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

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

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


TypeShell & tube .

LocationOxidation of EB section

UtilityLow pressure Steam

Material of ConstructionCarbon steel


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


ObjectiveIncrease Temperature of liquid effluent of CRV-100



TypeShell & tube .



Material of ConstructionCarbon steel


Cost)$( 85000

Operating Condition

Shell Side


temperature (oC)

158.79

Tube Side


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


ObjectiveIncrease Temperature of EB fed to T-100



TypeShell & tube .



Material of ConstructionStainless Steel


Cost)$( 8000

Operating Condition

Shell Side


temperature (oC)

158.79

Tube Side


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


DesignerEng. Salem Alkanimsh

TypeShell & Tube

LocationEB oxidation

UtilityCooling water



Cost)$( 15000

Operating Condition

Shell Side


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

wapap

wap

hngPlateSpaciFind

hhwhhh

AAMINAA

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


TypeSieve Tray distillation column

LocationEpoxidation of Propylene section


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 .


TypeTray Distillation column

LocationStyrene Production section



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


TypeCentrifugal Pump

LocationEB oxidation section


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


TypeCentrifugal Pump

LocationEB oxidation section


Insulation

Cost20,000$

Operating Condition

Inlet Temperature (oC)50.11Outlet Temperature

(oC)50.15

Inlet Pressure (psia)1.094Outlet Pressure (psia)14.7


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


Typereciprocating Compressor

LocationOxidation of EB .


Insulation

Cost100000$

Operating Condition

Inlet Temperature (oC)25Outlet Temperature

(oC)50

Inlet Pressure (psia)14.7Outlet Pressure

(psia)188.2


Equipment NameCompressor

ObjectiveIncrease Pressure of outlet of V-104

Equipment NumberK-101


Typerecirocating Compressor

LocationOxidation of EB .


Insulation

Cost202270$

Operating Condition

Inlet Temperature (oC)97Outlet Temperature (oC)97

Inlet Pressure (psia)1.094Outlet Pressure (psia)3.094


Documents

Equipments Design PO/Styrene Plant