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Thesis Group 09 PDF
Thesis Group 09 PDF
by OLEFLEX process.”
Project Advisor:
Dr. Usman Saeed
Group Members:
Zia-ur-Rehman Hashmi 2017-CH-740
Session 2017-2021
________________
External Examiner
Engr. Tahir Hameed
________________ ___________________
The project deals with the design of Propylene production plant. The plant we
designed is based on OLEFLEX process which is an advanced de-hydrogenation
process of Propane. Pakistan is importing Propylene from many other countries.
Because of high demand of propylene in the production of poly-propylene and
polymers, many of the neighbor countries like China, Iran, and Indonesia also import
it.
The basic demand of poly-propylene is increasing with time because of high
usage, propylene is Building block of poly-propylene. It offers a way to make Pakistan
self-supported in poly-propylene and to export the excess propylene to China (major
consumer of Propylene) and other countries such as, Indonesia and Malaysia.
Propylene also a basic need of our civilization. It is used 37% in packaging, 14% in
agriculture, 6% in health care. Automotive applications of propylene have been
growing strongly where there has been a drive to replace metals with plastics to reduce
the weight of motor. Thus, it can be concluded that the demand of propylene is bound
to increase in the upcoming years. In an average, China is importing 2.8 million metric
tons of Propylene a year. We will also produce propylene to fulfil the basic demand of
PAKISTAN and then can Export to the China.
Table of Contents
1 Introduction ................................................................................................................................................ 2
1.1 Structure of Propylene: ......................................................................................................................... 2
1.2 Project Background: ............................................................................................................................. 3
1.3 Project Objective: ................................................................................................................................. 3
1.4 Safety Data of Propylene: ..................................................................................................................... 3
1.4.1 Identification: ...............................................................................................................................3
1.4.2 Potential Hazards: .........................................................................................................................4
1.5 Exposure controls/personal protection: ................................................................................................ 5
1.5.1 Appropriate engineering controls: ................................................................................................5
1.5.2 Environmental exposure controls: ................................................................................................5
1.5.3 Hygiene measures:........................................................................................................................5
1.5.4 Eye/face protection: ......................................................................................................................5
1.5.5 Respiratory protection: .................................................................................................................5
1.5.6 Body protection: ...........................................................................................................................6
1.6 Physical properties: .............................................................................................................................. 6
1.7 Applications of propylene: ................................................................................................................... 6
1.8 About Propylene: .................................................................................................................................. 9
2 Market Analysis and Capacity Selection: .............................................................................................. 11
2.1 Worldwide Consumptions of Propylene: ........................................................................................... 11
2.2 Worldwide Demand of Propylene by Applications: ........................................................................... 11
2.3 Worldwide Production capacity of Propylene 2018-2030: ................................................................ 11
2.4 Trade of Propylene: ............................................................................................................................ 12
2.4.1 Exports:...................................................................................................................................... 12
2.4.2 Imports:...................................................................................................................................... 12
2.5 Market Analysis (Asia Pacific): ......................................................................................................... 12
2.6 Price difference between propane/propylene: .................................................................................... 13
2.7 Global market share by the end-use industry 2019: ........................................................................... 13
2.8 Market analysis (Asia pacific-2018): ................................................................................................. 13
2.9 Price analysis & CAGR: ..................................................................................................................... 14
2.10 Capacity selection:.............................................................................................................................. 14
2.11 Raw Material: ..................................................................................................................................... 15
3 Process Selection:...................................................................................................................................... 17
3.1 Commercial PDH Technologies: ........................................................................................................ 17
3.2 Comparison between CATOFIN & OLEFLEX: ................................................................................ 18
3.3 Selected process: ................................................................................................................................ 18
3.4 OLEFLEX (moving-bed) from UOP:................................................................................................. 19
4 Process Description: ................................................................................................................................. 21
4.1 Dehydrogenation of Propane: ............................................................................................................. 21
4.2 Feed Preparation section:.................................................................................................................... 21
4.3 Dehydrogenation process: .................................................................................................................. 21
4.4 Product purification section: ............................................................................................................... 21
4.5 Process Flow Diagram:....................................................................................................................... 23
5 Material Balance: ..................................................................................................................................... 25
5.1 Material Balance Around De-propanizer: .......................................................................................... 25
5.2 Material Balance Around Reactor: ..................................................................................................... 26
5.3 Material Balance Around Knockout Drum: ....................................................................................... 27
5.4 Material Balance Around Propane/Propylene Splitter: ...................................................................... 28
5.5 Material Balance Around Mixer: ........................................................................................................ 29
6 Energy Balance: ........................................................................................................................................ 31
6.1 Energy balance Around Distillation Column (DC-101): .................................................................... 31
6.2 Energy Balance of Reactor (R-101): .................................................................................................. 35
6.3 Energy Balance across Furnace (F-101):............................................................................................ 36
6.4 Energy Balance across Heat Exchanger (H-101): .............................................................................. 37
6.5 Energy balance across other Heat Exchangers: .................................................................................. 38
6.6 Energy Balance across Compressor (C-101): ..................................................................................... 38
6.7 Energy Balance across Compressor (C-102): ..................................................................................... 39
6.8 Energy Balance across Propane-Propylene Splitter (PP-101): ........................................................... 40
7 Equipment Design: ................................................................................................................................... 45
7.1 Design of Reactor (R-101): ................................................................................................................ 45
7.1.1 Introduction: .............................................................................................................................. 45
7.1.2 Reactor Selection Criteria:......................................................................................................... 45
7.1.3 Moving Bed Reactor: ................................................................................................................ 46
7.1.4 Catalyst Properties (Pt-Sn/Al2O3): ........................................................................................... 46
7.1.5 Reaction Kinetics: ..................................................................................................................... 46
7.1.6 Design Steps: ............................................................................................................................. 47
7.1.7 Kinetics of the reactions: ........................................................................................................... 47
7.1.8 Design Equation: ....................................................................................................................... 48
7.1.9 Calculate Weight of the Catalyst: .............................................................................................. 49
7.1.10 Calculate Volume of the Catalyst: ............................................................................................. 49
7.1.11 Calculate Volume of Reactor: ................................................................................................... 49
7.1.12 Calculate Residence Time and WHSV:..................................................................................... 50
7.1.13 Length and Diameter Calculations: ........................................................................................... 50
7.1.14 Bed Height Calculations: ........................................................................................................... 51
7.1.15 Minimum Fluidization velocity: .............................................................................................. 51
7.1.16 Terminal Fluidization Velocity: .............................................................................................. 52
7.1.17 Fluidization Velocity: ................................................................................................................ 52
7.1.18 Pressure Drop due to Catalytic Bed:.......................................................................................... 52
7.1.19 Pressure Drop due to Fluidization: .......................................................................................... 53
7.1.20 Mechanical Design of Reactor: ................................................................................................. 53
7.1.21 Specification Sheet of Reactor: ................................................................................................. 56
7.2 Design of Distillation Column (Depropanizer): ................................................................................. 57
7.2.1 Distillation: ................................................................................................................................ 57
7.2.2 Advantages of Distillation: ........................................................................................................ 57
7.2.3 Types of Distillation: ................................................................................................................. 57
7.2.4 Column Selection: ..................................................................................................................... 58
7.2.5 Internal Plates Selection: ........................................................................................................... 58
7.2.6 Design Steps: ............................................................................................................................. 59
7.2.7 Feed Condition: ......................................................................................................................... 59
7.2.8 Top Conditions: ......................................................................................................................... 60
7.2.9 Bottom Conditions: ................................................................................................................... 61
7.2.10 Reference Component: .............................................................................................................. 62
7.2.11 Relative Volatilities: .................................................................................................................. 62
7.2.12 Minimum number of stages: ...................................................................................................... 62
7.2.13 Minimum reflux ratio: ............................................................................................................... 63
7.2.14 Actual Reflux Ratio: .................................................................................................................. 63
7.2.15 Theoretical Number of Stages: .................................................................................................. 63
7.2.16 Efficiency: ................................................................................................................................. 63
