Plant Design for Production ofn-Butyraldehyde byHydroformylation of PropyleneSession: 2005-2009Pr oje c tA dv is ors Prof. Dr. Muhammad Zafar Noon Mr. Muhammad Faheem Pr oje c t Me m bers Hafiz Sajid Sattar2005-Chem-62Muhammad Waqas 2005-Chem-86Saeed Ur Rehman 2005-Chem-98Saad Ullah Mirza2005-Chem-74D EP AR TM EN TOF C H EMI C A L EN GI N EER I N G UNIVERISITY OF ENGINEERING & TECHNOLOGYPLANT DESIGN FOR Production of n-Butyraldehyde byHydroformylation of PropyleneThis report is submitted to department of Chemical Engineering, University of Engineering & Technology Lahore- Pakistan for the partial fulfillment of the requirements for theBachelors DegreeInCHEMICAL ENGINEERINGInternal Examiner:Sign: Name:External ExaminerSign: Name:DEPARTMENT OF CHEMICAL ENGINEERING UNIVERISITY OF ENGINEERING AND TECHNOLOGY LAHORE-PAKISTANDEDICATED TOOur Beloved Parents, Respected Teachers, And Sincere Friends!Page iACKNOW LEDGEMENTAll praises toALMIGHTY ALLAH, who provided us with thestrength toaccomplishthefinalyearproject.AllrespectsareforHisHOLY PROPHET (PBUH),whoseteachingsaretruesourceofknowledge& guidance for whole mankind.BeforeanybodyelsewethankourParentswhohavealwaysbeena source of moral support and driving force behind whatever we do. We are indebted toourprojectadvisorProfessorDr.Muhammad ZafarNoon forhisworthydiscussions,encouragement,inspiringguidance, remarkablesuggestions,keeninterest,constructivecriticism&friendly discussions which enabledustocompletethisreport.Hesparedalotof his precious time in advising & helping usin writing this report.Without hispainstakingtuition,kindpatronization,sincerecoachingand continuousconsultation,wewouldnothavebeen abletocomplete this arduous task successfully.WearealsogratefultoProf.Dr.A.R.Saleemi,Dr.Ing.Naveed Ramzan,Mr.Muhammad FaheemandHafiz ZaheerAslamfortheir profound gratitude and superb guidance in connection with the project.WearealsothankfultolibrariansofNationalLibraryofEngineeringSciences and Departmental Library.AuthorsPage iiPREFACEn-Butyraldehyde,alsoknownasnbutanal,isacolourless,flammableliquid withacharacteristicaldehydicordourm.Itwasdiscoveredshortlyafter1860 andwaspreparedbythereductionofcrotonaldehyde asearlyas1880. Butyraldehyde becameacommercialchemicalinthedecadefollowing World WarII.Itisusedchieflyasanintermediateintheproductionofsynthetic resins, rubbers accelerators, solvents and plasticizers. Because of large number of condensationandadditionreactionsitcanundergo,itisusefulstarting material in the production of wide variety of compounds containing at least six to eightcarbon atoms.N-butanal alsofindsitsapplication inPakistan forvriety of purposes.Keeping these points inmind we urged to work & we are feeling great to present our work on Production of n-Butanal by catalytic hydroformylation of propylene . Thisreportis dividedin differentsections.Firstof all the introductionofn-butanalisgiven,whichhighlightsitsimportance.Nextare differentmanufacturingprocessesforn-butanal production.Detailed descriptionofProductionofn-Butanalbycatalytichydroformylation of propyleneispresentedinpreceding chapter.Afterwardsmaterialandenergy balance is presented.In preceding chapters