Equipments Design PO/Styrene Plant
description
Transcript of Equipments Design PO/Styrene Plant
Equipments DesignPO/Styrene Plant
Done By:
Salem Alkanaimsh
Prof. M. FahimEng. Yousef Ismael
Agenda
Reactor Design. Heat Exchangers Design. Distillation Columns Design. Pumps Design. Compressors Design.
Reactor Design
Chemical reactors are the heart of chemical processes.
Reactors can be divided into:
1. Batch reactors.
2. Continues reactors. CSTR. PFTR. Example: Petroleum Refinery.
ktAA eCtC
o
nnAAA tkCnCtC
oo
11
111
Reactor Design
A
AAo
r
FFV
Finding The rate equation:
xkCkCr
xF
kr
F
oAAA
o
AoA
o
oo
1
1
Design Equation
Reactor Design
LrrArea
DV
D
LAssume
LDV
2
4
25.0
3
2
Diameter and length of reactor
cj
j
j
CPSE
t
Dr
6.0
Pr2
Thickness of Reactor
Where;t: thickness of reactor.
P: internal pressure. ri: radius of the vessel.
Ej: joint efficiency. S: stress of carbon steal. Cc: corrosion allowance
Equipment NameReactor
ObjectiveOxidation Of Ethyl Benzene.
Equipment NumberCRV-100
DesignerEng. Salem Alkanaimsh
TypeCSTR Reactor
LocationEthyl benzene oxidation section
Material of ConstructionCarbon Steel
InsulationFoam Glass
Cost851796 Operating Condition
Operating Temperature (oC)190Volume of Reactor (m3)784.376
Operating Pressure (psia)50Catalyst Type-
Feed Flow Rate (mole/s)2226 Catalyst Density (Kg/m3)-
Conversion(%) 1.908Catalyst Diameter (m)-
Weight of Catalyst (Kg)-Reactor Height (m)25.195
Number of Beds-Reactor Diameter (m)6.29875
Height of Bed/s (m)-Reactor Thickness (m)0.085
Height of Reactor (m)25.195Cost($) 851796
Heat Exchanger Design
Definition. Service.
1. Exchanger.
2. Condenser.
3. Heater. Type.
1. Shell and tube.
2. Air cooled HX.
Shell and Tube HX
1. Tubes. Pattern of Tubes.
2. Shell and nozzle.
3. Baffles.
Shell & Tube Heat Exchanger Design.
Assumptions: 1. Shell and tube heat exchanger counter flow is used because it is more efficient than the
parallel flow.2. The value of the overall heat transfer coefficient was assumed based on the fluid
assigned in both sides.
3. The outer, the inner diameter , the length of the tube, and the number of passes were assumed.
For a good design :
1. The assumed overall heat coefficient has to be equaled to the calculated overall heat transfer coefficient.,
2. The pressure drop in the tube side has to be lower than 1 bar.3. The pressure drop in the shell side has to be lower than 1 bar.
Shell & Tube Heat Exchanger Design.
Heat Load Log mean Temperature
Where;T1 is temperature of inlet hot stream.
(oC)T2 is the temperature of outlet hot
stream. (oC). t1 is the temperature of inlet cold
stream. (oC).t2 is the temperature of outlet cold
stream. (oC).
hotphotcoldpcold TcMTcMQ
lmtm
lm
TFT
tT
ttS
tt
TTR
tTtT
tTtTT
11
12
12
21
12
21
1221
;
ln
Shell & Tube Heat Exchanger
Heat Transfer Area
mTU
QA
DensityPassArea
FlowRateuvelocity
areatoncrossPasstubespassArea
dareaSectioncross
sesAssumedPas
tubesPassTubes
ubeareaOfOneT
totalAreatubes
LdubeAreaOfOneT
t
i
o
*/
sec//
25.0
#/
#
**25.0
2
2
Number of tubes
10.12.Re
.,; 11
1
1
1
FigadingDD
PassesNofnKK
NdD
bs
nt
ob
Shell and Bundle diameter
Where; Nt is the number of tubes .
