
16 ×125 3.2
183
Bolt size = M64 bolts (BS 4190:1967) root diameter = 2680
4614.785×103 47.436×103 𝑘𝑁
𝐹𝑏 = [ + ] = 640
𝜋(3)2 𝜋. (3) 𝑚
640 ×103
𝐿𝑏 = = 128 𝑚𝑚
5 × 103
This is the Min. width required: actual width will depend on the chair
design.
= 𝐿𝑟 + 𝑡𝑠 + 50 𝑚𝑚
𝐿𝑟 = 152 ⟹ 𝑓𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒 13.30
640 × 103 𝑁
𝑓𝑐, = = 2.9
220.2 × 103 𝑚𝑚2
3 𝑓𝑐,
𝑡𝑏 = 𝐿𝑟 × √
𝑓𝑟
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
184
Select standard flange design from Figure 13.37 chemical engineering
Vol. 6 page 866
D for Feed = 83.43 mm
185
Summary
Head thickness 7 mm
Total weight 47.436 KN
Loading 1124 N/m
Pressure stress σL 11 N/mm2
Pressure stress σH 22 N/mm2
Dead weight stress σw 1.15 N/mm2
Bending stresses σb 17.75 N/mm2
longitudinal stress
σz (upwind) 27.6 N/mm2
σz (downwind) −7.9 N/mm2
Bending stress in the Skirt σws (operating) 1.15 N/mm2
Number of bolts required 5
Skirt angle 69.02
Bolt size (Fig 13.30) M64
186
Mechanical Design Condenser for Distillation 1
Condition
Operating Pressure (bar) 10.4
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 49.68 - 46.1
Tube temperature °C 25 - 37
corrosion allowance mm 2
Shell diameter, mm 2518
Tube inside, outside diameter, mm 50, 52
Number of tubes 1015
Insulation thickness, mm 75
Design temperature 50 C.
From Table 13.2 Chemical Engineering vol. 6 page 812, typical design
stress = 165 N/mm2
Shell thickness
𝑃𝑖𝐷𝑖 1.14 ∗ 2518
𝑒= = = 12.73 𝑚𝑚
2𝑓 − 𝑃𝑖 2 ∗ 165 − 1.14
add corrosion allowance 12.73 + 2 = 14.73
say 15 mm plate
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=2.518
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
187
𝑅𝑘 = 6% 𝑅𝑐 = 151.08 𝑚𝑚
1 2518
𝐶𝑠 = (3 + √ ) = 1.77
4 151.08
Dead weight
Take 𝐶𝑣 = 1.08
2518 + 15
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 2.533 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.0522 − 0.052
= 1015 ∗ 7800 ∗ 9.81 ∗ 3.14
4
= 12437.396 𝑁 = 12 𝐾𝑁
188
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 1015 ∗ (0.052)2 = 2.15 𝑚
4
𝑒𝑚𝑝𝑡𝑦 𝐴 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = 𝐴 𝑠ℎ𝑒𝑙𝑙 − 𝐴 𝑡𝑢𝑏𝑒 = 2.82 𝑚
𝑊 = (1000 ∗ 2.82 + 627 ∗ 2.15) ∗ 9.81 = 38497.35 𝑁 = 38 𝐾𝑁
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 3.66 ∗ 75 ∗ 10−3 =
1.7328 𝑚3
weight = 1.7328 ∗ 130 ∗ 9.81 = 2198.439 𝑁
double this to allow for fittings, etc. = 4397 𝑁 = 4 𝐾𝑁
Total weight:
Shell 55
Pipes 12
Liquid 38
Insulation 4
Total 110 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 2.518 + (75 + 15) ∗ 10−3 =
2.608 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 2.608 = 3337.897
𝑚
189
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.14 ∗ 2.518 ∗ 103 𝑁
𝜎𝐿 = = = 48.88
4𝑡 4 ∗ 15 𝑚𝑚2
Bending stresses:
𝐷0 = 2518 + 2 ∗ 15 = 2547.5 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (2547.54 − 25184 ) = 4.66 ∗ 1010 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 48.88 − 0.94 + 0.31 = 48.25
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 48.88 − 0.94 − 0.31 = 47.63
𝑚𝑚2
190
As there is no torsional shear stress, the principal stresses will be σz and
σH.