introduction to different equipments of plant along with their designing procedure and specification sheets is presented.Instrumentation &Control,HAZOPStudy,EIAandCostEstimation for this plant are also included in this report.A compact disc is also provided with report which includes soft copy ofthis report and HYSYS simulation of this plant and other softwares.Page iiiTable of ContentsCHAPTER -1INTRODUCTION1CHAPTER -2PROCESS SELECTION4CHAPTER -3CAPACITY SELECTION 9CHAPTER -4MATERIAL BALANCE11CHAPTER -5ENERGY BALANCE23CHAPTER -6DESIGN OF EQUIPMENTS 37CHAPTER -7INSTRUMENTATION AND CONTROL 104CHAPTER -8HAZOP STUDY 116CHAPTER -9ENVIRONMENTAL IMPACT ASSESSMENT 125CHAPTER -10COST ESTIMATION 133References 138Page ivCHAPTER 1 INTRODUCTIONCHAPTER -1INTRODUCTIONINTRODUCTIONNormal-Butyraldehyde,alsoknown as Aldehydebutyrique (French),Aldeidebutirrica (Italian),Butal,Butaldehyde,Butalyde,Butanal,n-Butanal(Czech),Butanaldehyde, Butylaldehyde,n-Butylaldehyde,Butyral,Butyraldehyd(German)occursnaturally insmallquantities.Itisisolatedinsmallquantitiesintheessentialoilsofseveral plants.Itisalsodetectedin oil ofLavenderandEucalyptusglobulesof california,in tobacco smoke, in tea leaves and in other leaves.Normal-Butyraldehyde is a colourless,flammableliquid with acharacteristic aldehydicordourm.Itis usedchiefly asanintermediatein the production of synthetic resins,rubbersaccelerators,solventsandplasticizers.Becauseoflargenumberof condensation andaddition reactionsitcan undergo,itis useful startingmaterialin the production of widevariety of compounds containing at least six to eight carbon atoms. Butyraldehydebecameacommercial chemicalinthedecadefollowingWorldWarII. Itwasdiscoveredshortlyafter1860andwaspreparedbythereductionof crotonaldehyde as early as 1880.Normalbutyraldehydeismisciblewithallcommonorganicsolvents,e.g., alcohols, ketones,aldehydes, ethers, glycols, and aromatic and aliphatic hydrocarbons, butisonly sparinglysolublein water.Itisan extremelyflammableliquidandvapor. The vapor may cause a flash fire.N-butyraldehydemayirritatetheskinandburntheeyes.Upondegradation,peroxides are formed. Inhalation of vapors and mists may cause a narcotic effect.Page 1CHAPTER 1 INTRODUCTIONPHYSICAL PROPERTIESProperty DescriptionButyraldehydeMelting Point (0C)-99Boiling Point (0C) 75.7Density (g/cm3) 0.8048Vapour Density (Air=1) 2.48Refractive Index (n) 1.3843Flash Point (0C)-9.4Viscosity at 20 (0C) 0.433Heat of Formation (KJ/mol) 240.3Specific Heat (J/kg.K)2121Heat of Vaporization at boiling poinjt (J/g)436Heat of combustion (KJ/mol)2478.7Dipole Moment (vap.) C.m9.07 x 10-30Surface tension (mN/m) at 24 (0C)29.9Vapour Pressure (kPa) at 20 (0C) 12.2Page 2CHAPTER 1 INTRODUCTIONAPPLICATIONS OF N-BUTANALn-Butanalisawidely usedorganic compoundandits consumptionis approxemately65% of whole oxo chemicals consumption.i.The primary use for n-butyraldehyde is as a chemical intermediate in producing other chemical commodities such as 2-Ethylhexanol (2-EH) and n-butanol.ii.Other products requiring n-butyraldehyde include trimethylolpropane (TMP), n- butyric acid, polyvinyl butyral (PVB) and methyl amyl ketone.iii. Smaller applications include intermediates