K1, n1 are constants .Db is the bundle diameter (mm) Ds is the shell diameter. (mm)
Shell & tube heat exchanger Design
i
fi
ih
wh
pit
d
kNuh
d
LfjjNu
k
cdu
)(;PrRe
Pr;Re
14.033.0
Tube Side Heat Transfer Coefficient
Where is the density of fluid (kg/m3).
is the thermal conductivity (W/m.C).is specific heat (kJ/kg.k).
Re is the Reynolds number.Pr is the Prandtl number.Nu is the Nusselt number.
is the convective heat transfer coefficient (W/m2.C).
k
pc
e
fs
hw
h
pes
oto
e
ss
t
Bsots
ot
d
kNuh
cutbufflefjjNu
k
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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
Where ;.pt is the tube pitch (mm).
.lB is the baffle spacing (mm).As is the cross flow area (m2)
us is the velocity (m/s).de is the equivalent diameter for triangular arrangement
(mm).jh is the heat transfer factor
hs is the convective heat transfer coefficient (W/m2.C).
Shell & Tube Heat Exchanger Design .
ii
o
w
i
oo
oo hd
d
k
ddd
hU
1
2
ln11
Overall Heat Transfer coefficient
Tube side pressure Drop
25.28
2t
m
wifpt
u
d
LjNP
28
214.0
s
wBe
sfs
u
l
L
d
DjP
Shell Side Pressure Drop
cj
j
j
CPSE
t
Dr
6.0
Pr2
Thickness
Where; D is the shell diameter in m Rj is internal radius in (in) .
P is the operating pressure in psi S is the working stress (psi) .
E is the joint efficiency
Equipment NameHeater
ObjectiveIncrease Temperature of liquid effluent of CRV-100
Equipment NumberE-102
DesignerEng. Salem Alkanaimsh
TypeShell & tube .
LocationOxidation of EB section
UtilityLow pressure Steam
Material of ConstructionCarbon steel
InsulationFoam Glass
Cost)$( 17000 $
Operating Condition
Shell Side
Inlet temperature (oC)158.79Outlet
temperature (oC)
158.79
Tube Side
Inlet temperature (oC)80Outlet
temperature (oC)
97
Number of Tube Rows6Number of
Tubes347
Tube bundle Diameter (m)0.03Shell Diameter
(m)3
Q total (Btu/hr)16958400LMTD (oC)69.94
U (Btu/hr. oF . ft2)101.8965Heat
Exchanger Area (m2)
114.8
Equipment NameHeater
ObjectiveIncrease Temperature of liquid effluent of CRV-100
Equipment NumberE-104
DesignerEng. Salem Alkanaimsh
TypeShell & tube .
LocationOxidation of EB section
UtilityLow pressure Steam
Material of ConstructionCarbon steel
InsulationFoam Glass
Cost)$( 85000
Operating Condition
Shell Side
Inlet temperature (oC)158.79Outlet
temperature (oC)
158.79
Tube Side
Inlet temperature (oC)94.89Outlet
temperature (oC)
141
Number of Tube Rows6Number of
Tubes5730
Tube bundle Diameter (m)0.03Shell Diameter
(m)8.3
Q total (Btu/hr)43334350LMTD (oC)36
U (Btu/hr. oF . ft2)31.1307Heat Exchanger
Area (m2)1758
Equipment NameHeater
ObjectiveIncrease Temperature of EB fed to T-100
Equipment NumberE-105
DesignerEng. Salem Alkanaimsh
TypeShell & tube .