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 2.6 m choose the design that fit that diameter from
fig 13.26
191
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
Summary
Shell thickness 15 mm
Head thickness 17 mm
Total weight 110 KN
Loading 3337.897 N/m
Pressure stress σL 48.88 N/mm2
Pressure stress σH 97.77 N/mm2
Dead weight stress σw 0.94 N/mm2
Bending stresses σb 0.31 N/mm2
longitudinal stress
σz (upwind) 48.25 N/mm2
σz (downwind) 47.63 N/mm2
193
Mechanical Design Reboiler for Distillation 1
Condition
Operating Pressure (bar) 10.4
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 172-162.86
Tube temperature °C 250-171
corrosion allowance mm 2
Shell diameter, mm 1907
Tube inside, outside diameter, mm 28,30
Number of tubes 237
Insulation thickness, mm 75
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=1907
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
194
𝑅𝑘 = 6% 𝑅𝑐 = 114.42 𝑚𝑚
1 1907
𝐶𝑠 = (3 + √ ) = 1.77
4 114.42
Dead weight
Take 𝐶𝑣 = 1.08
1907 + 29
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 1.9 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.032 − 0.0282
= 237 ∗ 7800 ∗ 9.81 ∗ 3.14 = 1651.352𝑁
4
= 1.6 𝐾𝑁
195
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 237 ∗ (0.03)2 = 0.167 𝑚²
4
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 4.88 ∗ 75 ∗ 10−3 = 2.3 𝑚3
weight = 2.3 ∗ 130 ∗ 9.81 = 2931.25 𝑁
double this to allow for fittings, etc. = 5863𝑁 = 6 𝐾𝑁
Total weight:
Shell 93
Pipes 2
Liquid 16
Insulation 6
Total 116 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 1.907 + (75 + 29) ∗ 10−3 =
2.011 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 2.011 = 2573.734
𝑚
196
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 1.144 ∗ 1907 𝑁
𝜎𝐿 = = = 18.9
4𝑡 4 ∗ 29 𝑚𝑚2
Bending stresses:
𝐷0 = 1907 + 2 ∗ 29 = 1964 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (19644 − 19074 ) = 4 ∗ 1010 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 28.9 − 0.667 + 0.12 = 28.46
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 28.9 − 0.667 − 0.12 = 28.2
𝑚𝑚2
197
As there is no torsional shear stress, the principal stresses will be σz and
σH.
28.46 28.2
37.9 37.9
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 1.9 m choose the design that fit that diameter from
fig 13.26
198
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
199
D for shell = 146.4 mm
Summary
Shell thickness 29 mm
Head thickness 21 mm
Total weight 116 KN
Loading 5863 N/m
Pressure stress σL 28.9 N/mm2
Pressure stress σH 37.96 N/mm2
Dead weight stress σH 0.667 N/mm2
Bending stresses σb 0.12 N/mm2
longitudinal stress
σz (upwind) 28.46 N/mm2
σz (downwind) 28.2 N/mm2
200
Mechanical Design Heat Exchanger 4
Condition
Operating Pressure (bar) 7.4
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 25-60
Tube temperature °C 154.498-139
corrosion allowance mm 2
Shell diameter, mm 654
Tube inside, outside diameter, mm 28,30
Number of tubes 654
Insulation thickness, mm 75
Design temperature 42 C.