for producing pharmaceuticals, cropprotectionagents,pesticides,syntheticresins,antioxidants,vulcanization accelerators, tanning auxiliaries, perfumery synthetics and flavors.Page 3CHAPTER 2 PROCESS SELECTIONCHAPTER -2PROCESS SELECTIONDIFFERENT PRODUCTION ROUTS1.FermentationN-butyraldehydewasexclusivelyproducedbybacterialfermentationof carbohydratecontatingmaterialsuntiltheearly1930s.Pullickerindustries were using this process.However this technology is very old and selectivity of process is also very low.2.Aldol CondensationThealdolroutefromacetaldehydewasformerlythedominantsyntheticroute ton- butyraldehyde.Ithas been shutdown in favour of themore economical oxoroute in 1950s. Celanese in United States has been using this process.3.HydroformylationHydroformylationwhichisalsoknownasoxosynthesiswasdiscoveredin1938byOtto Roelen.Hedetectedthisnewchemicalreactionwhenheaimedat increasingthechainlength ofFisher-Tropschhydrocarbonsbypassingamixtureof ethylene and synthesis gas over cobalt containing catalyst at 150 0C and 100 bar in the laboratories of Ruhrchemie AG at Oberhausen, Germany.Inhydroformylationolefinicdoublebondreactswithsynthesisgas(carbon monoxide andhydrogen)in thepresence of transition metal catalysttoform linear (n) andbranched(b)aldehydescontainingan additionalcarbon atom asprimaryproducts shown below.RCH2 = CH2 + CO+H2 RCH2CH2CHO +RCH(CH3)CHStartingfrom mid1950shydroformylation gainedanimportance.In1997the totalworldwide oxo production capacitywas 6.5x106 t/year for aldehydes andPage 4CHAPTER 2 PROCESS SELECTIONalcohols.Todayhydroformylationisthelargestscaleapplicationof homogeneous organo-metallic catalysis.DIFFERENT TECHNIQUES OF HYDROFORMYLATIONThebasicclassificationofHydroformylationtechniquesinbasedonthe selectionof catalyst.1. Cobalt based catalyst2. Rhodium based catalystThe comparison of these two techniques is given in the table below.Catalyst Metal Cobalt RhodiumVariant Ligand UnmodifiedNoneModifiedPhosphinesUnmodifiedNoneModified PhosphinesProcess 1 2 3 4 5Active Catalyst RCo(CO)4 Hco(CO)3(L) HRh(CO)4 HRh(CO)(L)3 HRh(CO)(L)3Temperature deg. C 150-180 160-200 100-140 60-120 110-130Pressure (bar) 200-300 50-150 200-300 10--50 40-60Catalyst to Olefin % 0.1-1 0.6 0.0001-0.01 0.01-0.1 0.001-1Products Aldehydes Alcohols Aldehydes Aldehydes AldehydesBy Products High High Low Low Negligiblen/b ratio 80/20 88/12 50/50 92/8 43/1 45/1Selectivity to Poison No No No yes NoProcess 1: BASF Process Process 2: Shell Process Process 3: Ruhrchemie ProcessProcess 4: Union Carbide ProcessProcess 5: RCH/RP ProcessPage 5CHAPTER 2 PROCESS SELECTIONThemostimportantofrhodiumbasedprocessesonanindustrialscaleusestheso - called phosphine modified catalystsystem.The unmodified rhodium carbonyl complex is used for the reaction of special olefins.Asthereactionproductsconsistofroughlyequalamountofbranchedand linear aldehydes, this catalystis only applicableif both aldehyde are valuable products oriftheformationof thebranchedaldehydeisimpossible(e.g.,hydroformylationof ethylene to give propanal). Up until the mid 1970s cobalt was used as catalystmetal in commercial processes(e.g.,by BASF, Ruhrchemie,Kuhlmann).Because