CHEMICAL ENGINERING DEPARTMENTS4 NATIONAL DIPLOMACHEMICAL PROCESSES DESIGN PRINCIPLESCPD3111MAIN PROJECT

Ntsako Jason Maluleke 201209457Xitsunduxo Gladwin Nukeri201125145Bongani Abel Mkansi201220511

November 3, 2014Md. Tyson Makua (P.hd)East Coast Developments 85 HARRISON, JOHANNESBURG 2001Subject:Submission of production of di-methyl ether (DME)Dear Sir,We are pleased to submit the report that you asked for & gave us the authorization to work on DME production and costs estimations, we tried our best to work on it carefully and sincerely to make the report informative.The study we conducted enhanced our knowledge to make an executive report. This report has given us an exceptional experience that might have immense uses in the future endeavours and I sincerely hope that it would be able to fulfil your expectations.We have put our sincere effort to give this report a presentable shape and make it as informative and precise as possible. We thank you for providing us with this unique opportunity.Sincerely yours,MKANSI BA Signature MALULEKE NJ Signature NUKERI XG Signature

4. AbstractDimethyl ether (DME) is a sustainable substitute for diesel fuel. Its application involves both the chemical and automotive industries. In recent years the global market for DME has increased especially in emerging countries like China. The trend indicates increasing future demands in this project, natural gas (e.g. from biomass) and carbon dioxide (e.g. from power plants) are utilized as raw materials in a dry reforming process to produce syngas. Syngas production is followed by direct DME synthesis, in which conventional methanol synthesis and DME synthesis are integrated into a one-step process over a functional catalyst, resulting in a simplified overall process design. The literature search shows that DME is produced by the catalytic dehydration of methanol over zeolite catalyst, the required methanol is obtained from synthesis gas which is obtained from organic waste. Construction of plant with 50,000 metric-tons/y (50,000,000 kg/y) capacity. The objective of this project is to evaluate and analyse process design, costs and especially with respect to sustainability and environmental impact.

5. Introduction Over the mid-to-long term, energy consumption in the African region is expected to increase substantially during the 21st century. In realizing sustained growth in this region in the future, energy supply and environmental problems associated with mass energy consumption will be major problems. High expectations are placed on dimethyl ether (DME) as a new fuel which can be synthesized from diverse hydrocarbon sources, including natural gas, can be handled as easily as liquefied petroleum gas (LPG), and causes a small load on the environment. Thus, if DME can be produced and distributed at low cost and in large quantities, this fuel can make an important contribution to solving the energy supply problems and environmental problems resulting from expanded energy consumption expected in Asia in the future.

Our plant will be located in Umlwazi (Kwazulu Natal province) where the product will be easily transported even to the other South African countries through ships as Umlwazi is next to the sea. Since production of DME is in high demand we have conducted a survey across, we found out that the best method to use indirect method by dehydration reaction of methanol. While most of the DME is currently produced by the indirect method, technical development of the direct method has been carried out expecting its higher efficiency because the methanol itself is synthesized from the synthesis gas.

Problem statementIntroduction Dimethyl ether (DME) is used primarily as a propellant. It is miscible with most organic solvents and has high solubility with water. Recently, the use of DME as a fuel additive for diesel engines has been investigated due to its high volatility (desirable for cold starting) and high cetane number. As an engineering team, you are asked by the management to design a DME process in order to produce 50,000 metric-tons/y (50,000,000 kg/y). The literature search shows that DME is produced by the catalytic dehydration of methanol over zeolite catalyst. The reaction is as follows: 2CH3OH CH3OCH3 + H2OIn the temperature range of normal operations, there are no side reactions. Process Description Fresh methanol, Stream 1, is combined with recycled reactant, Stream 8, and vaporized prior to being sent to a fixed bed reactor, operating at 350C. The reactor effluent, Stream 4, is then cooled prior to being sent to the first of two distillation columns. DME product is taken overhead from the first column. The second column separates water from the unreacted methanol. The methanol is recycled back to the front end of the process, while the water is sent to waste treatment to remove trace amounts of organic compounds. Tasks 1. Draw the process flow diagram (PFD) with a stream table showing the material balance; 2. Determine the per-pass conversion of methanol assuming that the reactor operates at equilibrium; 3. Size and estimate the purchase cost of the process equipment; 4. Estimate the capital cost using detailed factorial method; 5. Estimate the operating cost; 6. Perform cash-flow analysis and determine the whether the process is economically viable. If yes, determine when the project will break even.

