Equipments Designpresentation

Done By:

Amer M. Al-Najdi

Agenda:

Distillation Absorber Heat Exchanger Cooler Air cooler Pump Compressor

Distillations

What is distillation : Distillation is a method used to separate

chemical compounds. It is based on the difference between a liquid mixture and the vapor formed from it. The composition difference of its products depends dissimilar of the volatilities or vapor pressure of the components of the liquid mixture. If such a dissimilar does not exist, then such a separation is not possible.

Distillation

T-105 T-add

T-105

T-add

Design calculations

Assumptions The total column efficiency (around 80%). The tray spacing (0.5 or 0.65 m). The flooding percentage (85%). The down comer area. The hole area is about (0.1 to 0.2) of the active area. The weir height is about (40 to 100) mm. The hole diameter is about 1 to 10 mm. The plate thickness is about 10 to 30 mm. The turn down percent is about 70 to 90 %. The unperforated strip round plate edge is about 50 mm. The wide calming zone is about 50 mm.

Calculation Procedure: Properties

The actual number of trays

Column diameter

o

hysysstagesal

hysysstages

o

E

NN

Nad

EAssume

1

Re

/Re

/

DMAXTakeD

AreaD

Downcomeru

RateFlowVolumetricArea

MwtmoleFlowRateFlowVolumetric

uFloodingu

Ku

KKCorrection

FSpacingPlatefKKFind

V

LF

bottomTopiV

Lad

c

i

i

f

ii

iv

iii

ff

iv

vLf

i

LV

iL

v

iLV

i

i

MAXii

iMAXi

ii

i

i

4

%

__

__

%

20

,;

,;Re

1

2.0

11

11

Liquid flow pattern

Provisional Plate design

Checking Weeping

liquid

MAX

MwtMoleflowFlowVolumertic

wc

w

c

d

ah

dca

dcn

cd

cc

lFindD

ladA

AFigad

holeAholeAreaA

AAActiveAreaA

AANetAreaA

DowmComerAreaDownComerAA

DA

Re31.11.Re

%

2

%

25.0 2

h

VAPORvapor

v

hh

wowMIN

wL

MINowMIN

wL

MAXMAXow

MAXMIN

MAX

h

w

A

FlowVolumetricTurnDownu

DKu

KadFig

hhFIND

l

LiquidRateh

l

LiquidRateh

LiquidRateTurndownLiquidRate

MoleFlowMwtLiquidRate

nessPlateThich

rHoleDiamteD

hWeirHeight

ASSUME

%

4.259.0

Re30.11.

750

750

%

:

:

2

2

Calculation Procedure

Down comer back up

Residence time

Entrainment

2:

;;166

10

w

owMAXdctb

apdmmL

wddc

wapap

wap

hngPlateSpaciFind

hhwhhh

AAMINAA

Lh

lhA

hh

wd

Lbcdr L

hAt

29.11.

%

FigFfFind

u

uFlooding

A

flowRateVolumetricu

LV

fMAX

v

nv

Perforated Area

Number of holes

Estimating thickness & cost

33.11.

min

minmin2min

2min

180

180

32.11.

Figdl

FindAAFind

gZoneAreaCaloratedEdgeAreaUnperfAATotalArea

gZoneWideCagcalMeanLengthgZoneAreaCal

SINeedPlateEdgUnperforatDgcalMeanLength

eedPlateEdgUnperforatMeanLengthoratedEdgeAreaUnperf

endedAngleSubtreedPlateEdgUnperforatDMeanLength

endedAngleSubtr

FigDlfFind

h

p

p

h

ap

cc

c

c

c

wc

oleAreaOfOneH

A

DoleAreaOfOneH

hholes

h

#

25.0 2

cj

j

j

CPSE

t

Dr

6.0

Pr2

inout

outout

out

inin

in

MMweight

VM

HAV

tDA

VM

HDV

traysSpacingTrayH

2

2

*2

2#_

Equipment NameDistillation column

Equipment NumberT-105

DesignerAmer Al-Najdi

TypeTray column

LocationPO productionSecond section

Material of ConstructionCarbon steel

Insulationfoam wool

Cost ($) (equipment + insulation)4.73E+05$

Column Flow Rates

Feed (kgmole/hr)716.1Recycle (kgmole/hr)2254

Distillate (kgmole/hr)292.4Bottoms (kgmole/hr)351.2

Key Components

LightPOHeavyEBperoxid

Dimensions

Diameter (m)5.2999Height (m)28.55

Number of Trays59Reflux Ratio3.2

Tray Spacing0.45Type of traySieve tray

Number of Holes202.242135Number of Caps/Holes202.242135

Cost( $)