ofinstability of cobalt carbonyl, the reaction conditions were harsh with the pressure range of 200-350 bar to avoid decomposition of the catalyst and deposition of the metallic cobalt.TheligandmodificationintroducedbyShellResearcherswas significant progressinhydroformylation.Thereplacementofcarbonmonoxidewith phosphines (orarsines)enhancestheselectivity towardslinearaldehyde(n/b)andthe stability of cobalt carbonyl, leading to reduced carbon monoxide pressure.In1974-1976UnionCarbideCorporation(UCC)andCelaneseCorporation, independentlyofoneanother,introducedrhodiumbasedcatalystsonanindustrial scale. These processes combined the advantages of ligand modification with the use of rhodium as a catalystmetal.As the reaction conditions weremuch milder, the process was named as low-pressure oxo (LPO).Thenlow-pressureoxo(LPO)processestook theleadingroleanddespitethe higherpriceofrhodium,cobaltcatalystsforthehydroformylationofpropenewas replacedinnearly all majorplants by rhodium catalysts.Higherpriceof rhodium was offsetbymildreactionconditions,simplerandthereforecheaperequipment,high efficiencyandhighyieldoflinearproductsandeasyrecoveryofthecatalyst.In addition,withrespecttorawmaterialutilizationandenergyconversation,theLPO processesweremoreadvantageousthanthecobalttechnology,thusleadingtotheir rapid growth.In 1980s elegantsolution with respect tocatalystrecovery was offeredby theRuhrchemie/Rhone-Poulenc(RCH/RP)process.Ideaoftwophasecatalysiswas applied to hydroformylation by using water soluble rhodium as a catalyst.Page 6CHAPTER 2 PROCESS SELECTIONTrisulfonatedtriphenylphosphine(TPPTS,assodiumsalt)astheligandyieldsthe watersolublecatalystHRh(CO)(TPPTS)3.Thebiphasicbuthomogeneousreaction systemexhibits distinct advantages over the conventionalone phaseprocesses. Becauseofmutualinsolubility,theseparationoftheaqueouscatalystphaseand reactionproducts,includinghigh-boilingby-products,isachievedmostsimplyand efficiently.However,theapplicationofthisprocessislimitedtolowmolecularmass olefinswhichhaveadequatewatersolubility.Thecommercialhydroformylationof higher olefins (C6 or larger) is performed exclusively with cobalt carbonyl catalyst. Several approaches have been developed for the hydroformylation of high olefins:1. Anchoring of rhodium catalyst to resins, polymeric or mineral support.2. Homogeneous catalyst with amphiphilic complexes which can be extracted in another phase at the end of the reaction.3. Aqueous organic biphasic catalyst involving use of particular ligands, co-solvent4. Supported hydrophilic liquid phase or aqueous phase catalysis.F-101F-104F-103V-1012615Ruhrchemie/Rhone-Poulenc(RCH/RP) ProcessRCH/RPprocessisbasedon awatersolublerhodiumcatalyst,namely HRh(CO)(TPPTS)3complex.Theuseof awatersolublecatalystsystembrings substantial advantages for industrial practice, because the catalyst can be considered to be heterogeneous. The separation of catalyst solution and reaction products, including high-boilingby-products,isachievedmostsimplyandefficiently.Lossesofthe rhodiuminthecrudealdehydestreamarenegligible.High-boilingby-productsare alsonegligiblebyusingthisaqueouscatalyst.Purificationofsynthesisgasand propene is not