7.2.17 Tray Efficiency: ......................................................................................................................... 63
7.2.18 Actual number of trays: ............................................................................................................. 63
7.2.19 Vapor & Liquid flow Rate in Distillation Column: ................................................................... 64
7.2.20 Top section diameter calculations: ............................................................................................ 64
7.2.21 Flooding velocity calculation: ................................................................................................... 65
7.2.22 Bottom section diameter calculations: ....................................................................................... 66
7.2.23 Flooding velocity calculation: ................................................................................................... 66
7.2.24 Height of Distillation column: ................................................................................................... 68
7.2.25 L/D Ratio: .................................................................................................................................. 68
7.2.26 Distillation Column Plate Design: ............................................................................................. 68
7.2.27 Weeping:.................................................................................................................................... 69
7.2.28 Actual minimum vapors velocity: ............................................................................................. 70
7.2.29 Pressure Drop: ........................................................................................................................... 71
7.2.30 Plate pressure drop: ................................................................................................................... 71
7.2.31 Down comer liquid backup: ...................................................................................................... 72
7.2.32 Residence Time: ........................................................................................................................ 72
7.2.33 Entrainment: .............................................................................................................................. 72
7.2.34 Perforated Area:....................................................................................................................... 73
7.2.35 Specification Sheet of Distillation Column: .............................................................................. 75
7.3 Design of Heat Exchanger: ................................................................................................................. 76
7.3.1 Types of Heat Exchanger: ......................................................................................................... 76
7.3.2 Selection criteria: ....................................................................................................................... 76
7.3.3 Transfer Process: ....................................................................................................................... 76
7.3.4 Pass arrangement: ...................................................................................................................... 76
7.3.5 Flow arrangement: ..................................................................................................................... 76
7.3.6 Phase of fluid: ............................................................................................................................ 77
7.3.7 Geometry of construction: ......................................................................................................... 77
7.3.8 Shell and Tube Heat Exchanger: ............................................................................................... 77
7.3.9 Types of shell and tube Heat Exchanger: .................................................................................. 77
7.3.10 Design steps of Heat Exchanger: ............................................................................................... 77
7.3.11 Design Calculation: ................................................................................................................... 78
7.3.12 True Temperature: ..................................................................................................................... 78
7.3.13 Provisonal Area : ....................................................................................................................... 78
7.3.14 Tube Specification: .................................................................................................................... 79
7.3.15 Shell configuration: ................................................................................................................... 79
7.3.16 Shell side heat transfer coefficient: ........................................................................................... 79
7.3.17 Tube side heat transfer coefficient: ........................................................................................... 80
7.3.18 Tube wall temperature: ............................................................................................................. 81
7.3.19 Overall heat transfer coefficient: ............................................................................................... 81
7.3.20 Pressure Drop calculation: ......................................................................................................... 82
7.3.21 Specification sheet of Heat Exchanger: ..................................................................................... 83
7.4 Design of Knock out vessel: ............................................................................................................... 84
7.4.1 Design Methodology: ................................................................................................................ 84
7.4.2 Process conditions: .................................................................................................................... 84
7.4.3 Calculations for settling velocity: .............................................................................................. 84
7.4.4 Calculations of volumetric flow rate for liquid and vapors: ...................................................... 85
7.4.5 Calculations of Area: ................................................................................................................. 85
7.4.6 Calculations of Diameter: .......................................................................................................... 86
7.4.7 Calculations of volume of liquid: .............................................................................................. 86
7.4.8 Specification Sheet of Knockout Drum: .................................................................................... 86
8 Process Simulation: .................................................................................................................................. 88
8.1 Steady State Simulation:..................................................................................................................... 88
8.2 Dynamic Simulation: .......................................................................................................................... 88
8.3 Distillation Simulation: ...................................................................................................................... 89
8.3.1 Add Components: ...................................................................................................................... 89
8.3.2 Applying Fluid Package: ........................................................................................................... 90
8.3.3 Open simulation environment and add Feed conditions: .......................................................... 90
8.3.4 Add Distillation Column and add specific conditions: .............................................................. 91
8.3.5 Results: ...................................................................................................................................... 91
9 Cost estimation: ........................................................................................................................................ 93
9.1 Types of Capital Cost Estimates:........................................................................................................ 93
9.2 Production of 150 tons/day of propylene: .......................................................................................... 93
9.3 Cost Index:.......................................................................................................................................... 94
9.4 Purchase Cost of Major Equipment’s: ................................................................................................ 94
9.5 Total Equipment Cost: ........................................................................................................................ 95
9.6 Total Capital Investment (TCI): ......................................................................................................... 95
9.6.1 FCI (Fixed capital investment): ................................................................................................. 95
9.6.2 WCI (Working Capital Investment): ......................................................................................... 95
9.7 Direct Cost: ......................................................................................................................................... 96
9.8 Depreciation Cost: .............................................................................................................................. 96
9.9 General Expenses: .............................................................................................................................. 97
9.10 Net Profit: ........................................................................................................................................... 97
9.11 Let the tax rate is 30%: ....................................................................................................................... 98
9.12 Rate of Return: ................................................................................................................................... 98
9.13 Payback Period: .................................................................................................................................. 98
10 Process Instrumentation and Control: ................................................................................................. 100
10.1 Design Steps of Control Scheme: ..................................................................................................... 100
10.2 Control Schemes on Knock out vessel: ............................................................................................ 100
10.3 Pressure Control Scheme:................................................................................................................. 101
10.3.1 Disturbance: ............................................................................................................................. 101
10.3.2 Control Variables: ................................................................................................................... 101
10.3.3 Manipulated Variable: ............................................................................................................. 101
10.4 Description: ...................................................................................................................................... 101
10.5 Level Control Scheme: ..................................................................................................................... 101
10.5.1 Disturbance: ............................................................................................................................. 101
10.5.2 Control Variables: ................................................................................................................... 101
10.5.3 Manipulated Variable: ............................................................................................................. 102
10.6 Description: ...................................................................................................................................... 102
11 HAZOP Study: ....................................................................................................................................... 104
11.1 Definition of HAZOP Term: ............................................................................................................ 104
11.1.1 Hazard: .................................................................................................................................... 104
11.1.2 Harm: ....................................................................................................................................... 104
11.1.3 Risk:......................................................................................................................................... 104
11.2 Guide word: ...................................................................................................................................... 105
11.3 HAZOP study of Heat Exchanger: ................................................................................................... 106
12 References: .............................................................................................................................................. 107
List of Figures:
1|Page
1 Introduction
Propylene, also called propene, a colorless, flammable, gaseous hydrocarbon, C3H6, obtained from
petroleum; large quantities of propylene are used in the manufacture of resins, fibers, and elastomers
(see polyolefin), and numerous other chemical products. See glycol; propyl alcohol. [1]
Propylene (C3H6) is a colorless fuel gas with a naturally pungent smell. Although similar to propane,
it has a double bond which gives it a combustion advantage i.e., it burns hotter. This fuel gas is
extremely flammable and non-toxic. Propylene is obtained during the refining of gasoline. But it can
also be produced by splitting, cracking and reforming hydrocarbon mixtures. [2]
The 2D chemical structure image of Propylene is also called skeletal formula, which is the standard
notation for organic molecules. The carbon atoms in the chemical structure of PROPYLENE are
implied to be located at the corner(s) and hydrogen atoms attached to carbon atoms are not indicated
each carbon atom is considered to be associated with enough hydrogen atoms to provide the carbon
atom with four bonds.
The 3D chemical structure image of PROPYLENE as shown above displays both the three-
dimensional position of the atoms and the bonds between them. The radius of the spheres is therefore
smaller than the rod lengths in order to provide a clearer view of the atoms and bonds throughout the
chemical structure model of PROPYLENE.