Catalyst and reactor information The process uses a crystalline silicon-aluminum oxide catalyst, called a zeolite. This particular catalyst performs well in the 200C-to-400C range, but deactivates rapidly if heated above 400C. The design will use a single packed bed reactor. Reactor sizing is out scope and will be covered at the BTech level. However, for costing purposes, the reactor will be assumed to account for 25% of the total purchase cost of the equipment.Supplemental Information Feed and Product Prices Methanol $ 0.60 per gallon Dimethyl ether $ 0.43 per pound Utility Costs Low Pressure Steam (618 kPa saturated) $6.62/1000 kg Medium Pressure Steam (1135 kPa saturated) $7.31/1000 kg High Pressure Steam (4237 kPa saturated) $8.65/1000 kg Natural Gas (446 kPa, 25C) $3.00/GJ Fuel Gas $2.75/GJ Use this price for fuel gas credit Electricity $0.06/kW h Boiler Feed Water (at 549 kPa, 90C) $2.54/1000 kg Cooling Water $0.16/GJ Refrigerated Water $1.60/GJ Available at 516 kPa and 10C Return pressure 308 kPa Return temperature is no higher than 20C Deionized Water $1.00/1000 kg Available at 5 bar and 30C Refrigeration $60/GJ

6. Process Flowsheet and Material balances

Overall Mass Balancekmol/hkg/h

InputOutputInputOutput

Methanol260.8120.9828356.9331.477

Water4627.3874757.30183362.36785702.773

Dimethyl Ether0129.91505985.042

Total4888.1984888.19891719.29791719.297

Overall Mass Balancekmol/hkg/h

InputOutputInputOutput

Methanol260.8120.9828356.9331.477

Water4627.3874757.30183362.36785702.773

Dimethyl Ether0129.91505985.042

Total4888.1984888.19891719.29791719.297

7. Process DescriptionAppendix A is a preliminary process flow diagram (PFD) for the dimethyl ether production process. The raw material is methanol, which may be assumed to be pure. The feed is pumped to the mixed where it is mixed with the recycle then passed to the vaporizer where it is heated, vaporized, and superheated and then sent to the reactor in which dimethyl ether (DME) is formed. The reactor effluent is cooled and partially condensed in a heat exchanger, and it is then sent to the first separation section called distillation column. Pure DME is produced in the top stream (distillate), with methanol and water in the bottom stream (bottoms). In the second distillation column the distillate contains methanol for recycle, and the bottoms contains waste water. The desired dimethyl ether production rate is 5985.0415kg/hr.Process DetailsFeed StreamStream 1: methanol, from storage tank at 1 atm and 25C, may be assumed pureEffluent StreamsStream 9: dimethyl ether product, required 5985.0415kg/hr. may be assumed pureStream 10: waste water stream, may be assumed pure in material balance calculations with 2340.4082 kg/hr, and is not pure, so there is a cost for its treatmentEquipmentPump The pump increases the pressure of the feed plus recycle to a minimum of 15 atm.Heat Exchanger 1:This unit heats, vaporizes, and superheats the feed to 153.78C at 42.37 atm. The source of energy for heating must be above 153.78C.Reactor:The following reaction occurs: methanol dimethyl ether 2CH3OH CH3OCH3 + H2O The reaction is equilibrium limited. The conversion per pass is 80% of the equilibrium conversion at the pressure and exit temperature of the reactor. Based on the catalyst and reaction kinetics, the reactor must operate at a minimum of 15 atm. The reactor operates isothermally, and, since the reaction is exothermic, the reactor effluent temperature will be 350C. Heat Exchanger 2:This unit cools and partially condenses the reactor effluent. The valve before this heat exchanger reduces the pressure. This exit pressure may be at any pressure below the reactor pressure, but must be identical to the pressure at which it operates.