LocationOxidation of EB section
UtilityLow pressure Steam
Material of ConstructionStainless Steel
InsulationFoam Glass
Cost)$( 8000
Operating Condition
Shell Side
Inlet temperature (oC)158.79Outlet
temperature (oC)
158.79
Tube Side
Inlet temperature (oC)25.128Outlet
temperature (oC)
40
Number of Tube Rows4Number of Tubes
3149
Tube bundle Diameter (m)0.07Shell
Diameter (m)
1.45
Q total (Btu/hr)7984440.5LMTD
(oC)126
U (Btu/hr. oF . ft2)130.581
Heat Exchanger Area
(m2)
24.728
Equipment NameCooler
ObjectiveDecrease Temperature of recycle EB
Equipment NumberE-116
DesignerEng. Salem Alkanimsh
TypeShell & Tube
LocationEB oxidation
UtilityCooling water
Material of ConstructionStainless Steel
InsulationFoam Glass
Cost)$( 15000
Operating Condition
Shell Side
Inlet temperature (oC)196.4Outlet
temperature (oC)
186.78
Tube Side
Inlet temperature (oC)25Outlet
temperature (oC)
30
Number of Tube Rows8Number
of Tubes
3354
Tube bundle Diameter (m)0.07Shell
Diameter (m)
2.5
Q total (Btu/hr)5015866.5LMTD
(oC)162.44
U (Btu/hr. oF . ft2)17.73
Heat Exchanger Area
(m2)
90.35
Distillation column
A separation unit based on the difference between a liquid mixture and the vapor formed from it.
It can be subdivided according to:
1. How complex the unit is: Simple Distillation. Flash distillation. Fractionation.
2. The internal Design of the column: Tray Column. Packing Column.
Distillation Column Design . Assumptions:1. Column Efficiency.
2. Tray spacing.
3. Flooding Percentage.
4. Down Comer Area.
5. Hole area) 0.1 of Active area(.
6. Weir height ) 40~100(mm.
7. Hole diameter )10 mm(.
8. Plate Thickness )10~30 mm(.
9. Turn down Percentage )70%(
Good Design:1. No weeping.
2. Down comer back up is less than half ) plate thickness+ weir height(.
3. No entrainment.
4. Calculated percentage flooding equal to the assumed one.
5. Residence time exceeds 3 secs.
Distillation Column Design .Actual Number of trays
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
Column Diameter
Where; FLV is the vapor-liquid flow factor .
is the density in (kg/m3). is the surface tension in
(mN/m) . uf is the velocity of vapor in
(m/s) . D is the column diameter (m).
Distillation Column Design
liquid
MAX
MwtMoleflowFlowVolumertic
Liquid Flow Pattern
wc
w
c
d
ah
dca
dcn
cd
cc
lFindD
ladA
AFigad
holeAholeAreaA
AAActiveAreaA
AANetAreaA
DowmComerAreaDownComerAA
DA
Re31.11.Re
%
2
%
25.0 2
Provisional Plate design
Distillation Column Design Checking Weeping
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
2:
;;166
10
w
owMAXdctb
apdmmL
wddc
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wap
hngPlateSpaciFind
hhwhhh
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Lh
lhA
hh
Down Comer Back up
Residence time
wd
Lbcdr L
hAt
Distillation column design
Entrainment
29.11.
%
FigFfFind
u
uFlooding
A
flowRateVolumetricu
LV
fMAX
v
nv
Number of holes
oleAreaOfOneH
A
DoleAreaOfOneH
hholes
h
#
25.0 2
Estimating the Thickness
cj
j
j
CPSE
t
Dr
6.0
Pr2
Cost
inout
outout
out
inin
in
MMweight
VM
HAV
tDA
VM
HDV
traysSpacingTrayH
2
2
*2
2#_
Equipment NameDistillation Column
ObjectiveSeparates the Final product (PO)
Equipment NumberT-104
DesignerEng. Salem Alkanimsh
TypeSieve Tray distillation column
LocationEpoxidation of Propylene section
Material of ConstructionCarbon Steel
Insulation
Cost)$( 216,000
Column Flow Rates
Feed (kgmole/hr)852.6Recycle
(kgmole/hr)4372
Distillate (kgmole/hr)411.1Bottoms
(kgmole/hr)441.5
Key Components
LightPOHeavyEthyl bezene
Dimensions
Diameter (m)4.37Height (m)29
Number of Trays30Reflux Ratio10
Tray Spacing (m) 0.9Type of traySieve
Number of Holes91248Number of Caps/Holes
Cost
Vessel180000$ Trays36000$
Condenser Unit2500 $ Reboiler10000
Equipment NameDistillation column
ObjectiveSeparates Styrene from H2O.