2|Page
1.2 Project Background:
Final year design project team has been assigned to design a Polymer grade Propylene plant
using dehydrogenation of Propane having production capacity of 150 metric tons per day. The team
needs to incorporate safety aspects, site location, conceptual design, Material balance, Energy
balance and preliminary economic evaluation in the early design of project of plant.
3|Page
1.4.2 Potential Hazards:
Eye contact:
Immediately flush eyes with plenty of water, occasionally lifting the upper and lower eyelids. Check
for and remove any contact lenses. Continue to rinse for at least 10 minutes. Get medical attention if
irritation occurs.
Inhalation:
Remove victim to fresh air and keep at rest in a position comfortable for breathing. If not breathing,
if breathing is irregular or if respiratory arrest occurs, provide artificial respiration or oxygen by
trained personnel. It may be dangerous to the person providing aid to give mouth-to-mouth
resuscitation. Get medical attention if adverse health effects persist or are severe. If unconscious,
place in recovery position and get medical attention immediately. Maintain an open airway. Loosen
tight clothing such as a collar, tie, belt or waistband.
Skin contact:
Flush contaminated skin with plenty of water. Remove contaminated clothing and shoes. To avoid
the risk of static discharges and gas ignition, soak contaminated clothing thoroughly with water
before removing it. Get medical attention if symptoms occur. Wash clothing before reuse. Clean
shoes thoroughly before reuse.
Hazard pictograms:
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1.5 Exposure controls/personal protection:
Exposure limits- 500 ppm 8 hours.
5|Page
1.5.6 Body protection:
Personal protective equipment for the body should be selected based on the task being performed and
the risks involved and should be approved by a specialist before handling this product. When there is
a risk of ignition from static electricity, wear antistatic protective clothing. For the greatest protection
from static discharges, clothing should include anti-static overalls, boots and gloves.
Property Value
Molecular weight 42.081 kg / kmol
6|Page
Polypropylene may also be blow-molded or
thermoformed, but these processes are less often
used.
Polypropylene is extremely corrosion resistant,
lightweight, flexible, and formed or welded.
7|Page
phenolic resins, caprolactam and bisphenol A.
8|Page
1.8 About Propylene: [9]
Propylene is the other name of Propene, also known as methyl ethylene, is an unsaturated organic
compound having the chemical formula 𝐶𝐶3 𝐻𝐻6 . It has one double bond, and is the second simplest
member of the alkene class of hydrocarbons. It is a colorless gas with a faint petroleum-like odor.
Propylene is a byproduct of oil refining and natural gas processing. During oil refining, ethylene,
Propylene, and other compounds are produced as a result of cracking larger hydrocarbons. A major
source of propylene is naphtha cracking intended to produce ethylene, but it also results from
refinery cracking producing other products. Propylene can be separated by fractional distillation from
hydrocarbon mixtures obtained from cracking and other refining processes; refinery-grade propylene
is about 50 to 70%.
Propylene can also be produced in an on-purpose reaction (for example, in propane dehydrogenation,
metathesis or syngas-olefins plants).
Commercially, Propylene is traded in three grades:
Polymer grade (PG): min. 99.5% of purity.
Chemical Grade: (CG) 90-96% of purity.
Refinery Grade (RG): 50-70% of purity.
9|Page
Chapter # 2
Market analysis of Propylene.
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2 Market Analysis and Capacity Selection:
2.1 Worldwide Consumptions of Propylene:
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Figure 2.3: Production capacity in 2018-30 [12]
2.4.1 Exports:
In 2019 the top exporters of Propene (propylene) were South Korea ($1.49B), Japan ($749M),
United States ($715M), Netherlands ($700M), and Chinese Taipei ($542M).
2.4.2 Imports:
In 2019 the top importers of Propene (propylene) were China ($2.72B), Germany ($871M), Belgium
($730M), Netherlands ($469M), and Mexico ($280M).
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2.6 Price difference between propane/propylene:
% use
18%
37% packaging
7% automation
construction
5% life style
4% heath care
6% electrical
9% agricultural
14%
13 | P a g e
5 Indonesia -101612 1056
We will purchase LPG from “Parco Pearl Gas Limited (PPGL). PPGL is producing 85000 MT
Annually. On the behalf total available RAW MATERIAL and market situations we decided the
capacity of our plant “150 MTPD”.
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2.11 Raw Material: [8]
component %Age
Propane 85-95
Butane 7-10
Pentane 3-5
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Chapter # 03
Process Selection
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3 Process Selection: [8]
The main processes for the production of Propylene are given below:
Propane Dehydrogenation.
Metathesis.
Methanol-to-Olefins (MTO).
Olefins Conversion Technology (OCT).
Metathesis of from
Dehydrogenation of propane
Ethylene & Butene
17 | P a g e
Each technology has its own advantages and disadvantages. Differences arise in the utilized catalyst,
technology process, operating conditions (temperature and pressure) and performance.
CATOFIN and OLEFLEX are the only commercials proven PDH technologies
Gas reactions are easy to handle in vertical reactors so the OLEFLEX process is suitable.
Catalyst life:
Catalyst Recycling:
Catalyst regeneration:
Continuous regeneration is most suitable for continuous process, which OLEFLEX provides.
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Regeneration Time:
OLEFLEX process provide slow regeneration of catalyst which required less energy.
DeH-14 catalyst maintains high activity and allows for high productivity and selectivity which is
characterized by lower platinum costs than previously used catalysts. Besides propane
dehydrogenation, OLEFLEX unit can be used for dehydrogenation of Iso-butane, normal butane, or
Iso-pentane feedstock separately or as mixtures.
OLEFLEX technology was commercialized in 1990, and by 2002 more than 1,250,000 MTA of
propylene was produced from various OLEFLEX units located in different places in the world.
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Chapter # 4
Process description and process flow diagram
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4 Process Description: [9]
4.1 Dehydrogenation of Propane:
Propane is dehydrogenated in the presence of Pt-Sn/Al2 O3 catalyst in R-101.
C3 H8 ⇔ C3 H6 + H2 (Main Reaction)
The flowsheet can be broadly divided into the following sections: depropanizer column, reactor,
section, effluent cooling and compression, Knockout drum and the propylene-propane splitter
column.
Propane also has the properties of “Refrigerant” so we are utilizing its refrigerant property to liquefy
of product stream. CD-101 is used for this purpose. Here the liquid propane is gasified and the
gaseous product get liquefy.
Gaseous propane is then sent to the “Waste Heat Recovery Unit” where we are utilizing the waste
heat of our reactor outlet to preheat our raw material. For this purpose, HE-101 is used. Outlet
temperature of HE-101 is 348°C.
We need temperature of 600˚C in Reactor. So, the pre-heated propane gas is sent to the Furnace.
Furnace F-101 add more heat to it by burning furnace oil and raise the temperature of feed to the
600°C.
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From the outlet of reactor, hot gas is passed through waste heat recovery unit where its temperature
decreases to 221.05°C. Then it is sent to the cooler HE-102 where it is cooled to ambient
temperature 35°C.
In compression section, the cooled gas is sent to the series of compressors (C-101 & C-102) where
its pressure increased from 1atm to 19atm.
After compression, compressed and cooled gas is sent to the condenser, where it gets liquefied. On
this stage just propane and propylene get liquefied. Hydrogen, Methane and ethane will not liquefy
because the operating temperature is higher than the critical temperatures of the components.
Outlet stream of the condenser is sent to the knock out V-101. Where the gases and liquids will
separate out on the basis of density difference by giving them disengaging space. Top gaseous
stream is sent to the furnace where it will mix with fuel to heat up our feed propane.
Downstream of the knock out is sent to propane/propylene splitter (PP-101) here our final product
propylene is obtained from top and unreacted propane from bottom section. Unreacted propane is
recycled to the system after some treatments.