From Table 13.2 Chemical Engineering vol. 6 page 812, typical design
stress = 165 N/mm2
Shell thickness
𝑃𝑖𝐷𝑖 0.814 ∗ 654
𝑒= = = 4.525 𝑚𝑚
2𝑓 − 𝑃𝑖 2 ∗ 165 − 0.814
add corrosion allowance 4.525 + 2 = 6.525
say 7 mm plate
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=654
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
201
𝑅𝑘 = 6% 𝑅𝑐 = 39.24 𝑚𝑚
1 654
𝐶𝑠 = (3 + √ ) = 1.77
4 39.24
Dead weight
Take 𝐶𝑣 = 1.08
654 + 15
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 0.66 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.032 − 0.0282
= 654 ∗ 7800 ∗ 9.81 ∗ 3.14 = 445.934 𝑁
4
= 0.445𝐾𝑁
202
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 654 ∗ (0.03)2 = 0.335 𝑚²
4
𝑒𝑚𝑝𝑡𝑦 𝐴 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = 𝐴 𝑠ℎ𝑒𝑙𝑙 − 𝐴 𝑡𝑢𝑏𝑒 = 0.2905 𝑚²
𝑊 = (987 ∗ 0.2905 + 829 ∗ 0.335) ∗ 9.81 = 2800.625 𝑁 = 2.8 𝐾𝑁
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 3.66 ∗ 75 ∗ 10−3 =
1.7328 𝑚3
weight = 1.7328 ∗ 130 ∗ 9.81 = 2198.439 𝑁
double this to allow for fittings, etc. = 4397 𝑁 = 4 𝐾𝑁
Total weight:
Shell 2.634
Pipes 0.4459
Liquid 2.8
Insulation 2.198
Total 8.08 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 0.654 + (75 + 15) ∗ 10−3 =
0.736 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 0.736 = 941.472
𝑚
203
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 0.814 ∗ 654 ∗ 103 𝑁
𝜎𝐿 = = = 20.396
4𝑡 4 ∗ 15 𝑚𝑚2
Bending stresses:
𝐷0 = 654 + 2 ∗ 15 = 667 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (6774 − 6544 ) = 3.64 ∗ 108 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 20.396 − 0.597 + 0.233 = 20.03
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 20.396 − 0.597 − 0.233 = 19.567
𝑚𝑚2
204
As there is no torsional shear stress, the principal stresses will be σz and
σH.
20.03 19.567
40.792
40.792
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 2.6 m choose the design that fit that diameter from
fig 13.26
205
0.654 35 0.48 0.15 0.55 0.24 0.19 0.095 6 5 20 25
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
15 21.3 80 12 20 40 2 4 11 55 30
25 30 100 14 35 60 2 4 11 75 42
Summary
Shell thickness 7 mm
Head thickness 5 mm
Total weight 8.08 KN
Loading fx 941.4 N/m
Pressure stress σL 20.396 N/mm2
Pressure stress σH 40.792 N/mm2
Dead weight stress σw 0.597 N/mm2
Bending stresses σb 0.2336 N/mm2
The greater difference 21.226
σz (upwind) 20.03 N/mm2
σz (downwind) 19.565 N/mm2
207
Mechanical Design Distillation 2
Condition
Operating Pressure (bar) 7.3
Material Stainless steel
Density of material, kg/m3 7800
Diameter, m 0.71
Length of column, m 10
Insulation thickness, mm 75
corrosion allowance mm 2
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
𝑅𝑘 = 6% 𝑅𝑐 = 0.0432 𝑚
1 0.072
𝐶𝑠 = (3 + √ ) = 1.77
4 0.0432
208
add corrosion allowance 3.77 + 2 ≈ 6 𝑚𝑚
Dead weight
Take 𝐶𝑣 = 1.15 for distillation column
𝐷𝑚 = 𝐷𝑖 + 𝑡 = 0.72 + 14 ∗ 10−3 = 0.734 𝑚
209
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 0.72 + 2(14 + 75) ∗ 10−3 =
0.809 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 0.809 = 1035
𝑚
Analysis of stresses
As a first trial, divide the column into five sections (courses), with the
thickness
increasing by 2 mm per section. Try 10, 12, 14 mm
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 0.803 ∗ 0.72 ∗ 103 𝑁
𝜎𝐿 = = = 10.3
4𝑡 4 ∗ 14 𝑚𝑚2
Bending stresses:
𝐷0 = 720 + 2 ∗ 14 = 748 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (7484 − 7204 ) = 1.06 ∗ 109 𝑚𝑚4
64 64
𝑀𝑥 𝐷𝑖 51776 ∗ 103 720 𝑁
𝜎𝑏 = ∓ ( + 𝑡) = ∓ ( + 14) = ∓18.34
𝐼𝑣 2 1.06 ∗ 109 2 𝑚𝑚2
210
The resultant longitudinal stress is:
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 10.3 − 0.93 + 18.34 = 27.7
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 10.3 − 0.93 + 18.34 = −8.9
𝑚𝑚2
211
Design of Skirt support
532
𝑀𝑠 (𝑠𝑘𝑖𝑟𝑡 ) = 1.150× = 4486.59 𝐾𝑁. 𝑚
0.72
𝑊
𝜎𝑤𝑠 =
𝜋( 𝐷𝑠 + 𝑡𝑠 )𝑡𝑠
39.941 × 103 𝑁
𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) = = 0.957
𝜋 (720+18)18 𝑚𝑚2
44.339 × 103 𝑁
𝜎𝑤𝑠 (𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) = = 1.06
𝜋 (720+18)18 𝑚𝑚2
212
Note: the (test) condition is with the vessel full of water for the
hydraulic. The weight of liquid on plates has been counted twice.