Vessel1.7x105Trays4500

Condenser Unit2350Reboiler2300

Equipment NameDistillation column

ObjectivePurification of styrene

Equipment NumberT-add

DesignerAmer Al-Najdi

TypeTray column

LocationStyrene production section

Material of ConstructionCarbon steel

Insulationfoam wool

Cost ($) (equipment + insulation)2.07E+05$

Column Flow Rates

Feed (kgmole/hr)555.1Recycle (kgmole/hr)5608

499.4292.4Bottoms (kgmole/hr)55.782

Key Components

LightstyreneHeavyACP

Dimensions

Diameter (m)5.4189Height (m)9.2

Number of Trays12Reflux Ratio5

Tray Spacing0.6Type of traySieve tray

Number of Holes4463.53Number of Caps/Holes4463.53

Cost( $)

Vessel1.2x105Trays5500

Condenser Unit4300Reboiler2100

stripper

stripper is a mass transfer operation in which a soluble gaseous component is removed from a gas stream by dissolving in a liquid.

stripper can be used to recover valuable gaseous components such as hydrocarbons or to remove unwanted gaseous components such as hydrogen sulfide from a steam. Liquid and recovered in a pure, concentrated from by distillation or stripping (desertion).

stripper

Abs.(T-100)

-DESIGN PROCEDURES:

Specify the properties of outlets streams Calculate the maximum liquid and vapor outlet flow rate. FLV = ( LW/VW)*( ρv / ρL)^. Choose tray spacing and then determine K1 and K2 Calculate correction factor for Bottom K1 and Top K1. K1correction = (σ/0.02)*K1 Design for X% flooding at maximum flow rate for top and bottom part of distillation. uf= K1 ((ρL- ρv)/ ρv) 0.5 (bottom) uf= K2 ((ρL- ρv)/ ρv) 0.5(Top) uv = uf*x Calculate the maximum flow rates of liquid. Max liquid flow-rate = (Lw*Mwt / ρL*3600) Calculate Net area required. Anet = Mmax/uv Take down comer area as %Y of the total column cross sectional area. Ad = An/(1-y*10^-2) Calculate the column diameter. D = Ad/(4/3.14)

.

Calculate the column height using the actual number of stage.

Actual number of stages = (hysys number stages/η)

Calculate column area, down comer area, active area, net area, hole area and weir length. H= (Tray spacing * actual NO. stage ) + D Calculate the actual min vapor velocity. MVL = (Lbottom*Mwt)/(3600* ρL) Calculate Back-up in down comer. Check residence time.tr =

Percent flooding=

Calculate number of holes. Area of one hole = (π/4)*(5E-03)2, m2 Total number of holes = Ah / 1.964E-05 Holes on one plate = total Number of holes/Area of one

Calculate Thickness of the Absorber Thickness = [(ri P)/(Ej S-0.6P)]+Cc

flowmassliquid

ρhA Lbδ

f

vu

u

Spec sheetEquipment Namestripper column

ObjectiveRecover EB from reactor gases & recycle it back

Equipment NumberT-100

DesignerAmer Al-Najdi

TypeTray stripper

LocationEB oxidation section

First section

Material of ConstructionCarbon steel

InsulationFoam wool

Cost ($) (equipment + insulation)22.4E+05$

Operating Condition

Operating Temperature (oC)115Feed Flow Rate (Kmole/hr)3028

Operating Pressure (psia)45Steam Flow Rate (Kmole/hr)2.84x104

Feed Flow Rate (mole/s)8744Inert Typesteam

Diameter (m)4.81Number of Beds5

Height (m)5.5Height of Bed/s (m)5.5

Thickness (m)0.02416Volume of Inert (m3)2.84x104

Heat Exchanger

What is Heat Exchanger ? Heat exchangers are the

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

Heat Exchanger

E-108

propene

Propene&PO

Calculation procedure Define the duty

Collect together the fluid physical properties required

Select a trail value for the overall coefficient, U.

Calculate the mean temperature difference, ΔTm.

Calculate the area required from Q=UAΔTm.

Decide the exchanger layout.

Calculate the individual coefficients.

Calculate the overall coefficient and compare with the trail value

calculated value differs significantly from the estimated value

calculated for the estimated value and return to step f.