22 | P a g e
4.5 Process Flow Diagram:
T=567°C
8 P=1.3atm
R-101
CCR
T=55°C T=600°C
5 P=5atm T=348°C
T=44°C E-101 P=1.8atm
T=44.75°C T=44.75°C P=4atm
P=15atm P=6atm 7
P=15atm
T=48.35°C
P=15atm 2 3 PV-101 4 6
LPG MX-101 CD-101 F-101 T=311.15°C
1 DC-101
9 P=1.1atm
14 T=54°C
P=19atm
3 13 12 11 10
T=105.45°C
E-104 T=80.43°C C-102 T=35°C T=164°C T=35°C E-102
P=15atm P=9atm E-103 P=9atm C-101
P=19atm P=1atm
17
T=26°C T=23°C 19
T=30°C
15 P=19atm P=15atm P=15atm
18 T=36.85°C
P=15atm
T=23°C
PV-102 16 P=15atm 20 21
V-101 PP-101
T=167°C T=44.75°C
P=15atm E-105 P=15atm
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Chapter # 5
Material Balance
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5 Material Balance:
Mass balance (Material balance) are very important techniques to use during the design of chemical
engineering processes. They are direct application of the law of conservation of mass “mass neither
be created nor destroyed”. Chemical engineer invested this law in the design of chemical processes.
The purpose of mass balance is to produce 150 MTPD propylene from LPG source. The LPG
consists of 85-95% propane, 7-10% butane and 3-5% pentane. The propylene is produced by Oleflex
process.
Assumption:
F=D+W
F × xf = Dxd × Wxw
Propane
LPG
F DC-101
Butane
Pentane
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Components Inlet kg/hr Distillate kg/hr Bottom kg/hr
Propane 6851.250349 6844.399098 6.851250349
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Outlet
Inlet
Propylene 0 6364.101019
Hydrogen 0 304.8960944
Ethylene 0 47.13588761
Methane 0 26.95399777
Inlet
Liquid out
Figure 5.3: Schematic diagram representing material balance around Knockout drum
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Feed: 16857.29 kg/hr
Assumption:
Hydrogen, Methane and Ethylene are in gas phase they will remove from top.
Propane and propylene are liquid phase they will remove from the bottom.
Note: Hydrogen, methane and ethylene are above at their critical temperature. So, these three
components are in gas phase.
F=D+W
99% pure propane with solvent will be exit from the bottom.
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General Mass Balance:
F=D+W
F PP-101
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Chapter # 6
Energy Balance
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6 Energy Balance: [19]
“The First Law of Thermodynamics is a statement of energy conservation. Although energy cannot
be created or destroyed, it can be converted from one form to another.”
For example, internal energy stored in molecular bonds can be converted into kinetic energy,
potential energy can be converted too kinetic or too internal energy, etc. Energy can also be
transferred from one point to another, or from one body to a second body. The general energy
balance for a process can be expressed as
Accumulation of Energy in System = Energy input to System – Energy Output from System.
Top Stream
Bubble Temperature 44.75℃
Feed Stream
Dew Temperature 46℃
Bubble Temperature 48℃
Dew Temperature 59℃ Mole Fraction
Propane = 0.999
Mole Fraction Butane = 0.0000089
Propane = 0.9
Butane = 0.08 Bottom Stream
Mole Fraction
Propane = 0.0089
Butane = 0.793
Pentane = 0.1984
Figure 6.1: Schematic diagram representing energy balance around Distillation Column
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Feed Stream:
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 155.367 0.9 66.52
𝑇𝑇𝑓𝑓 = 321.5𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
n = F = 172.63 kmol/hr
kJ
∆𝐇𝐇𝐟𝐟 = 273139.1544
hr
∆𝐇𝐇𝐟𝐟 = 75.8719 kW
Top Stream:
a) Enthalpy of vapors at top
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 155.21163 0.9999 30.7973
𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑 = 319.15𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
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R = 0.80617
D = 155.225 kmol/hr
L = 125.138 kmol/hr
V = 280.363 kmol/hr
kJ
∆𝐇𝐇𝐯𝐯 = 181320.56
hr
∆𝐇𝐇𝐯𝐯 = 50.366 kW
b) Heat of Condensation
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 𝐧𝐧𝐧𝐧
kJ
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 3649.633
hr
kJ
∆𝐇𝐇𝐯𝐯 = 184970.1935
hr
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 317.9𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
R = 0.80617
33 | P a g e
D = 155.225 kmol/hr
L = 125.138 kmol/hr
kJ
∆𝐇𝐇𝐝𝐝 = 300611.2121
hr
Condenser Duty:
Qc = Qv + Q latent + Qd
𝐤𝐤𝐤𝐤
𝐐𝐐𝐜𝐜 = 𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒. 𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒
𝐡𝐡𝐡𝐡
Bottom Stream:
a) Enthalpy of Liquid at bottom
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 0.155367 0.008927 78.00425
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 378.6𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
kJ
∆𝐇𝐇𝐰𝐰 = 140924.6097
hr
34 | P a g e
Reboiler Duty:
QB = Qc + Hw+ HD –HF
QB = 653978.073 kJ/hr
QB = 181.6606 kW
6.2 Energy Balance of Reactor (R-101):
Main Reaction:
C3 H8 ⇔ C3 H6 + H2
Side Reaction:
C3 H8 → C2 H4 + CH4
kJ
∆Hr1 at 25℃ = 125.11
kmol
kJ
∆Hr2 at 25℃ = 82.13
kmol
35 | P a g e
kJ
Q in = n × Cp × ∆T = −36054942.49
hr
kJ
Q out = n × Cp × ∆T = 14419698.03
hr
kJ
∆Hr1 at 600℃ = 50493561.92
hr
kJ
∆Hr2 at 600℃ = 21784632.65
hr
kJ
∆Hr = 72278194.57
hr
kJ
Q = 21803554
hr
Q = 6056.54 kW
Propane:
Inlet Temperature: 621.15K
Cp avg: 3.4127 kJ/kg. K
Mass Flow rate: 16858.12kg/hr
Propane:
Outlet Temperature: 873.15K
Cp avg: 3.4127 kJ/kg. K
Mass Flow rate: 16858.12kg/hr
Duty of Furnace:
𝐐𝐐 = 𝐦𝐦 × 𝐂𝐂𝐂𝐂 × ∆𝐓𝐓
36 | P a g e
Q = 30212419.8 kJ/hr
Q = 8392.34 kW
Figure 6.4: Schematic diagram representing energy balance across Heat Exchanger
kJ
𝑄𝑄𝐶𝐶 = 11904027.81
hr
37 | P a g e
Heat released from Hot Stream:
𝟑𝟑𝟑𝟑𝟑𝟑.𝟏𝟏𝟏𝟏
𝑸𝑸𝑯𝑯 = � 𝐦𝐦 × 𝐂𝐂𝐂𝐂 × ∆𝐓𝐓
𝟓𝟓𝟓𝟓𝟓𝟓
kJ
Q H = −11904027.81
hr
kJ kJ
11904027.81 = −11904027.81
hr hr
In this Heat Exchangers, water is used as a cooling medium and Cp of water is 4.167kJ/kg.℃.