Distillation Column 1:This distillation column separates DME from methanol and water. The separation may be assumed to be perfect, i.e., pure DME is produced in the distillate. The temperature of the distillate is the temperature at which DME condenses at the chosen column pressure. Distillation Column 2:This distillation column separates methanol for recycle from water. For this semester only, the separation may be assumed to be perfect. However, since we know this cannot be true in practice, the water stream is actually a waste water stream, and there is a cost for its treatment. The temperature of the distillate is the temperature at which methanol condenses at the chosen column pressure. Other Equipment:For two or more streams to mix, they must be at identical pressures. Pressure reduction may be accomplished by adding a valve. All of these valves are not necessarily shown on the attached flowsheet, and it may be assumed that additional valves can be added as needed at no cost. Flow occurs from higher pressure to lower pressure. Pumps increase the pressure of liquid streams, and compressors increase the pressure of gas streams

8. Energy balance and Utility RequirementsOverall Energy BalanceMJ/h

InputOutput

Feed Streams-6.57E+06

Product Streams-6.57E+06

Total Heating5949.63

Total Cooling-10007.7

Power Added24.5302

Power Generated0

Total-6.57E+06-6.57E+06

Steam

sell/1000 kg 8.60

Flow rate (kg/hr) 6,549.84

Cost ($) 468,766.45

Gibbs Reactor Summary

Equip. No.4

Name

Thermal mode2

Reaction Phase1

Temperature C350

Heat duty MJ/h10864.9102

Overall Heat of Rxn-3123.1519

(MJ/h)

Approach DT C0.01

Electricity

Heat Duty (MJ/h)

Evaporator 11,979.40

Reactor 1,804.03

Condensor 9,628.69

Coloumn 1 -4,244.98

Coloumn 2 -883.48

Total (MJ/hr) 152,156,595.22

Total (KW/hr) 42,265,720.89

Cost ($) 2,535,943.25

Cooling water

Cost ($/GJ) 0.16

Heat Duty (MJ/hr) 9,628.69

Heat Duty (MJ) 80,129,986.47

Heat Duty (GJ) 80,129.99

$ 12,820.80

9. Unit description

Pump The pump increases the pressure of the feed plus recycle to a minimum of 15 atm. For sizing the pump refer to appendix 5 Heat exchanger1 This unit heats, vaporizes, and superheats the feed to 153.78C at 42.37 atm. The source of energy for heating must be above 153.78C. The heating source used is the low pressure steam. For sizing we used chemcad to simulate and get the heat area required (appendix 3) Material of construction we used carbon steel for tube and carbon steel for shell side, carbon steel has the highest value heat transfer coefficient. The feed will take the shell side and the low pressure steam will take the tube side.

Heat exchanger 2(condenser) This unit cools and partially condenses the reactor effluent. The valve before this heat exchanger reduces the pressure. This exit pressure may be at any pressure below the reactor pressure, but must be identical to the pressure at which it operates. Water is used to cool down the temperature of the reactor effluent. For sizing we used chemcad to simulate and get the heat area required (appendix 4) Material of construction we used carbon steel for tube and carbon steel for shell side, carbon steel has the highest value heat transfer coefficient. The reactor effluent will take the tube side and the cooling water will take the shell side.