𝑡
𝜎𝑠^ (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) > 0.125 E ( 𝑠 ) sin 𝜃
𝐷𝑆
18
598.21 > 0.125 ×200 ,000 ( ) 𝑠𝑖𝑛 90
720
598.21 > 625
Both criteria are satisfied, add 2 mm for Correction, gives a design thick.
213
Base ring and anchor bolts
920𝜋
𝐵𝑜𝑙𝑡 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 = = 4.81
600
𝑁
𝑇𝑎𝑘𝑒 𝑏𝑜𝑙𝑡 𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 = 125
𝑚𝑚2
𝑀𝑠 = 4486.95 𝐾𝑁. 𝑚
1 4𝑀𝑠
𝐴𝑏 = [ − 𝑊]
𝑁𝑏 . 𝐹𝑏 𝐷𝑏
1 4 ×4486.59 ×103
= [ − 44.339× 103 ]
12 ×125 0.92
= 31140.03
31140.03 ×4
𝐵𝑜𝑙𝑡 𝑟𝑜𝑜𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = √ = 119.11 𝑚𝑚
𝜋
214
Taking the bearing pressure at 5 N/mm2
The min. weight of the base ring is
𝐹𝑏 1 110.47 ×103
𝐿𝑏 = × 3= = 2208.94𝑚𝑚
𝐹𝑐 10 5 × 103
3
Skirt angle 𝜃𝑠 = tan−1 (1 ) = 69.19
(3−0.7)
2
𝑠𝑖𝑛𝜃𝑠 = 𝑠𝑖𝑛 (69.02) = 0.934
1 4 ×4986.5 × 103
𝐴𝑏 = [ − 44.339×103 ] = 2781.94 𝑚𝑚2
16 ×125 3.2
215
Bolt size = M64 bolts (BS 4190:1967) root diameter = 2787
4×4486.59×103 47.436×103 𝑘𝑁
𝐹𝑏 = [ + ] = 639.751
𝜋(3)2 𝜋. (3) 𝑚
640 ×103
𝐿𝑏 = = 127 𝑚𝑚
5 × 103
This is the Min. width required: actual width will depend on the chair
design.
= 𝐿𝑟 + 𝑡𝑠 + 50 𝑚𝑚
𝐿𝑟 = 152 ⟹ 𝑓𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒 13.30
= 152 + 18 + 50 = 220 𝑚𝑚
639.715 × 103 𝑁
𝑓𝑐, = = 2.90
220 × 103 𝑚𝑚2
3 𝑓𝑐,
𝑡𝑏 = 𝐿𝑟 × √
𝑓𝑟
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
216
Select standard flange design from Figure 13.37 chemical engineering
Vol. 6 page 866
D for Feed = 30 mm
25 30 100 14 35 60 2 4 11 75 42
217
Summary
Head thickness 6 mm
Total weight 44.339 KN
Loading 1035 N/m
Pressure stress σL 10.3 N/mm2
Pressure stress σH 20.64 N/mm2
Dead weight stress σw 0.93 N/mm2
Bending stresses σb 18.34 N/mm2
longitudinal stress
σz (upwind) 27.7 N/mm2
σz (downwind) −8.9 N/mm2
Bending stress in the Skirt σws (operating) 1.06 N/mm2
Number of bolts required 5
Skirt angle 69.02
Bolt size (Fig 13.30) M64
218
Mechanical Design Condenser for Distillation 2
Condition
Operating Pressure (bar) 7.4
Material Stainless steel
3
Density of material, kg/m 7800
Shell temperature °C 126.25 – 125.75
Tube temperature °C 25 - 80
corrosion allowance mm 2
Shell diameter, mm 2598
Tube inside, outside diameter, mm 50, 52
Number of tubes 1010
Insulation thickness, mm 75
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=2.598
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
219
𝑅𝑘 = 6% 𝑅𝑐 = 155.88 𝑚𝑚
1 2598
𝐶𝑠 = (3 + √ ) = 1.77
4 155.88
Dead weight
Take 𝐶𝑣 = 1.08
2598 + 16
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 2.614 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.0522 − 0.052
= 1010 ∗ 7800 ∗ 9.81 ∗ 3.14
4
= 12376.13 𝑁 = 12 𝐾𝑁
220
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 1010 ∗ (0.052)2 = 2.154 𝑚
4