38 | P a g e
Outlet Temperature of Compressor:
𝐏𝐏𝟐𝟐 𝐤𝐤−𝟏𝟏
𝐓𝐓𝟐𝟐 = 𝐓𝐓𝟏𝟏 × ( ) 𝐤𝐤
𝐏𝐏𝟏𝟏
T2 = 164℃
𝐏𝐏𝟐𝟐 𝐤𝐤−𝟏𝟏
𝐓𝐓𝟐𝟐 = 𝐓𝐓𝟏𝟏 × ( ) 𝐤𝐤
𝐏𝐏𝟏𝟏
T2 = 80.43℃
39 | P a g e
6.8 Energy Balance across Propane-Propylene Splitter (PP-101):
Top Stream
Bubble Temperature 36.85℃
Dew Temperature 44.85℃
Feed Stream
Bubble Temperature 68.85℃ Mole Fraction
Dew Temperature 157℃ Propane = 0.015
Propylene = 0.98
Solvent = 0.0038
Mole Fraction
Propane = 0.3324
Bottom Stream
Propylene = 0.2192
Bubble Temperature 85.85℃
Solvent = 0.4484
Dew Temperature 167.85℃
Mole Fraction
Propane = 0.422
Propylene = 0.0028
Solvent = 0.574
Feed Stream:
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 229.3778 0.3324 71.39
40 | P a g e
𝑇𝑇𝑓𝑓 = 342𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
n = F = 689.989 kmol/hr
kJ
∆𝐇𝐇𝐟𝐟 = 1918373
hr
∆𝐇𝐇𝐟𝐟 = 532.8 kW
Top Stream:
a) Enthalpy of vapors at top
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 2.2937 0.0150 30.655
𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑 = 318𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
n = 152.6025 kmol/hr
kJ
∆𝐇𝐇𝐯𝐯 = 99167.36
hr
∆𝐇𝐇𝐯𝐯 = 27.55 kW
b) Heat of Condensation
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 𝐧𝐧𝐧𝐧
41 | P a g e
kJ
∆𝐇𝐇𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥𝐥 = 1921.956
hr
kJ
∆𝐇𝐇𝐯𝐯 = 101089.315
hr
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 310𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
n = 152.6025 kmol/hr
kJ
∆𝐇𝐇𝐝𝐝 = 105942.4
hr
Condenser Duty:
Qc = Qv + Q latent + Qd
𝐤𝐤𝐤𝐤
𝐐𝐐𝐜𝐜 = 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐. 𝟕𝟕
𝐡𝐡𝐡𝐡
42 | P a g e
Bottom Stream:
a) Enthalpy of Liquid at bottom
Components Feed (kmol/hr) Mole Fraction Cp (kJ/kmol. K)
Propane 227.0841 0.4226 85.814
𝑇𝑇𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 = 359𝐾𝐾
𝑇𝑇𝑟𝑟 = 298.15𝐾𝐾
n = 537.38 kmol/hr
kJ
∆𝐇𝐇𝐰𝐰 = 2816782.04
hr
Reboiler Duty:
QB = Qc + Hw+ HD –HF
QB = 1211383 kJ/hr
QB = 336.495 kW
43 | P a g e
Chapter # 07
Equipment design
44 | P a g e
7 Equipment Design:
Estimation of design parameters:
For every engineering process the heart of the process is considered to be its design. As the PFD of
the process describe earlier in chapter number two the major equipment of the plant in our process
are
Reactors
Homogeneous Heterogeneous
PLUG Fluidized
C.S.T.R Fixed bed Moving Bed
FLOW bed
Selection of the appropriate reactor for the process is as important as the accurate temperature and
pressure conditions for carrying out the reaction. Selection of the reactor depends on the following
factors;
Mode of operations.
45 | P a g e
Type of flow reactor.
Catalyst bed (Fixed, Fluidized and moving bed).
Reaction phase (Homogenous and Heterogeneous).
600℃
C3 H8(g) C3 H6(g) + H2(g)
Pt-Sn/Al2 O3
46 | P a g e
∆H1 = 125.11 KJ/mol
Side Reaction:
600℃
C3 H8(g) C2 H4(g) + CH4(g)
Pt-Sn/Al2 O3
Operating Pressure and Temperature is 1.8atm and 600℃. At these conditions, reaction is
Endothermic.
PC3H8 − PH2
PC3H8 −
−ra = k1 ( K1 )
1 + K e Pe
Where;
mol
ra = rate of reaction ( . hr)
kg
47 | P a g e
mol
k1 = 0.0296 ( )
kg. min. bar
K e = 0.9454 (bar −1 )
K1 = 66.64 (bar −1 )
R = 8.314 (J/kmol. K)
T = 873.15 K
kmol
Cao = 0.025
m3
Order of reaction = 1
PC3H8 − PH2
PC3H8 −
−ra = k1 ( K1 )
1 + K e Pe
Cb. Cc
Ca − K
1
−ra = k1 RT( )
1 + K e Pe
2 2
0.01088mol Cao Xa
−ra = RT �Cao (1 − Xa ) − �
kg. min. bar 66.64
Generate the data between Xa & 1/-ra and calculating the area under the curve by applying Simpson
rule,
48 | P a g e
Xa vs 1/-ra
0.9
0.8
0.7
0.6
0.5
-1/-ra
0.4
0.3
0.2
0.1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45
Xa
𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘
Fao = 382.2864
ℎ𝑟𝑟
Mass
Volume =
Volume
49 | P a g e
Void fraction = 0.8
𝑉𝑉𝑏𝑏𝑏𝑏𝑏𝑏 = 18.5 m3
𝑉𝑉𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = 21.85 m3
We know;
1
τ=
s
τ = 0.3hr
Fao = Cao . vo
kmol
Fao = 382.2964
hr
kmol
Cao = 0.025
m3
m3
vo = 15291.86
hr
3 4 × 𝑣𝑣𝑣𝑣𝑣𝑣.
𝐷𝐷𝐷𝐷𝐷𝐷 = �
3 × 3.14
D = 2.10m
L = 3 * Diameter
L = 6.30 m
Area = 3.14 * D * L
50 | P a g e
7.1.14 Bed Height Calculations:
Bed Volume = 3.7 𝑚𝑚3
𝜋𝜋
Bed area = × 𝐷𝐷2
4
𝑊𝑊
Bed height =
𝜌𝜌𝜌𝜌(1−𝜀𝜀)
Where;
kg
ρp = 1120
m3
dp = 0.0018m
m
g = 9.8
s2
kg
ρf = 1.11
m3
𝒎𝒎
𝒖𝒖𝒎𝒎𝒎𝒎 = 𝟐𝟐. 𝟐𝟐𝟐𝟐
𝒔𝒔
51 | P a g e
7.1.16 Terminal Fluidization Velocity: [27]
kg
μf = 0.0199cp = 0.000199
m. s
𝟑𝟑. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎
𝐮𝐮𝐟𝐟 =
𝐬𝐬
F = w = mg
F
∆P =
A
52 | P a g e
N
∆P = 11672.19
m2
∆P = 0.115atm
∆P = 0.115 + 0.16
Material of construction
Thickness of shell
Head selection
Design Temperature
Design Pressure
Material of Construction:
According to the conditions suitable material for selection is “Low-alloy steel (SA-387)”
53 | P a g e
Reactor wall thickness: [28]
𝑃𝑃𝑃𝑃𝑃𝑃
t= + 𝐶𝐶𝐶𝐶
𝑆𝑆𝑆𝑆𝑆𝑆−0.6𝑃𝑃
Where;
E = Joint efficiency (E = 1)
t = 0.028m
t = 28mm
Selection of Head:
Pressure bar Head type
P < 15 Toro spherical
P > 15 Hemisphere
P> 15 ellipsoidal
Hemispherical is stronger in strength than any other but is not economical so, Toro spherical is
selected.
Head Thickness:
𝟎𝟎. 𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖𝟖
𝐭𝐭 𝐡𝐡𝐡𝐡𝐡𝐡𝐡𝐡 = + 𝐂𝐂𝐂𝐂
𝐒𝐒𝐒𝐒𝐒𝐒 − 𝟎𝟎. 𝟏𝟏𝟏𝟏
La=inside radius=1.05m
54 | P a g e
S = Maximum allowable stress = 6900Kpa
E = Joint efficiency = 1
t = 0.025m
t = 25mm
Design Pressure:
PD = P *1.1
PD = 1.9 bar
Design Temperature:
Design temperature is mostly used at industrial scale is 10% in excess of operating Pressure.