Equipment Number2nd dis .
DesignerEng. Salem Alkanaimsh
TypeTray Distillation column
LocationStyrene Production section
Material of ConstructionStainless Steel
InsulationFoam Glass
Cost)$( 186500
Column Flow Rates
Feed (kgmole/hr)566.9Recycle
(kgmole/hr)399.2
Distillate (kgmole/hr)11.74Bottoms
(kgmole/hr)555.2
Key Components
LightWaterHeavyStyrene
Dimensions
Diameter (m)2.183Height (m)12
Number of Trays11Reflux Ratio34
Tray Spacing0.9Type of traySieve
Number of Holes142988Number of Caps/Holes
Cost
Vessel170000 $ Trays16500$
Condenser Unit2300$ Reboiler 6500 $
Pump Design
Definition. Suction Calculations. Discharge Calculations. NPSH.
Pump Design .
Actual Head of pump
12 pp
ha
550a
f
QhP
Water horse Power
BHP
WHP
Efficiency
Equipment NamePump
ObjectiveIncrease pressure of EB Feed to CRV-100 & T-100
Equipment NumberP-100
DesignerEng. Salem Alkanaimsh
TypeCentrifugal Pump
LocationEB oxidation section
Material of ConstructionStainless Steel
Insulation
Cost20000 $
Operating Condition
Inlet Temperature (oC)25Outlet
Temperature (oC)25.09
Inlet Pressure (psia)14.7Outlet Pressure
(psia)50
Efficiency(%) 75Power (Hp)343
Equipment NamePump
ObjectiveIncrease pressure of EB recycled in 1st section
Equipment NumberP-101
DesignerEng. Salem Alkanaimsh
TypeCentrifugal Pump
LocationEB oxidation section
Material of ConstructionCarbon Steel
Insulation
Cost20,000$
Operating Condition
Inlet Temperature (oC)50.11Outlet Temperature
(oC)50.15
Inlet Pressure (psia)1.094Outlet Pressure (psia)14.7
Efficiency(%) 27Power (Hp)123
Compressor Design
Definition. Types: 1. Centrifugal.
2. Axial.
3. Reciprocating. Compression: 1. Adiabatic.
2. Isothermal. Intercooler stage Pressure Ratio (PR).
Reduce temperature and work required.
Compressors Design .
1
1
2
1
2
k
k
T
T
p
p
Work
11
503.3
1
1
211
k
k
p
pqp
k
kehp
Efficiency =0.8 Isentropic Compression
Equipment NameCompressor
ObjectiveIncrease Pressure of air fed to CRV-100
Equipment NumberK-100
DesignerEng. Salem Alkanimsh
Typereciprocating Compressor
LocationOxidation of EB .
Material of ConstructionStainless Steel
Insulation
Cost100000$
Operating Condition
Inlet Temperature (oC)25Outlet Temperature
(oC)50
Inlet Pressure (psia)14.7Outlet Pressure
(psia)188.2
Efficiency(%) 80Power (Hp)3980
Equipment NameCompressor
ObjectiveIncrease Pressure of outlet of V-104
Equipment NumberK-101
DesignerEng. Salem Alkanimsh
Typerecirocating Compressor
LocationOxidation of EB .
Material of ConstructionCarbon Steel
Insulation
Cost202270$
Operating Condition
Inlet Temperature (oC)97Outlet Temperature (oC)97
Inlet Pressure (psia)1.094Outlet Pressure (psia)3.094
Efficiency(%) 80Power (Hp)5150