Distillation column 1 This distillation column separates DME from methanol and water. The separation may be assumed to be perfect, i.e., pure DME is produced in the distillate. The temperature of the distillate is the temperature at which DME condenses at the chosen column pressure. For tray spacing and baffle cuts refer to appendix 2

Distillation column 2 This distillation column separates methanol for recycle from water. For this semester only, the separation may be assumed to be perfect. However, since we know this cannot be true in practice, the water stream is actually a waste water stream, and there is a cost for its treatment. The temperature of the distillate is the temperature at which methanol condenses at the chosen column pressure For tray spacing and baffle cuts refer to appendix 2

Other equipment

For two or more streams to mix, they must be at identical pressures. Pressure reduction may be accomplished by adding a valve. All of these valves are not necessarily shown on the attached flowsheet, and it may be assumed that additional valves can be added as needed at no cost. Flow occurs from higher pressure to lower pressure. Pumps increase the pressure of liquid streams, and compressors increase the pressure of gas streams

10. Specification sheet1. Distillation columnsSCDS Rigorous Distillation Summary

Equip. No.89

Name

No. of stages1320

1st feed stage711

Condenser mode55

Condenser spec129.914748.1452

Cond comp i pos.31

Reboiler mode55

Reboiler spec.48.6315129.9144

Reboiler comp i12

Est. dist. Rate131.729751.2819

(kmol/h)

Est. reflux rate150.75583.4697

(kmol/h)

Est. T top C31.4828112.9309

Est. T bottom C141.5592165.5509

Est. T 2 C32.9164123.6994

Calc cond duty MJ/h-5679.1475-4327.9614

Calc rebr duty MJ/h1434.21064444.4697

Initial flag66

Calc Reflux mole180.227887.6667

(kmol/h)

Calc Reflux ratio1.3821.7258

Calc Reflux mass kg/h8293.28912808.9199

Column diameter m0.91440.6096

Tray space m0.60960.6096

Thickness (top) m0.00480.0032

Thickness (bot) m0.00630.0119

No of sections11

No of passes (S1)11

Weir side width m0.13970.1016

Weir height m0.05080.0508

System factor11

Optimization flag11

Calc. tolerance0.00050.0002

2. Heat exchangersHeat Exchanger Summary

Equip. No.36

Name

1st Stream T Out C135

2nd Stream T Out C22555

1st Stream VF Out1

Calc Ht Duty MJ/h11979.42389628.7148

LMTD (End points) C136.9068187.5326

LMTD Corr Factor11

Utility Option:11

1st Stream Pout atm1515

2nd Stream Pout atm41.26571

3. Pump Pump Summary

Equip. No.1

Name

Output pressure atm17

Efficiency0.7

Calculated power MJ/h24.5302

Calculated Pout atm17

Head m209.3727

Vol. flow rate m3/h10.584

Mass flow rate kg/h8356.9297

NPSH available m10.9108

Cost estimation flag1

Install factor2.8

Basic pump cost $4352

Basic motor cost $690

Total purchase cost $5042

Total installed cost14118

($)

Request NPSH calc1

4. ReactorGibbs Reactor Summary

Equip. No.4

Name

Thermal mode2

Reaction Phase1

Temperature C350

Heat duty MJ/h10864.9102

Overall Heat of Rxn-3123.1519

(MJ/h)

Approach DT C0.01

5. MixerMixer Summary

Equip. No.2

Name

Output Pressure atm15

6. Valve Valve Summary

Equip. No.5

Name

Pressure out atm7

11. Equipment Cost Summary

Summary of Equipment Cost :

Equipment :Cost ($)