TD = T *1.1
TD = 949℃
55 | P a g e
7.1.21 Specification Sheet of Reactor:
Identification
Item Reactor
Operation Continuous
Orientation Vertical
Catalyst Pt-Sn/Al2O3
56 | P a g e
7.2 Design of Distillation Column (Depropanizer):
7.2.1 Distillation:
A separation process of liquid mixtures based on their boiling points or relative volatility. In simple
distillation process, a volatile compound is evaporated and channeled through a distillation column
into a condenser, where it is eventually captured. Distillation columns consist of an array of trays, in
which the lowest and highest boiling liquids are collected at the top and bottom of the column,
respectively.
One of the biggest benefits of fractional distillation is that it’s easy to use. As long as you set up a
fully functional and well-designed system, you can leave it as is to do its job. You only need to check
the system on a regular basis to ensure its functioning properly, find out if it needs repairs, and fix
whatever needs fixing. Modern fractional distillation setups are automated using microprocessors,
which make the process even easier.
Fractional distillation has been proven by countless experiments and actual processes to be effective.
In fact, it’s widely used in many industrial settings to create the products that modern society needs.
Fractional distillation is also highly efficient, especially for systems that use stacked distillation
columns, which produce more output at lower costs.
Fractional distillation.
Azeotropic Distillation.
Extractive Distillation.
Vacuum Distillation.
Steam Distillation.
57 | P a g e
7.2.4 Column Selection:
Comparison between packed and plate column:
Based on above mentioned qualification the best suited column for our process is “Plate Distillation
Column”
Sieve tray.
Valve Tray.
Bubble cap Tray.
Sr. No. Factor Sieve Tray Valve Tray Bubble Cap Tray
1 Capacity High High Moderate High
58 | P a g e
6 High: tends to collect
Fouling Tendency Low Low to moderate
solids
7 Effect of
Low Low to moderate High
corrosion
8 Entrainment Moderate Moderate High
59 | P a g e
Pentane 72.15 33.3239 -2422.7 -9.2354 9.019E-11 4.105E-06 0.02
𝑩𝑩
𝑳𝑳𝑳𝑳𝑳𝑳 𝑷𝑷 = 𝑨𝑨 + + 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 + 𝑫𝑫𝑫𝑫 + 𝑬𝑬𝑻𝑻𝟐𝟐 [19]
𝑻𝑻
K-Values:
𝑃𝑃𝑖𝑖
𝐾𝐾𝑖𝑖 =
𝑃𝑃
Bubble Temperature:
Dew temperature:
Σ yi/ki= 1 Temperature= 59 ℃
𝑩𝑩
𝑳𝑳𝑳𝑳𝑳𝑳 𝑷𝑷 = 𝑨𝑨 + + 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 + 𝑫𝑫𝑫𝑫 + 𝑬𝑬𝑻𝑻𝟐𝟐
𝑻𝑻
K-Values:
Pi
Ki =
P
Bubble Temperature:
60 | P a g e
Σ kixi= 1 Temperature= 44.75 ℃
Dew Temperature:
Σ yi/ki= 1 Temperature= 46 ℃
𝑩𝑩
𝑳𝑳𝑳𝑳𝑳𝑳 𝑷𝑷 = 𝑨𝑨 + + 𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪𝑪 + 𝑫𝑫𝑫𝑫 + 𝑬𝑬𝑻𝑻𝟐𝟐
𝑻𝑻
K-Values:
Pi
Ki =
Pt
Bubble Temperature:
Dew Temperature:
61 | P a g e
7.2.10 Reference Component:
𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = ∑𝑛𝑛𝑖𝑖=1(𝑥𝑥𝑥𝑥 ∗ 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤ℎ𝑡𝑡)=45.39kg/kgmole
𝐇𝐇.𝐤𝐤 𝐇𝐇.𝐤𝐤
𝛂𝛂𝐚𝐚𝐚𝐚𝐚𝐚 = �𝛂𝛂 � � 𝐃𝐃 × 𝛂𝛂 � � 𝐁𝐁
𝐇𝐇.𝐊𝐊 𝐇𝐇.𝐊𝐊
Nmin = 7.28
𝛂𝛂𝐢𝐢𝐢𝐢 ×𝐙𝐙𝐢𝐢
𝟏𝟏 − 𝐪𝐪 = ∑𝐧𝐧𝐢𝐢=𝟏𝟏
𝛂𝛂𝐢𝐢𝐢𝐢 − 𝛗𝛗
φ = 𝟎𝟎. 𝟑𝟑𝟑𝟑𝟑𝟑
n
αij × DxiD
Vmin = �
αij − φ
i=1
62 | P a g e
Lmin = Vmin − D
Lmin = 92.23kgmol/hr
R min = 0.584
𝐑𝐑 =0.788
R − R min
X=
R+1
N − Nmin
Y=
N+1
𝐍𝐍 = 𝟏𝟏𝟏𝟏
7.2.16 Efficiency:
𝛂𝛂𝐋𝐋.𝐊𝐊
𝐄𝐄 = 𝟎𝟎. 𝟒𝟒𝟒𝟒𝟒𝟒 (𝛍𝛍𝐋𝐋 � � 𝐚𝐚𝐚𝐚𝐚𝐚)^ − 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐
𝛂𝛂𝐇𝐇.𝐊𝐊
N= 28
63 | P a g e
𝟐𝟐 𝟎𝟎.𝟐𝟐𝟐𝟐𝟐𝟐
𝐍𝐍𝐑𝐑 𝐙𝐙𝐇𝐇.𝐤𝐤 𝐗𝐗 𝐋𝐋.𝐤𝐤,𝐖𝐖 𝐖𝐖
= �� �×� � × � ��
𝐍𝐍𝐒𝐒 𝐙𝐙𝐋𝐋.𝐤𝐤 𝐗𝐗 𝐇𝐇,𝒌𝒌,𝑫𝑫 𝐃𝐃
N = 28
NR
= 0.258
NS
NR = 21
NS = 7
Ln
R=
D
Ln = R ∗ D
kmol
Ln = 124.2
hr
Vn = Ln + D
kmol
Vn = 281.68
hr
Bottom Section
Lm = Ln + F
kmol
Lm = 299.35
hr
Vm = Lm − W
kmol
Vm = 281.68
hr
64 | P a g e
ρv = 29.42 kg/m3
ṁ m3
Vapour Volumetric flow = = 0.161
ρ sec
kmol
Ln = 124.2
hr
ρL = 461.41 kg/m3
Were,
α = surface tension
𝐋𝐋 𝛒𝛒𝐯𝐯
𝐟𝐟𝐋𝐋𝐋𝐋 = �
𝐕𝐕 𝛒𝛒𝐋𝐋
65 | P a g e
𝐟𝐟𝐋𝐋𝐋𝐋=𝟎𝟎.𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏
Csb= 0.08
α = 4.65 dyne/cm
m
Operating Velocity = 0.058
s
ṁvap
Net Area = An = = 2.35 m2
Operationg Velocity
An
Cross sectional Area = Ac = = 2.76 m2
0.80
4 ∗ Ac 4 ∗ 2.76
D 𝑇𝑇𝑇𝑇𝑇𝑇 = � =� = 1.87m
π π
ρv = 29.42 kg/m3
ṁ m3
Vapour Volumetric flow = = 0.161
ρ sec
kmol
Lm = 299.35
hr
ρL = 990.41 kg/m3
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Were,
Csb= Souders and Brown factor
α = surface tension
ρL= density of liquid
𝐋𝐋 𝛒𝛒𝐯𝐯
𝐟𝐟𝐋𝐋𝐋𝐋 = �
𝐕𝐕 𝛒𝛒𝐋𝐋
fLv=0.1834
Csb= 0.06
α = 8.35 dyne/cm
m
Operating Velocity = 0.107
s
ṁvap
Net Area = An = = 1.505 m2
Operationg Velocity
An
Cross sectional Area = Ac = = 1.77 m2
0.80
67 | P a g e
4 ∗ Ac 4 ∗ 1.77
D𝐵𝐵𝐵𝐵𝐵𝐵 = � =� = 1.502m
π π
H𝑡𝑡 = 14.61 m
Hole diameter 5 mm
Plate thickness 5 mm
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Figure 7.6: Wire length
lw
= 0.763
Dc
lw = 1.434 m
7.2.27 Weeping:
kg