Calculate the exchanger pressure

Calculations procedure and equations

heat Load:

Log mean

temperature:

hotphotcoldpcold TcMTcMQ

lmtm

lm

TFT

tT

ttS

tt

TTR

tTtT

tTtTT

11

12

12

21

12

21

1221

;

ln

Heat transfer Area :

Number of tubes

mTU

QA

DensityPassArea

FlowRateuvelocity

areatoncrossPasstubespassArea

dareaSectioncross

sesAssumedPas

tubesPassTubes

ubeareaOfOneT

totalAreatubes

LdubeAreaOfOneT

t

i

o

*/

sec//

25.0

#/

#

**25.0

2

2

Bundle and shell diameter :

Tube side heat transfer coefficient

10.12.Re

.,; 11

1

1

1

FigadingDD

PassesNofnKK

NdD

bs

nt

ob

i

fi

ih

wh

pit

d

kNuh

d

LfjjNu

k

cdu

)(;PrRe

Pr;Re

14.033.0

e

fs

hw

h

pes

oto

e

ss

t

Bsots

ot

d

kNuh

cutbufflefjjNu

k

cdu

dpd

d

A

FlowRateu

p

lDdpA

dp

_Re,;PrRe

Pr;Re

917.01.1

25.1

14.033.0

22

• Shell side heat transfer coefficient

Overall coefficient

Tube Side pressure Drop

Shell side pressure drop

ii

o

w

i

oo

oo hd

d

k

ddd

hU

1

2

ln11

25.28

2t

m

wifpt

u

d

LjNP

28

214.0

s

wBe

sfs

u

l

L

d

DjP

Estimating thickness :

cj

j

j

CPSE

t

Dr

6.0

Pr2

Spec sheetEquipment NameHeat exchanger

ObjectiveDecrease Temperature of liquid effluent of CRV-101 Increase

Temperature of recycled propylene

Equipment NumberE-108

DesignerAmer Al-Najdi

TypeShell and tube

LocationPO production section

Material of ConstructionCarbon steel

InsulationFoam glass

Cost ($) (equipment + insulation)1.08E+04$

Operating Condition

Shell Side

Inlet temperature (oC)

57.84Outlet temperature (oC)70.17

Tube Side

Inlet temperature (oC)115Outlet temperature (oC)105

Number of Tube Rows4Number of Tubes167

Tube bundle Diameter (m)2.599Shell Diameter (m)2.687

Q total (W)5.27E+05LMTD (C)45.065

U (W/m2.C)150Heat Exchanger Area (m2)78

coolers

E-114

E-104-2

Spec sheetEquipment NameHeat exchanger

ObjectiveDecrease Temperature of stream fed to T-103-2

Equipment NumberE-104-2

DesignerAmer Al-Najdi

TypeShell and tube

LocationStyrene production section

UtilityCooling water

Material of ConstructionCarbon steel

InsulationFoam wool

Cost ($) (equipment+ insulation)1.78E+04

Operating Condition

Shell Side

Inlet temperature (oC)25Outlet temperature (oC)50

Tube Side

Inlet temperature (oC)120Outlet temperature (oC)106

Number of Tube Rows6Number of Tubes1555

Tube bundle Diameter (m)3.86Shell Diameter (m)3.94

Q total (W)2.19E+05LMTD (oC)74.61

U (W/C.m2)23Heat Exchanger Area (m2)127.66

Spec sheetEquipment NameHeat exchanger

ObjectiveDecrease Temperature of hydrogen feed

Equipment NumberE-114

DesignerAmer Al-Najdi

TypeShell and tube

LocationStyrene production section

UtilityCooling water

Material of ConstructionCarbon steel

InsulationFoam wool

Cost ($) (equipment + insulation)3.35E+03$

Operating Condition

Shell Side

Inlet temperature (oC)25Outlet temperature

(oC)50

Tube Side

Inlet temperature (oC)470.1Outlet temperature

(oC)149

Number of Tube Rows6Number of Tubes89

Tube bundle Diameter (m)1.219Shell Diameter (m)1.297

Q total (W)1.82E+05LMTD (oC)237.8

U (W/C.m2)100Heat Exchanger

Area (m2)7.66

Air cooler

What is air cooler? Air coolers are devices to

reject heat from a process fluid directly to ambient air.