Pump18000285

Evaporiser163439.8919

Reactor188515.7

Condensor16343.98919

Valve500

Dist. Coloumn 139,895.95

Dist. Coloumn 216334

Total ($)18425314.53

12. Fixed-Capital Investment Summary

13. Important considerations

Environmental problems The plant emission has been evaluated based on the conceptual design of the plant. The key result is that the plant will abide by all environmental regulations and not discharge any material which is harmful to the environment. Furthermore, by treating the flue gas from the plant, which is currently discharged to the atmosphere, the combined emissions from both plants will be much less, and thus the overall environmental impact is improved. Short half-life in atmosphere.Health and safety DME has been proven to be stable in the presence of LPG under normal storage conditions. Equipment to store, transport, bottle, dispense and use DME are substantially similar to those required for LPG. Significant studies into materials compatibility, and the thermal and chemical properties of such blends in China, Japan and Korea provide clear guidelines for safe handling and use. Waste water is pretreated and remove all materials that can be easily collected from waste water before they damage or clog the pumps. Objects that are commonly removed during pretreatment include trash, tree limbs, leaves and other large objects. On our plant we will use the device known as the American Petroleum Institute oil-water separator which is designed to separate oil and suspended solids from the waste water effluents. Non toxic, non-carcinogenic and Approved as consumer product propellant

14. Operating Cost and Economic Analysis

The fixed capital cost has to be installed over a 3-year period (2014-2016) in steps of 50%, 30% and 20%. Just prior to start-up, 15% of fixed capital is required as working capital. The production cost (excluding capital charges) is estimated as 0.593283616 $/kg and the selling price 1.08 $/kg. The plant capacity of 50,000,000 kg/y is reached in the third year of operation as follows: in the first year the plant operates at 50% capacity, second year at 75% capacity and third year at full capacity. The estimated life of the project is 15 years. The interest rate is 15% and tax of 30%

15. Conclusions and recommendations

DME is a very promising new, multi-purpose fuel, manufactured from methanol. It has many opportunities and many driver are dependent on DME as a fuel and a significant global DME effort has evolved led by Asia. If the DME production is successful it would be the first DME production in AFRICA. DME community has joined forces for advancement of DME

16. Acknowledgement

We would like to thank our tutor Samson for fruitful discussions and guidance during our project. Especially your comments and advice concerning the project writing process was most beneficial. We would also like to thank our fellow classmates and B-Tech students from University Of Johannesburg for useful discussions from time to time. I hope we can continue exchanging research ideas and results. A special thanks goes to Professor Jalama Kalala from University Of Johannesburg of Department of Chemical Engineering for his supervision on our project and for interesting discussions.

17. Bibliography

Perry, R. H. and D. Green, eds., Perrys Chemical Engineering Handbook (7th ed.), McGraw-Hill, New York, 1997. Felder, R. M. and R. W. Rousseau, Elementary Principles of Chemical Processes (3rd ed.),Wiley, New York, 2000 Dimethyl Ether Technology and Markets 07/08-S3 Report, HYPERLINK "http://www.chemsystems.com/reports/search/docs/abstracts/0708S3_abs.pdf"ChemSystemsHYPERLINK "http://www.chemsystems.com/reports/search/docs/abstracts/0708S3_abs.pdf", December 2008. http://www.japantransport.com/conferences/2006/03/dme_detailed_information.pdf, Conference on the Development and Promotion of Environmentally Friendly Heavy Duty Vehicles such as DME Trucks, Washington DC, March 17, 2006 DuPont Talks About its DME Propellant, Aerosol Age, May and June, 1982 Bondiera, J., and C. Naccache, Kinetics of Methanol Dehydration in Dealuminated H-Mordenite: Model with Acid and Base Active Centres, Applied Catalysis, 69,139-148 (1991). T. A. Semelsberger, R. L. Borup, H. L. Greene, "Dimethyl Ether (DME) as an Alternative Fuel," J. Power Sources 156, 497 (2006). C.-J. Yang and R. B. Jackson, "China's Growing Methanol Economy and Its Implications for Energy and the Environment," Energy Policy 41, 878 (2012). Fei JH, Yang MX, Hou ZY, Zheng XM (2004) Effect of the addition of manganese and zinc on the properties of copper-based catalyst for the synthesis Of syngas to dimethyl ether. Energy Fuel 18:1584 Jun KW, Lee HS, Roh HS, Park SE (2003) highly water-enhanced H-ZSM-5 catalysts for dehydration of methanol to dimethyl ether. Bull Korean Chem Soc 24:104 University Of Johannesburg :Chemical Engineering S4, process design notes(2014) Liquid Phase Dimethyl Ether Demonstration in the LaPorte Alternative Fuels Development Unit, DOE Topical Report, Cooperative Agreement No. DE-FC22 92PC90543, January 2001. Hoffmann, M.R., Martin, S.T., Choi, W. and Bahnemann, D.W. (1995) Environmental Applications of Semiconductor Photocatalysis. Chemical Reviews, 95, 69-96. STEPHENSON, R. M. Introduction to the Chemical Process Industries, 1966 (New York: Reinhold Publishing Corporation). J. H. GARVIE, Chem. Proc. Engng, Nov. 1967, pp. 55 65. Synthesis gas manufacture