Maximum liquid flowrate = 5.088
s
kg
Minimum liquid flowrate = 3.54177
s
L𝑤𝑤
h𝑜𝑜𝑜𝑜 = 750 ∗ [ ]2/3
𝜌𝜌𝐿𝐿 l𝑤𝑤
Were,
K 2 = 30.3
31 − 0.90(25.4 − 5) m
umin = = 2.21
(29.24) 0.5 s
Trail – 1
0.1134
vactual = = 0.53 < vmin
0.211577
Trail – 2
0.1134
vactual = = 2.6149 > vmin
0.042
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7.2.29 Pressure Drop:
Dry plate drop:
uh max. ρV
hd = 51
C0 ρL
Plate thicknes
=1
Hole Diameter
Ah
∗ 100 = 7.4
Ap
C0= 0.825
Residual Head:
12.5 ∗ 103
Hr = = 12.612 mm liquid
ρL
Total drop:
ht = hd + (hw + how) + hr
∆P𝑡𝑡 = 1.06kPa
N = 28
lwd 2
hdc = 166 � � =14.77 mm liquid
ρLAap
hb = 187.83mm liquid
7.2.33 Entrainment:
𝐔𝐔 𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯𝐯 𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟 𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫
𝐧𝐧=
𝐧𝐧𝐧𝐧𝐧𝐧 𝐚𝐚𝐚𝐚𝐚𝐚𝐚𝐚
Un=0.0762=0.532 m/s
0.143
%Age flooding,
u𝑣𝑣
%age flooding = ∗ 100 = 53.47%
u𝑓𝑓
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f𝐿𝐿𝐿𝐿 = 0.1825
Entrainment = ψ = 0.005
θ = 99°
= 0.12 m2
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Mean length, Calming zone = Weir length + Width of Calming zone
Aℎ 0.0422
Number of holes = = = 2150.9056 holes
Area of one hole 0.000019
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7.2.35 Specification Sheet of Distillation Column:
Table 7-8: Specification sheet of Distillation column
Identification
Item Distillation
No. required 1
Operation Continuous
Function
Separation of Propane from LPG
Design Data
Number of trays 28
Pressure 15 atm
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7.3 Design of Heat Exchanger:
Heat exchanger is a device that is used to transfer heat between two fluids at different
temperature.
Thermal Requirements.
Operation Maintains.
Cost.
Material compatibility.
Environmental, Health and safety consideration.
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7.3.6 Phase of fluid:
Gas-Gas.
Liquid-Liquid.
Gas-liquid.
Obtain the required thermo physical properties of hot and cold fluid at caloric
temperature of streams.
Perform energy balance and find out the heat duty (Q) of the exchanger.
Calculate the LMTD.
Assume overall heat transfer coefficient (u).
Calculate provisional area and number of tubes.
Specify the shell and tube configuration.
Calculate hi and ho.
Calculate the overall heat transfer coefficient (u).
Calculate pressure drop.
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7.3.11 Design Calculation:
LMTD (Log mean temperature difference)
Assume
Q=11902740 KJ/hr
A = 21.56𝑚𝑚2 = 231𝑓𝑓𝑓𝑓 2
Caloric Temperature
tc/th=1.14
kc=0.3
Fc=0.48
Tc=Tout+Fc(T)
Tc =706 K
tc=tout+Fc(T)
tc=761 K
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7.3.14 Tube Specification:
Selecting:
Tube length
L= 18 ft
BWG=16
O.D=0.0254m I.D=0.022m
Clearance = Pt - O.D
C=0.00625 m
Nt=52, n=2
K1 = 0.175 n1 = 2.285
Db = 0.27m
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For triangular pitch
De= 0.019 m
Now
𝐃𝐃𝐞𝐞 ×𝐆𝐆
Re = = 27800
𝛍𝛍
Jh=80
𝟏𝟏
𝑪𝑪𝒑𝒑 × 𝝁𝝁 𝟑𝟑
𝑷𝑷𝒕𝒕 = � �
𝒌𝒌
Pr=0.6
1
k Cp × μ 3
ho = jh � � � � ∅e
D k
𝒉𝒉𝒐𝒐
= 791 kJ/𝒎𝒎𝟐𝟐 hr K
∅𝒆𝒆
Gs =426639.22 kg/𝑚𝑚2 hr
Now
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𝐃𝐃𝐢𝐢 × 𝑮𝑮𝒔𝒔
Re =
𝛍𝛍
Re=32590.4
Jh=95
𝟏𝟏
𝑪𝑪𝒑𝒑 × 𝝁𝝁 𝟑𝟑
𝑷𝑷𝒕𝒕 = � �
𝒌𝒌
Pr=0.8
1
k Cp × μ 3
ho = jh � � � � ∅e
D k
𝒉𝒉𝒐𝒐
= 6865 kJ/𝒎𝒎𝟐𝟐 hr K
∅𝒆𝒆
tw=788 K
µw(shell)=0.000022 kg/ms
µw(tube)=0.00006 kg/ms
𝝁𝝁
∅𝒆𝒆 = ( )𝟎𝟎.𝟏𝟏𝟏𝟏
𝝁𝝁𝒘𝒘
Øe = 0.9
Øi = 1.04
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U = Q/A*T = 323 W/𝑚𝑚2 K
𝒇𝒇𝒇𝒇𝟐𝟐
f = 0.0019
𝒊𝒊𝒊𝒊𝟐𝟐
Gs = 21660.90 lb/𝑓𝑓𝑓𝑓 2 hr
Ds = 0.28m = 0.91 ft
Ps = fGsDs(N+1)/5.22*10^10 De*s*Øs
Ps = 0.0019*21660.90*0.91*587/5.22*10^10*0.019*0.453*0.9
Ps = 0.0229 psi
𝒇𝒇𝒇𝒇𝟐𝟐
f = 0.0001
𝒊𝒊𝒊𝒊𝟐𝟐
Gs = 87720.2 lb/𝑓𝑓𝑓𝑓 2 hr
Di = 0.022m = 0.072 ft
Øt = 1.04
Pt = f*Gs^2*L*n/5.22*10^10*Di*s*Øt
Pt = 0.16 psi
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𝑉𝑉 2
P= = 0.0052
2𝑔𝑔
𝑉𝑉 2
Pr = 4n/s * = 0.16
2𝑔𝑔
83 | P a g e
7.4 Design of Knock out vessel:
7.4.1 Design Methodology: [30]
Find the densities of the liquid and vapor at the given temperatures.
Find flow rates of liquid and vapor streams.
Find vapor velocity using Blackwell’s relation.
Find the area of the column.
Using calculated area find the diameter.
Find the liquid holdup volume.
Find liquid holdup height and subsequently the total height of column.
Pressure (atm) 15 15
(𝝆𝝆(𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍𝒍) − 𝝆𝝆(𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗)
𝑼𝑼𝑼𝑼 = 𝑲𝑲𝑲𝑲�
𝝆𝝆(𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗𝒗)
𝑊𝑊𝑙𝑙 𝜌𝜌(𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣)
𝐹𝐹𝐹𝐹𝐹𝐹 = �
𝑊𝑊𝑣𝑣 𝜌𝜌(𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙)
Where Wl and Wv are the liquid and vapor flow rates in kg/hr.
