Hamad Alhajri

Group #:

Individual Writing Assignment - I

Preliminary DME Distillation Tower Design

October 2, 2021

I pledge that I have neither given nor received aid on this work, except for that provided
by the instructor.

A.Y. Manisali ____________signature_______________________

 Preliminary CHEMCAD simulation for Biphenyl Processing
a) There are multiple steps to creating a CHEMCAD flowsheet for the 'Rigorous Design of
Biphenyl Process with Recycle Stream Added Only'. To compute the cost of each piece of
equipment, the model must first be run (the system must converge), and then each piece of
equipment must be scaled using the attached purchased equipment cost. The fixed capital
investment required to calculate EAOC in component b will be the total equipment cost
generated. After sketching the equipment and supplying all essential parameters, including the
capacity of the reactor, the flowsheet of the Biphenyl process with recycle stream added solely
will be as shown in Figure 1below:
7

6
3 Comp Sep
PFR 5
Flash Drum
14 7
SCDS Tower
4
2 Cooler HX
Fired Heater 6
3 12
8
2
4
5
15

1
10

1
Mixer

11
13

8
Divider
16

Figure 1: Biphenyl Process Flow Diagram

After introducing the Gibbs reactor to CHEMCAD as the first step mixer and inserting all
specifications and modifying the shortcut column but retaining the shortcut column as the
first step, the process flow stream will be as follows. We obtained a flow summary of all
streams by generating a consolidated report and selecting the stream composition tab, as
shown in Table 1 below:
 Table 1: Stream Flow Summary

We must size the equipment employed in the process in order to calculate the EAOC. Table 2
summarizes the equipment sizes from CHEMCAD and their accompanying costs.

Equipment Size Purchased Cost ($)

Mixer V̇ =247.93 Ft3/h 2098.27

Divider V̇ =178.61 Ft3/h 1908.56

Fired Heater Q̇ =2.706 MMBtu/h 170540.95

PFR V =15 Ft3 77882.97

Cooler A = 27.62 m2 28768.02

Flash m= 1178.507 Kg 25471.11

SCDS Column D=3.5 ft 29978.046

Component Separator m= 1178.507 Kg 25471.11

Table 2: Equipment Sizing with their Respective Purchased Cost

A sensitivity study must be undertaken using the CHEMCAD sensitivity analysis tool to plot
Benzene flow versus hydrogen flow, as shown in Figure 2 below.

Figure 2: Hydrogen vs. Benzene Flow Rate

b) The equivalent annual operational cost is calculated using the following equation:

 EAOC=FCI∗ ( AP , i , n)+Utility Cost

m

EAOC=$ 1,172,910.793

Detailed calculation is represented in Appendix B.

c) This section of the "Rigorous Design of Biphenyl Process" considers mass balancing and heat
integration. The flow chart for the procedure is shown in Figure 3:

6
3
5 Comp Sep
PFR
Flash Drum
14 7
SCDS Tower
4
2 Cooler HX
Fired Heater 6
8 12
2
4

15

1 5
10
3
1 17
Mixer 9
18

8
Divider
13 11

16

Figure 2: The Biphenyl Process Diagram with Mass and Heat Integration

All of the equipment contained in part an of the project, as well as their related sizes and costs,
will remain the same in part C when heat integration is added to the system, with the exception
of the heat exchangers. This includes the fired heater, cooler, reboiler, and condenser. The FCI is
expected to see a minor gain in value as a result of the inclusion of new equipment (New heat
exchanger that is responsible of the heat integration).

In the new design of part C, the Utility Cost is expected to decrease since the heat integration
will minimize the amount of heat duty and utility required for this heat transfer. As a result, only
adjustments will have an impact on the new EOAC computation. Appendix C has a detailed
computation of the new EAOC.

 New EAOC=$ 971020.2626

The amount of energy saved is calculated by calculating the difference between the new and old
amount of total energy consumed by the condenser, reboiler, cooler and fired heater.

 Q1=Qcond + Q reboiler + Q cooler +Q fired heater =1.38+4.55+ 9.715+2.706=18.351 MMBTU /h

(Before energy integration)
 Q2=Qcond + Q reboiler + Q cooler +Q fired heater =1.38+4.55+ 7.0225+ 0.2366=13.189 MMBTU /h
(After energy integration)
 Energy saved =Q1−Q2 =18.351−13.189=5.162 MMBTU /h
 Appendix A
Calculation of Equipment Cost

Except for the chiller, which was sized by hand, all of the equipment used in the process
was sized using CHEMCAD. Table 7.2 is then used to calculate the cost of acquisition
using the matching equipment size:

I. Mixer: (static mixer)

 Volumetric flow rate = stream <1>+ stream <13> + stream <2> = 247.93 ft3/h
L
 Thus V̇ =1.95
s
 S=V̇
 a=570 , b=1170 , n=0.4
 C e =a+b∗Sn
 C e =570+1170∗(1.95)0.4
 C e =$ 2098.27

II. Divider: (static mixer)

3 L
 V̇ =V 12=178.61 f t / h=1.4
s
 S=V̇
 a=570 , b=1170 , n=0.4
 C e =a+b∗Sn
 C e =570+1170∗(1.4)0.4
 C e =$ 1908.56

III. Fired heater: (Cylindrical shape)

 Q̇=2.706 MMBtu /h
 S= Q̇=0.793 MWh
 a=80000 , b=109000 ,n=0.8
 C e =80000+109000∗(0.793)0.8
 C e =$ 170540.95
IV. Reactor:

 V =15 f t 3
 S=V =424 m 3
 a=61500 , b=32500 , n=0.8
 C e =61500+32500∗(0.424)0.8
 C e =$ 77882.97

V. Cooler:
Q
 S= A=
U∗LMTD
MMBTU
 Q=9.715 =2.846 × 106 W
h
 LMTD=158.64 ℉=343.5 K
w 2.846 ×10
6
 Assume U =300 (cooling) S= A= =27.62 m
2
m2 . K 300∗343.5
 Assume U-tube shell and tube cooler a=28000 , b=54 , n=1.2
 C e =28000+54∗(27.62)0.8
 C e =$ 28768.02

VI. Flasher: (Vertical alignment and assumed as pressure vessel)

 Shell weight=2598.1633 lb=1178.507 Kg

 S=m
 a=11600 , b=34 , n=0.85
0.85
 C e =11600+34∗(1178.507)
 C e =$ 25471.11

VII. Component Separator:

Because it cannot be scaled in CHEMCAD and is classified as a pressure vessel,

it will have the same shell weight as flash and, as a result, the same purchased
cost→ Ce =$ 25471.11
VIII. SCDS Column: (valve tray)

 The SCDS has a total of 9 trays, including the reboiler and condenser.
 d= 3.5 therefore ft = 1.0668 m
 S=1.0668m
 a=210 , b=400 , n=1.9
 C e =[ 210+400 × (1.0668 )1.9 ] × 9
 C e =$ 5960.616
 Now calculate the shell weight of the column: (pressure vessel)
 S=m=2280.8789lb=1034.589 Kg
 a=11600 , b=34 , n=0.85
0.85
 C e =11600+34 ×(1034.589)
 C e =$ 24017.43
 Total Cost = $ 5960.616+ $ 24017.43=$ 29978.046
 Appendix B
EAOC Calculation

The following formula is used to compute the EAOC:

A
( )
 EAOC=FCI∗ , i m , n +Utility Cost
P
n
i m∗( 1+i m )
 ( A
P )
,i m , n = n
( 1+i m ) −1
 i m=10 %
 n=12 years

( )
12
A 0.1∗( 1+0.1 )
 ,i , n = =0.1467
P m 12
( 1+0.1 ) −1

FCI=∑ Purchased equipment cost=2098.27+1908.56+170540.95+77882.97+28768.02+25471.11+29

 Utility Cost =Cost of cooling water + High pressure steam cost+Cost of natural gas

Table 3: Utility cost before heat integration

Equipment Heat Duty (MMbtu/h) Heat Duty (GJ/h)

Cooler 9.715 10.25

Condenser 1.38 1.46

Reboiler 4.55 4.805

 Fired heater Fuel usage = 4022.458 ft3


$ $ $
Cost of cooling water ( $ per hour )=C cw ( cooler ) +C cw ( condenser ) =Q̇cooler ×0.35 + Q̇condenser ×0.35 =
GJ GJ h
$ $
 High pressure steam cost=Q̇reboiler ∗17.7
= 85.065
GJ h
Usage∗$ $
 Cost of natural gas=Fuel 0.005= 20.11
ft
3
h
 $
 Utility Cost =4.0985+ 85.065+20.11= 109.2735
h
$ h $
 Utility Cost = 109.2735 × 8400= 917897.4( operating hours=8400)
h yr yr
 EAOC=( $ 362119.036× 0.1467 ) +917897.4=$ 971020.2626

Appendix C
Biphenyl Process with Mass and Heat Integration

Table 4: Biphenyl Process Flow Summary with heat integration

Table 5: Utility Cost with Heat Integration

Equipment Heat Duty (MMbtu/h) Heat Duty (GJ/h)

Cooler 7.0224 7.409

Condenser 1.38 1.46

Reboiler 4.55 4.805

 Fired heater Fuel usage = 436.059 ft3


$ $ $
Cost of cooling water ( $ per hour )=C cw ( cooler ) +C cw ( condenser ) =7.409× 0.35 +1.46 ×0.35 = 3.
GJ GJ h
$ $
 High pressure steam cost=Q̇reboiler ×17.7 = 83.4
GJ h
 $ $
 Cost of natural gas=436.059 × 0.005= 2.18
ft
3
h
$
 Utility Cost =3.104+ 83.4+2.18= 88.684
h
$ h $
 Utility Cost = 2.18 × 8400= 744945.6
h year year
 FCI=$ 362119.036+Cost of heat exchanger
MMBTU
 Q=9.8 =2.87 × 106 W
h
 LMTD=28.11℉=271 K
w 2.87 ×10
6
 Assuming U =300 2 S= A= =35.3 m
2
m ∗k 300× 271
 Assume U-tube shell and tube heat exchanger a=28000 , b=54 , n=1.2
0.8
 C e =28000+54∗(35.3)
 C e =$ 28934.6
 FCI=$ 362119.036+28934.6=$ 391053.63
 EAOC new =391053.63 ×0.1467+744945.6=$ 802313.1687