18. AppendixAppendix A1. Calculation of mass flowrates of DME, methanol and water:Mass Flowrate of DME =6008.17 kg/hr 2CH3OH CH3OCH3 + H2O Mass flowrate of water = =2457.89 kg/hrMass flowrate of methanol = = 8739.16 kg/hr2. Distillation column informationUnit type : SCDS Unit name: Eqp # 8

* Net Flows *

TempPresLiquidVaporFeedsProductDuties

StgCatmkmol/hkmol/hkmol/hkmol/hMJ/h

131.57180.23130.41-5679

232.97164.47310.64

342.87114.84294.88

473.9788.15245.25

592.4785.08218.56

698779.44215.49

7105.97222.33209.86311.61

8109.17221.9841.13

9113.97221.7340.78

10120.37221.8440.53

111277222.3340.64

12132.87222.5741.13

13139741.37181.21434

Mole Reflux ratio1.382

Total liquid entering stage7at105.396C222.404kmol/h.

Unit type : SCDS Unit name: Eqp # 9

* Net Flows *

TempPresLiquidVaporFeedsProductDuties

StgCatmkmol/hkmol/hkmol/hkmol/hMJ/h

1112.8787.6750.8-4328

2123.7789.03138.46

3124.7788.42139.83

4125.4787.54139.22

5126.2786.45138.34

6127.3785.07137.24

7128.7783.36135.87

8130.7781.29134.15

9133.3779132.08

10136.4776.89129.79

11139.67258.1127.69181.2

12140.27257.76127.69

131417256.93127.36

14142.47255.32126.53

15145.47252.89124.92

16150.37250.54122.49

17156.27249.41120.14

181617249.3119.01

19163.77249.45118.9

20164.97119.05130.44444

Mole Reflux ratio1.726

Total liquid entering stage11at138.087C257.988kmol/h.

Heat exchanger 1 (vaporizer)3.1 TABULATED ANALYSIS FOR HEAT EXCHANGER 1

Overall Data:

Area Total (m)19.53% Excess-1.94

Area Required (m)19.15U Calc. (W/m-K)1019.61

Area Effective (m)18.78U Service (W/m-K)1039.74

Area Per Shell (m)18.78Heat Duty (MJ/h)9.63E+03

Weight LMTD C 141.65 LMTD CORR Factor 0.9670 CORR LMTD C 136.98

Shellside Data:

Rho V2 IN kg/m-sec2 2302.40 Press. Drop (Dirty) atm 0.43

Avg. SS Vel. m/sec8.95

Film Coef. (W/m-K)2518.47Calc. Press. Drop (atm)0.25

Allow Press. Drop (atm)0.34Press. Drop/In Nozzle (atm)0.02

Inlet Nozzle Size (m)0.15Press. Drop/Out Nozzle (atm)0

Outlet Nozzle Size (m)0.13Mean Temperature (C)195.45

Rho V2 IN (kg/m-sec)2302.4Press. Drop (Dirty) (atm)0.43

Tubeside Data:

Film Coef. (W/m-K)8704.8

Allow Press. Drop (atm)0.34Calc. Press. Drop (atm)0.27

Inlet Nozzle Size (m)0.15Press. Drop/In Nozzle (atm)0

Outlet Nozzle Size (m)0.15Press. Drop/Out Nozzle (atm)0

Interm. Nozzle Size (m)0Mean Temperature (C)40

Velocity (m/sec)2.1Mean Metal Temperature (C)91.89

Clearance Data:

Baffle (m)0.0063Outer Tube Limit (m)0.2908

Tube Hole (m)0.0008Outer Tube Clear. (m)0.0457

Bundle Top Space (m)0Pass Part Clear. (m)0

Bundle Btm Space (m)0

Baffle Parameters:

Number of Baffles13

Baffle TypeSingle Segmental

Inlet Space (m)0.191

Center Space (m)0.212

Outlet Space (m)0.191

Baffle Cut, % Diameter21

Baffle Overlap (m)0.04

Baffle Cut DirectionVertical

Number of Int. Baffles0

Baffle Thickness (m)0.003

Shell:

Shell O.D. (m)0.36OrientationH

Shell I.D. (m)0.34Shell in Series1

Bonnet I.D. (m)0.34Shell in Parallel1

TypeAESMax. Heat Flux Btu/ft2-hr0

Imping. Plate Impingement Plate Sealing Strip 5

Tubes:

Number102Tube TypeBare

Length (m)3.05Free Int. Fl Area (m)0

Tube O.D. (m)0.02Fin Efficiency0

Tube I.D. (m)0.016Tube PatternTRIANGULAR 30

Tube Wall Thk. (m)0.002Tube Pitch (m)0.025

No. Tube Pass2

Inner Roughness (m)1.6E-06

Resistances:

Shellside Film (m-K/W) 0.0004

Shellside Fouling (m-K/W)0.00018

Tube Wall (m-K/W) 0.00004

Tubeside Fouling (m-K/W) 0.00018

Tubeside Film (m-K/W) 0.00011

Reference Factor (Total outside area/inside area based on tube ID)1.25

Pressure Drop Distribution :

Tube SideShell Side

Inlet Nozzle (atm)0.0042Inlet Nozzle (atm)0.0206

Tube Entrance (atm)0.0141Impingement (atm)0.0148

Tube (atm)0.1772Bundle (atm)0.2431

Tube Exit (atm)0.0432Outlet Nozzle (atm)0.0025

End (atm)0.0276Total Fric. (atm)0.2662

Outlet Nozzle (atm)0.0022Total Grav. (atm)-0.0011

Total Fric. (atm)0.2684Total Mome. (atm)-0.0121

Total Grav. (atm)0Total (atm)0.2531

Total Mome. (atm)0.0001

Total (atm)0.2685

3.2COSTING OF HEAT EXCHANGER 1

Area Required (m)19.15

Pressure (bar)15

Pressure Factor1.1

Type Factor1

Bare Cost ($)120000

Puchase Cost in 2004 ($)132000

Puchase Cost in 2014 ($)163439.8919

1 US Dollar = 11,02 ZAR

Purchase Cost in 2014 ZAR1801107.609

3.3YearCE Index (CEPSI)

2004444.2

2009521.9

2014550

Heat exchanger 24.1TABULATED ANALYSIS

Overall Data:

Area Total (m)19.53% Excess-1.94

Area Required (m)19.15U Calc. (W/m-K)1019.61

Area Effective (m)18.78U Service (W/m-K)1039.74

Area Per Shell (m)18.78Heat Duty (MJ/h)9.63E+003

Weight LMTD C 141.65 LMTD CORR Factor 0.9670 CORR LMTD C 136.98

Shellside Data:

Avg. SS Vel. (m/sec)8.95

Film Coef. (W/m-K)2518.47

Allow Press. Drop (atm)0.34Calc. Press. Drop (atm)0.25

Inlet Nozzle Size (m)0.15Press. Drop/In Nozzle (atm)0.02

Outlet Nozzle Size (m)0.13Press. Drop/Out Nozzle (atm)0.00

Mean Temperature (C)195.45

Rho V2 IN (kg/m-sec)2302.40Press. Drop (Dirty) (atm)0.43

Tubeside Data:

Film Coef. (W/m-K)8704.80

Allow Press. Drop (atm)0.34Calc. Press. Drop (atm)0.27

Inlet Nozzle Size (m)0.15Press. Drop/In Nozzle (atm)0.00

Outlet Nozzle Size (m)0.15Press. Drop/Out Nozzle (atm)0.00

Interm. Nozzle Size (m)0.00Mean Temperature (C)40.00

Velocity (m/sec)2.10Mean Metal Temperature (C)91.89

Clearance Data:

Baffle (m)0.0063Outer Tube Limit (m)0.2908

Tube Hole (m)0.0008Outer Tube Clear. (m)0.0457

Bundle Top Space (m)0.0000Pass Part Clear. (m)0.0000

Bundle Btm Space (m)0.0000

Baffle Parameters:

Number of Baffles13

Baffle TypeSingle Segmental

Inlet Space (m)0.191

Center Space (m)0.212

Outlet Space (m)0.191

Baffle Cut, % Diameter21.000

Baffle Overlap (m)0.040

Baffle Cut DirectionVertical

Number of Int. Baffles0

Baffle Thickness (m)0.003

Shell:

Shell O.D. (m)0.36OrientationH

Shell I.D. (m)0.34Shell in Series1

Bonnet I.D. (m)0.34Shell in Parallel1

TypeAESMax. Heat Flux Btu/ft-hr0.00

Imping. Plate Impingement Plate Sealing Strip 5

Tubes:

Number102Tube TypeBare

Length (m)3.05Free Int. Fl Area (m)0.00

Tube O.D. (m)0.020Fin Efficiency0.000

Tube I.D. (m)0.016Tube PatternTRI30

Tube Wall Thk. (m)0.002Tube Pitch (m)0.025

No. Tube Pass2

Inner Roughness (m)0.0000016

Resistances:

Shellside Film (m-K/W) 0.00040

Shellside Fouling (m-K/W) 0.00018

Tube Wall (m-K/W) 0.00004

Tubeside Fouling (m-K/W) 0.00018

Tubeside Film (m-K/W) 0.00011

Reference Factor (Total outside area/inside area based on tube ID) 1.250

Pressure Drop Distribution:

Tube SideShell Side

Inlet Nozzle (atm)0.0042Inlet Nozzle (atm)0.0206

Tube Entrance (atm)0.0141Impingement (atm)0.0148

Tube (atm)0.1772Bundle (atm)0.2431

Tube Exit (atm)0.0432Outlet Nozzle (atm)0.0025

End (atm)0.0276Total Fric. (atm)0.2662

Outlet Nozzle (atm)0.0022Total Grav. (atm)-0.0011

Total Fric. (atm)0.2684Total Mome. (atm)-0.0121

Total Grav. (atm)0.0000Total (atm)0.2531

Total Mome. (atm)0.0001

Total (atm)0.2685

4.2COSTING OF HEAT EXCHANGER 2

Area Required (m)19.15

Pressure (bar)15

Pressure Factor1.1

Type Factor1

Bare Cost ($)12000

Puchase Cost in 2004 ($)13200

Puchase Cost in 2014 ($)16343.99

1 US Dollar = 11,02 ZAR

Purchase Cost in 2014 ZAR180110.8

4.3YearCE Index (CEPSI)

2004444.2

2009521.9

2014550

Pump Pump Summary

Equip. No. 1

Name

Output pressure atm 17

Efficiency 0.7

Calculated power MJ/h 24.5302

Calculated Pout atm 17

Head m 209.3727

Vol. flow rate m3/h 10.584

Mass flow rate kg/h 8356.9297

NPSH available m 10.9108

Cost estimation flag 1

Install factor 2.8

Basic pump cost $ 4352

Basic motor cost $ 690

Total purchase cost $ 5042

Total installed cost 14118

($)

Request NPSH calc 1

Appendix B