necessary, because the catalyst is not sensitive to oxo poisonsthat mayenterwiththefeed.ThefollowingfigureshowstheflowsheetofRCH/RPprocess.Page 7CHAPTER 2PROCESS SELECTIONProcess Flow Diagram for RCH/RP Process for Hydroformylation of Propylene.1K-10127M-1012529E-106 E-107 E-108E-10928 302323334 35WaterE-101WaterE-105 24K-107K-108K-109K-110Water31 WaterWaterWater36323K-102185V-102F-102S-101C-101142122 39V-10338 37K-103 46R-10116E-104M-102204043E-111M-10345E-102Water7 13R K-1048Water121117K-106Water19E-110E-112Steam41WaterD-10144WaterE-1039K-10510SteamE-11342The hydroformylation plant has major four units. Propylene is compressed in compressors K-101 and K-102 with an intercooler E-101 and sent to reactor R-101 for reaction. Synthesis gas is compressed in compressors K-103, K-104 and K-105 with intercoolers E-102 and E-103andsenttothestripperS-101,whereitstripsouttheunreactedPropylenefrom aldehydeproductscomingfrom reactorR-101.Unreactedpropyleneandsynthesisgasis compressedinK-106andrecycledbackto reactor R-101.Fromreactor R-101 gases leaving contain n-butanal and iso-butanal,which are separatedbyseveralflashing aftercompressionandcoolingincompressorK-107,K-108,K-109,K-110and in coolerE-106,E-107,E-108,E-109respectivelyandmixedwithn-butanaland iso-butanal comingfrom reactorin mixer M-102. After this themixture of n-butanal and iso-butanal isheatedinheatexchangerE-112.AfterpassingthroughheatexchangerE-112itissenttodistillationcolumnC-101wheren-butanalisobtainedasbottom productandiso-butanalandsome impuritiesareobtainedfromtopofthedistillation column.Thecondenserindistillationcolumnispartialcondenserbecausesomegases arepresentintop product stream.Page 8CHAPTER 3 CAPACITY SELECTIONCHAPTER -3CAPACITY SELECTIONCAPACITY SELECTIONIn order to select the capacity of plant, we needed to have the knowledge of followingMaterial InMaterial OutStream 1 = 8827.9 kg/hrStream 5 = 8712 kg/hrTotal= 17539 kg/hr=Stream 42 = 13888.6 kg/hr Stream 44 = 413.05 kg/hr Stream 45 = 3237.57 kg/hrTotal = 17539 kg/hr1. Consumption of n-Butanal in different industrial sectors of Pakistan.2. Current production of n-Butanal in Pakistan.3. Import of n-Butanal from different countries to Pakistan.Consumption of n-ButanalMain uses of n-Butanal in Pakistan are listed below.1.Production of n-Butanol by catalytic hydrogenation of n-Butanal. It is widely used as a solvent and as an esterifying agent. For exampleits ester with acrylic acid is used in paint, adhesive and plastic industries.2. It is used in production of 2-Ethylexanol which is a colorless liquid and it is one of the chemicalusedforproducingPVCplasticizers,trimethylolpropane(TMP),n-butyric acid, polyvinyl butyral (PVB), and methyl amyl ketone.3. Smaller applications include intermediates for producing pharmaceuticals, crop protection agents, pesticides, synthetic resins, antioxidants, vulcanization accelerators, tanning auxiliaries, perfumery synthetics, and flavors.The overall use of n-Butanal in different industries in Pakistan is estimated.1. Paint industries 40%2. Plastic industries60%Production n-Butanal in PakistanCurrently there is no plant for production of n-Butanal in Pakistan.Page 