𝑒𝑚𝑝𝑡𝑦 𝐴 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙 = 𝐴 𝑠ℎ𝑒𝑙𝑙 − 𝐴 𝑡𝑢𝑏𝑒 = 3.15 𝑚
𝑊 = (1000 ∗ 2.154 + 702.7 ∗ 3.15) ∗ 9.81 = 42777.33 𝑁 = 43 𝐾𝑁
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 4.88 ∗ 75 ∗ 10−3 =
2.298 𝑚3
weight = 2.298 ∗ 130 ∗ 9.81 = 2931.251 𝑁
double this to allow for fittings, etc. = 5863 𝑁 = 6 𝐾𝑁
Total weight:
Shell 77
Pipes 12
Liquid 43
Insulation 6
Total 138 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 2.598 + (75 + 16) ∗ 10−3 =
2.689 𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 2.689 = 3442.21
𝑚
221
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 0.814 ∗ 2.598 ∗ 103 𝑁
𝜎𝐿 = = = 32.58
4𝑡 4 ∗ 16 𝑚𝑚2
Bending stresses:
𝐷0 = 2598 + 2 ∗ 16 = 2630.46 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (2630.464 − 25984 ) = 5.64 ∗ 1010 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 32.58 − 1.03 + 0.29 = 31.8
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 32.58 − 1.03 − 0.29 = 31.2
𝑚𝑚2
222
As there is no torsional shear stress, the principal stresses will be σz and
σH.
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 2.6 m choose the design that fit that diameter from
fig 13.26
223
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
Summary
Shell thickness 16 mm
Head thickness 15 mm
Total weight 138 KN
Loading 3442.21 N/m
Pressure stress σL 32.58 N/mm2
Pressure stress σH 65.16 N/mm2
Dead weight stress σw 1.03 N/mm2
Bending stresses σb 0.29 N/mm2
longitudinal stress
σz (upwind) 31.8 N/mm2
σz (downwind) 31.2 N/mm2
225
Mechanical Design Reboiler for Distillation 2
Condition
Operating Pressure (bar) 7.3
Material Stainless steel
Density of material, kg/m3 7800
Shell temperature °C 165.4-163.52
Tube temperature °C 250-175
corrosion allowance mm 2
Shell diameter, mm 4321.7
Tube inside, outside diameter, mm 36,50
Number of tubes 872
Insulation thickness, mm 75
Head thickness
Choose Tori spherical
𝑃𝑖 ∗ 𝑅𝑐 ∗ 𝐶𝑠
𝑒=
2𝐹𝑗 + 𝑃𝑖(𝐶𝑠 − 0.2)
Rc=Di=2410.9
1 𝑅𝑐
𝐶𝑠 = (3 + √ )
4 𝑅𝑘
226
𝑅𝑘 = 6% 𝑅𝑐 = 144.65 𝑚𝑚
1 2410.9
𝐶𝑠 = (3 + √ ) = 1.77
4 144.65
Dead weight
Take 𝐶𝑣 = 1.08
2410.9 + 19
𝐷𝑚 = 𝐷𝑖 + 𝑡 = = 2.43 𝑚
1000
Weight of pipes:
Density of stainless steel = 7800 kg/m3
𝑑𝑜 2 − 𝑑𝑖 2
𝑊 = 𝑁𝑜. 𝑜𝑓 𝑝𝑖𝑝𝑒𝑠 ∗ 9.81𝜌𝜋
4
0.032 − 0.0262
= 738 ∗ 7800 ∗ 9.81 ∗ 3.14 = 9929.735 𝑁
4
= 10 𝐾𝑁
227
Weight of Liquid:
𝑊 = 𝜌𝑙 ∗ 𝐴
3.14
𝐴 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 = 738 ∗ (0.03)2 = 0.52𝑚²
4
Weight of insulation:
mineral wool density = 130 kg/m3
approximate volume of insulation= 𝜋 ∗ 2 ∗ 4.88 ∗ 75 ∗ 10−3 = 2.3 𝑚3
weight = 2.3 ∗ 130 ∗ 9.81 = 2931.25 𝑁
double this to allow for fittings, etc. = 5863𝑁 = 6 𝐾𝑁
Total weight:
Shell 82
Pipes 10
Liquid 24
Insulation 6
Total 122 KN
Wind loading
Take dynamic wind pressure as 1280 N/m2.