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𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝑜𝑜𝑜𝑜 𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 = 12.32 𝑘𝑘𝑘𝑘/𝑚𝑚3
378.98 12.32
𝐹𝐹𝐹𝐹𝐹𝐹 = �
16478.97 820.12
A = -1.88774
B = -0.81458
C = -0.18707
D = -0.01425
E = -0.001014
𝐾𝐾𝑙𝑙 =0.1510
16478.97
= 820.12
= 200.9 m3/h or 0.055 m3/s
𝑄𝑄𝑙𝑙 0.55
𝐴𝐴 = = = 0.0457 m2
𝑈𝑈𝑙𝑙 1.22
85 | P a g e
7.4.6 Calculations of Diameter:
Now for diameter we can use the already calculated area
𝜋𝜋𝐷𝐷2
𝐴𝐴 =
4
4A
D=� = 0.24 𝑚𝑚
π
V𝑙𝑙 = 𝑄𝑄𝑙𝑙 × t
Where Ql is the liquid flow rate and t is the holdup time. Suppose a holdup time of 60
seconds.
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Chapter # 8
Process simulation
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8 Process Simulation:
Process simulation is a model-based representation of chemical, physical, biological, and
other technical processes and unit operations in software.
Process simulation is a key activity in Process Engineering covering the whole life cycle of a
process, from Research & Development to conceptual design and plant operation. In this
context, flow sheeting is a systematic description of material and energy streams in a process
plant by means of computer simulation with the scope of designing the plant or understanding
its operation.
We just add components, fluid package, reactions, temperature, and pressure conditions and
then solve.
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8.3 Distillation Simulation:
Steps:
Add components.
Apply fluid package.
Open simulation environment.
Select Feed stream and add the specific properties feed composition, molar flow,
temperature, pressure.
Add Distillation column to model pallet.
Add specific properties of column like number of stages, feed position, and name tags
of other streams.
Add the operating temperature and pressure of distillation column.
Add component fraction set go to the spec summary.
Click run button.
Match results.
8.3.1 Add Components:
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8.3.2 Applying Fluid Package:
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8.3.4 Add Distillation Column and add specific conditions:
8.3.5 Results:
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Chapter # 9
Economic Evaluation of whole Project
92 | P a g e
9 Cost estimation:
The capital needed to supply the necessary plant facilities is called fixed capital investment
while that for the operation of the plant is called the working principal and sum of two Before
the plant to be operated, specified money must be supplied to purchase and install the capitals
is called total capital investment.
It is essential that chemical engineer be aware of the many different types of cost involved in
manufacturing processes. Capital must be allocated for direct plant expenses; such as those
for raw materials, labor, and equipment. Besides direct expenses, many other indirect
expenses are incurred and these must be included if a complete analysis of the total cost is to
be obtained. Some examples of these indirect expenses are administrative salaries, product
distribution costs and cost for interplant communication.
A capital investment is required for any industrial process and, determination of the necessary
investment is an important part of a plant design project. The total investment for any process
consists of fixed capital investment for physical equipment and facilities in the plant plus
working capital, which must be available to pay salaries, keep raw materials and products on
hand, and handle other special items requiring a direct cost outlay. Thus, in an analysis of
cost in industrial processes, capital investment costs, manufacturing cost, and general
expenses, including income taxes must be taken into consideration.
93 | P a g e
Preliminary estimate (budget authorization estimate; scope estimate) based on
sufficient data to permit the estimate to be budgeted; probable accuracy of estimate
within ± 20%.
Definitive estimate (project control estimate). It based on almost complete data but
before completion of drawings and specification, probable accuracy of estimate
within ± 10%.
Detailed estimate (contractor's estimate). It based on complete engineering drawings,
specifications, and site surveys; probable accuracy of estimate within ± 5%.
C = Cr[I/Ir] [S/Sr] n
94 | P a g e
S = capacity of the equipment
So FCI = $2458488.818
WCI = $370273.77
TCI = $2821981.591
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9.7 Direct Cost:
Depreciation = D = (V-Vs)/N
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V = FCI = 2468488.818$
Vs = 0.05* 2468488.818
Vs = 123424.59$
N = No. of years = 15
D = 156337.015$
Total Manufacturing Cost = Fixed Charges + Direct Production Cost + Plant Overhead
= 2065466.243$
= 41242807.605$
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= $117000/day
= $42705000/year
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Chapter # 10
Process Instrumentation and Control
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10 Process Instrumentation and Control:
Instruments are provided to monitor the key process variable during plant operation. They
may be incorporated in automatic control loops or used for manual monitoring of the process
operation. They may also be a part of an automatic computer data logging system.
Instruments monitoring critical process variable will be fitted with automatic alarm to alert
the operator to critical and hazardous situation.
It is desirable that the process variable to be monitored be measured directly, often, however,
this is impractical and some dependent variable that is easier to measure is monitored in its
place. For example, in the control of distillation columns the continuous on line, analysis of
the overhead product is desirable but difficult and expensive to achieve reliably, so
temperature is often monitored as an indication of composition.
The temperature instrument may form part of a control loop controlling, say, reflux flow;
with the composition of the overhead checked frequently by sampling and laboratory.
100 | P a g e
10.3 Pressure Control Scheme:
To maintain the pressure of our Knock out at desired value we use the following control
scheme.
10.3.1 Disturbance:
Variation in the upstream pressure of the knock out vessel can cause the pressure disturbance
in the vessel.
10.4 Description:
This control scheme will work in order to control the pressure of the column in the following
ways:
10.5.1 Disturbance:
Variation in feed flow rate can change liquid level in knock out vessel.
101 | P a g e
10.5.3 Manipulated Variable:
Flow of liquid outlet.
10.6 Description:
In vessel we are providing disengaging space for separation.
When the liquid flow rate is higher in upstream, then it will hold up in the bottom of
the vessel and the liquid level will rise up.
As the liquid level rise up the disengaging space will be minimized.
Minimize in disengaging space will decrease the efficiency of separation.
We have used feedback level controller for this issue.
LT- level transmitter will sense the level of liquid in vessel and transmit the signals to
controller.
Controller will analyze and send command to LV- level valve.
LV is basically a liquid flow control valve; in these manners it will control the level of
in the vessel.
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Chapter # 11
Hazop Study
103 | P a g e
11 HAZOP Study:
HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible hazards
in a work process. HAZOP's meticulous approach is commonly used with chemical
production and piping systems, where miles of pipes and numerous containers can cause
logistical headaches.
The purpose of the HAZOP is to investigate how the system or plant deviate from the design
intent and create risk for personnel and equipment and operability problems. HAZOP studies
have been used with great success within chemical and the petroleum industry to obtain safer,
more efficient and more reliable plants.
A HAZOP study identifies hazards and operability problems. The concept involves
investigating how the plant might deviate from the design intent.
11.1.2 Harm:
Physical injury or damage to the health of people or damage to property or the environment.
11.1.3 Risk:
In simple terms, risk is the possibility of something bad happening. Risk involves uncertainty
about the effects/implications of an activity with respect to something that human’s value,
often focusing on negative, undesirable consequences. Many different definitions have been
proposed.
A HAZOP study encourages the use of “guide words” to help explore all potential deviations.
Here is an example of how the team could use common guide words to explore deviations
involving the input and mixture of RO water:
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11.2 Guide word:
Before Step was performed before it should have in the process sequence
.
After Step was performed after it should have in the process sequence
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11.3 HAZOP study of Heat Exchanger:
Unit:
Heat Exchanger
Parameter:
Flow
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2. Linde, Industrial Gases. 2018.
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promoter. 2006. 7(11): p. 860-866.
22. Komasi, M., et al., Kinetic modelling of propane dehydrogenation over a Pt–Sn/hierarchical
SAPO-34 zeolite catalyst, including catalyst deactivation. 2017. 42(4): p. 344-360.
23. SINNOT, R.K., Chemical Engineerig Design- Coulson & Richardson Volume 6. 2008.
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PRODUCTION IN A PETROCHEMICAL PLANT. 2008. 2: p. H2.
25. Levenspiel, O., Chemical Reaction Engineering, 3rd Edition. 1998.
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