9CHAPTER 3CAPACITY SELECTIONImport of n-Butanal to PakistanDataobtainedfromLahorechamberofcommerceshowsthatinyear2001-2002 import of n-Butanal was about 52468MTPY from countries China, . And in year 2002-2003 it was about 57954MTPY.Amountofn-ButanalimportedinrecentyearsaccordingtothedataobtainedfromLahore chamber of commerce is listed below.Material InMaterial OutStream 1 = 8827.9 kg/hrStream 5 = 8712 kg/hrTotal= 17539 kg/hr=Stream 42 = 13888.6 kg/hr Stream 44 = 413.05 kg/hr Stream 45 = 3237.57 kg/hrTotal = 17539 kg/hrMaterial InMaterial OutStream 16 = 14364.9 kg/hrTotal = 14364.9 kg/hr=Stream 17 = 14329.44 kg/hrStream 18 = 35.46 kg/hrTotal = 14364.9 kg/hrYearAmount of n-Butanal imported (MTPY)YearAmount of n-Butanal imported (MTPY)1997-1998 32235 2000-2001 465891998-1999 36524 2001-2002 524681999-2000 41524 2002-2003 57954A graph is potted and is extrapolated up to year 2010 as shown blow.Accordingtographtheamountofn-Butanalrequiredupto2010ismorethan100000MTPY so we selected the capacity of our plant 100000MTPY.Page 10CHAPTER 4 MATERIAL BALANCECHAPTER -4MATERIAL BALANCEMaterial InMaterial OutStream 1 = 8827.9 kg/hrStream 5 = 8712 kg/hrTotal= 17539 kg/hr=Stream 42 = 13888.6 kg/hr Stream 44 = 413.05 kg/hr Stream 45 = 3237.57 kg/hrTotal = 17539 kg/hrMaterial InMaterial OutStream 16 = 14364.9 kg/hrTotal = 14364.9 kg/hr=Stream 17 = 14329.44 kg/hrStream 18 = 35.46 kg/hrTotal = 14364.9 kg/hrCapacity of plant = 100,000 MT/Year of 98.8% n-ButanalSelectivity of n/iso= 43.4/1So total production of Butanal= 105284.4 MT/YearProduction of butanal= 14622.84 kg/hr= 202.79 kmol/hrProduction of n-butanal= 198.2 kmol/hr= 14290.5 kg/hrProduction of i-butanal = 4.59 kmol/hr= 331 kg/hrConversion is 95%2C3H6 + 2H2 + 2CO nC4H8O + iso C4H8OBy calculating the recycled propylene and butanal the propylene neededPropylene (99.5%) needed= 209.7 kmol/hr= 8927 kg/hrSyn. Gas and Propylene ratio= 2.66Syn. Gas needed= 536.8 kmol/hr= 8712 kg/hrButanal to purification plant = 733.9 kg/hr98.8% butanal achieved= 13889 kg/hr= 100,000 MT/yearPage 11CHAPTER 4 MATERIAL BALANCEOVERALL MATERIAL BALANCE OF PLANTMaterial InMaterial OutStream 1 = 8827.9 kg/hrStream 5 = 8712 kg/hrTotal= 17539 kg/hr=Stream 42 = 13888.6 kg/hr Stream 44 = 413.05 kg/hr Stream 45 = 3237.57 kg/hrTotal = 17539 kg/hrMaterial InMaterial OutStream 16 = 14364.9 kg/hrTotal = 14364.9 kg/hr=Stream 17 = 14329.44 kg/hrStream 18 = 35.46 kg/hrTotal = 14364.9 kg/hrStream number161718Hydrogen (kg/hr)3.551.881.67CO (kg/hr)80.7948.6032.20Propylene (kg/hr)202.49201.830.66Propane(kg/hr)43.7343.610.12n-butanal (kg/hr)13718.6313717.850.79I-butanal (kg/hr)315.70315.670.03Total (kg/hr)14364.9014329.4435.46Basis : 1 hour ProcessStream number 1 5 42 44 45Hydrogen (kg/hr) 0.00 549.04 0.00 0.00 140.27CO (kg/hr) 0.00 8162.96 0.00 0.02 2483.30Propylene (kg/hr) 8781.69 0.00 0.00 1.96 246.47Propane(kg/hr) 46.24 0.00 0.00 0.66 45.23n-butanal (kg/hr) 0.00 0.00 13722.02 275.16 291.88I-butanal (kg/hr) 0.00 0.00 166.64 135.25 30.42Total kg/hr 8827.91 8712 1388.6 413.05 3237.57Page 12CHAPTER 4 MATERIAL BALANCEMaterial InMaterial OutStream 16 = 14364.9 kg/hrTotal = 14364.9 kg/hr=Stream 17 = 14329.44 kg/hrStream 18 = 35.46 