Mean diameter, including insulation = 2.410 + (75 + 19) ∗ 10−3 =
2.5𝑚
𝑁
Loading (per linear meter) 𝐹𝑤 = 1280 ∗ 2.410 = 3206.4
𝑚
228
Analysis of stresses
At bottom, tangent line
Pressure stresses:
𝑃𝐷𝑖 0.809 ∗ 2410 𝑁
𝜎𝐿 = = = 29
4𝑡 4 ∗ 19 𝑚𝑚2
Bending stresses:
𝐷0 = 2410.9 + 2 ∗ 19 = 2449.1 𝑚𝑚
𝜋 3.14
𝐼𝑣 = (𝐷04 − 𝐷𝑖4 ) = (2449.14 − 2410.94 ) = 5.3 ∗ 1010 𝑚𝑚4
64 64
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑤 ∓ 𝜎𝑏
𝜎𝑤 is compressive and therefore negative
𝑁
𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 29 − 0.84 + 0.23 = 28.4
𝑚𝑚2
𝑁
𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 29 − 0.84 + 0.23 = 27.93
𝑚𝑚2
229
As there is no torsional shear stress, the principal stresses will be σz and
σH.
28.4 27.93
50.68 50.68
Support Design
Choose saddles support must be designed to withstand the load imposed
by the weight of the vessel and contents. They are constructed of bricks
or concrete, or are fabricated from steel plate. The contact angle should
not be less than 120º, and will not normally be greater than 150 º. Wear
plates are often welded to the shell wall to reinforce the wall over the area
of contact with the saddle.
The dimensions of typical “standard” saddle designs are given in Figure
13.26 chemical engineering Vol. 6 page 847
For shell diameter of 2.6 m choose the design that fit that diameter from
fig 13.26
230
Flange Design
Use for Flanges (Two for shell and two for tubes)
𝐷 = 282 ∗ 𝐺 0.52 ∗ 𝜌−0.32
231
D for shell = 122 mm
Summary
Shell thickness 19 mm
Head thickness 17 mm
Total weight 122 KN
Loading 5863 N/m
Pressure stress σL 29 N/mm2
Pressure stress σH 50.68 N/mm2
Dead weight stress σH 0.84 N/mm2
Bending stresses σb 0.23 N/mm2
longitudinal stress
σz (upwind) 28.4 N/mm2
σz (downwind) 27.93 N/mm2
232
References
Journal Article
[1] Troy A. Semelsbergera, Rodney L. Borupa and Howard L. Greeneb,
Dimethyl ether (DME) as an alternative fuel, 2005
Book
[2] Coulson and Richardson's, Chemical Engineering Volume 6, 2005
[3] Coulson and Richardson's, Chemical Engineering Volume 2, 2002
[4] Richard M. Felder and Ronald W. Rousseau, Elementary Principles of
Chemical Processes 3rd Edition, 2004
[5] Robert H. Perry, Perry's Chemical Engineers' Handbook 8th Edition,
2007
[6] J. M. Smith, Introduction to Chemical Engineering Thermodynamics,
7th Edition, 2005
[7] James A Anderson and Marco J. Castaldi, Catalysis Volume 21, 2009
Website
[8] https://en.wikipedia.org/wiki/Dimethyl_ether
[9] http://www.peacesoftware.de/einigewerte/calc_dampf.php5
[10] http://webbook.nist.gov/cgi/cbook.cgi?ID=115-10-6
[11] https://www.google.com/patents/US20070142482
[12] https://www.google.com/patents/US5750799
[13] http://www.oil-gasportal.com/dimethyl-ether-dme-production-2
[14]
http://ddbonline.ddbst.de/DIPPR105DensityCalculation/DIPPR105Calcul
ationCGI.exe?component=Diethyl%20ether
[15] http://webbook.nist.gov/cgi/cbook.cgi?ID=C115106&Mask=7#ref-2
[16] http://www.tarimsalkimya.com.tr/dimethyl_ether/eng/itici.php
233