Equipments Design presentation Done By: Amer M. Al-Najdi.
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Transcript of Equipments Design presentation Done By: Amer M. Al-Najdi.
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