Procedure for calculation of Air Coolers

calculate the heat duty Q= m Cp ΔT

calculate the LMTD Δtm=((Ue+1)/10)*((Δtm/2)-t1))

calculate the extended surface area Ae=Q/UeΔtm calculate # of tubes

Nt=Ae/Af*L

Procedure for calculation of Air Coolers

calculate the mass flow of tube G=( lbs/ (hr of tube side fluid * Np * 144) )/(Nt *At *3600)

calculate Reynolds number for tube side Re=di*G/µ

calculate the inside film coefficient hi= K/D*((C µ/K)^(1/3))*(( µ/ µw)^.14). Ф(DG/Z)

calculate the weight of the air weight =Q/(Cair*Δt air)

calculate mass velocity of the air Ga =(lb per hr of air flow)/(Af)

calculate overall heat transfer coefficient 1/Uo=(1+(rt*Ft)+rw+1)/At)

calculate required fan area Fan area = (0.4 * Face area Af)/(Assumed no. of fans)

calculate the pressure drop ΔP= ΔPa * #of rows/ Dr

calculate horse power Hydraulic HP = ( ACFM * Density of air * Diff head in ft)/33000 Diff head = (Total ΔP @ fan in ins H2O *5.193)/Density Bhp = Hydraulic HP/ η

Spec sheetEquipment NameHeat exchanger

ObjectiveDecrease Temperature of vent gas

Equipment NumberE-100

DesignerAmer Al-Najdi

TypeAir cooler

LocationEB oxidation section

First section

Material of ConstructionCarbon steel

InsulationFoam glass

Cost ($) (equipment + insulation)5.72E+04$

Operating Condition

Shell Side

Inlet temperature (oF)90Outlet

temperature (oF)

158

Tube Side

Inlet temperature (oC)173.5Outlet

temperature (oC)

49

Number of Tube Rows-Number of

Tubes-

Tube bundle Diameter (m)-Shell

Diameter (m)

-

Q total (Btu/hr)22085627LMTD (oF)154.35

U (Btu/hr. oF . ft2)72.05564Heat

Exchanger Area (ft2)

19.73627

pump

What is pump?

It is a device that convert energy of a prime mover (a electric motor or turbine) first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped

pumps

P-107P-102

Design (centrifugal pump )

Actual Head of pump

Water Horse Power

Overall Efficiency

BHP

WHP

550a

f

QhP

g

ppha

12

Spec sheetEquipment NamePump

ObjectiveIncrease pressure of EBHP fed to CRV-

101

Equipment Numberp-102

DesignerAmer Al-Najdi

TypeCentrifuge pump

LocationEB oxidation section

First section

Material of ConstructionCarbon steel

InsulationFoam wool

Cost (equipment + insulation)25164$

Operating Condition

Inlet Temperature (oC)97Outlet

Temperature (oC)

97

Inlet Pressure (psia)1.09Outlet

Pressure (psia)

320

Efficiency(%) 17Power (Hp)

115.8

Spec sheetEquipment Namepump

ObjectiveIncrease pressure of ACP & MBA

fed to CRV-100-2

Equipment NumberP-107

DesignerAmer Al-Najdi

TypeCentofugal pump

LocationPO production section

Second section

Material of ConstructionCarbon steel

InsulationFoam wool

Cost5076$

Operating Condition

Inlet Temperature (oC)152.38Outlet

Temperature (oC)

152.4

Inlet Pressure (psia)3.86Outlet

Pressure (psia)

20

Efficiency(%) 0.5Power (Hp)3.057

compressor

What is compressor?

A gas compressor is a mechanical device that increases the pressure of a gas by reducing

its volume

compressor

K-100-2

Design equations

Finding outlet pressure

Power in (ft.Ibf/Ibm)

)1)1

2((11

1/)1(

kk

P

PvP

k

kpower

)1)1

2((1

1

10*03.3 /)1(1

5

kkfm P

PqP

k

kHP

)1/()1

2(

1

2 kk

T

T

P

P

Spec sheet Equipment Namecompressor

ObjectiveIncrease Pressure of hydrogen fed to CRV-101-2

Equipment Numberk-100-2

DesignerAmer Al-Najdi

Typereciprocating Compressor

LocationStyrene production section

Material of ConstructionCarbon steel

InsulationFoam wool

Cost (equipment + insulation)13230$

Operating Condition

Inlet Temperature (oC)25

Outlet Temperature (oC)

470

Inlet Pressure (psia)14.7

Outlet Pressu

re (psia)

200

Efficiency(%) 75Power (Hp)

14.44

Thank you