kg/hrTotal = 14364.9 kg/hrStream number161718Hydrogen (kg/hr)3.551.881.67CO (kg/hr)80.7948.6032.20Propylene (kg/hr)202.49201.830.66Propane(kg/hr)43.7343.610.12n-butanal (kg/hr)13718.6313717.850.79I-butanal (kg/hr)315.70315.670.03Total (kg/hr)14364.9014329.4435.46Material InMaterial OutStream 21 = 13839.5 kg/hrTotal = 13839.5 kg/hr=Stream 22 = 13753.6 kg/hrStream 23 = 85.91 kg/hrTotal = 13839.5 kg/hrMATERIAL BALANCE AROUND REACTORStream number 4 13 14 150.00 547.35 3.55 135.02CO (kg/hr) 0.00 8142.78 80.79 2382.38Propylene (kg/hr) 8781.69 199.84 202.49 246.59Propane(kg/hr) 46.24 42.35 43.73 44.87n-butanal (kg/hr) 0.00 260.44 13718.63 830.25I-butanal (kg/hr) 0.00 8.63 315.70 25.22Total (kg/hr) 8827.91 9201.39 14364.90 3664.32Material In Material OutStream 4 = 8827.9 kg/hr Stream 14 = 14364.9 kg/hrStream 13 = 9201.4 kg/hr Stream 15 = 3664.32 kg/hrTotal = 18029 kg/hr=Total = 18029 kg/hrPage 13CHAPTER 4 Stream number161718Hydrogen (kg/hr)3.551.881.67CO (kg/hr)80.7948.6032.20Propylene (kg/hr)202.49201.830.66Propane(kg/hr)43.7343.610.12n-butanal (kg/hr)13718.6313717.850.79I-butanal (kg/hr)315.70315.670.03Total (kg/hr)14364.9014329.4435.46Material InMaterial OutStream 21 = 13839.5 kg/hrTotal = 13839.5 kg/hr=Stream 22 = 13753.6 kg/hrStream 23 = 85.91 kg/hrTotal = 13839.5 kg/hrStream number212223Hydrogen (kg/hr)3.580.083.49CO (kg/hr)68.762.1666.60Propylene (kg/hr)1.181.090.09Propane(kg/hr)0.900.840.06n-butanal (kg/hr)13458.0313442.8815.16I-butanal (kg/hr)307.06306.550.51Total (kg/hr)13839.5013753.6085.91Material InMaterial OutStream 36 = 3283.17 kg/hrTotal = 3283.17 kg/hr=Stream 37 = 3178.46 kg/hrStream 38 = 104.70 kg/hrTotal = 3283.17 kg/hrMATERIAL BALANCEMATERIAL BALANCE AROUND FLASH SEPARATORStream number161718Hydrogen (kg/hr)3.551.881.67CO (kg/hr)80.7948.6032.20Propylene (kg/hr)202.49201.830.66Propane(kg/hr)43.7343.610.12n-butanal (kg/hr)13718.6313717.850.79I-butanal (kg/hr)315.70315.670.03Total (kg/hr)14364.9014329.4435.46Material InMaterial OutStream 21 = 13839.5 kg/hrTotal = 13839.5 kg/hr=Stream 22 = 13753.6 kg/hrStream 23 = 85.91 kg/hrTotal = 13839.5 kg/hrStream number212223Hydrogen (kg/hr)3.580.083.49CO (kg/hr)68.762.1666.60Propylene (kg/hr)1.181.090.09Propane(kg/hr)0.900.840.06n-butanal (kg/hr)13458.0313442.8815.16I-butanal (kg/hr)307.06306.550.51Total (kg/hr)13839.5013753.6085.91Material InMaterial OutStream 36 = 3283.17 kg/hrTotal = 3283.17 kg/hr=Stream 37 = 3178.46 kg/hrStream 38 = 104.70 kg/hrTotal = 3283.17 kg/hrStream number363738Hydrogen (kg/hr)140.18140.160.02CO (kg/hr)2481.102480.610.49Propylene (kg/hr)243.75240.862.89Propane(kg/hr)44.2643.630.62n-butanal (kg/hr)360.47262.6597.82I-butanal (kg/hr)13.4110.552.85Total (kg/hr)3283.173178.46104.70Page 14CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND FLASH SEPARATORStream number 25 26 27Hydrogen (kg/hr) 135.02 0.00 135.02CO (kg/hr) 2382.38 0.07 2382.31Propylene (kg/hr) 246.59 3.59 243.00Propane(kg/hr) 44.87 0.79 44.08n-butanal (kg/hr) 830.25 485.72 344.53I-butanal (kg/hr) 25.22 12.35 12.87Total (kg/hr) 3664.32 502.52 3161.80Material In Material OutStream 25 = 3664.32 kg/hr Stream 26 = 502.52 kg/hrStream 27 = 3161.8 kg/hrTotal = 3664.32 kg/hr= Total = 3664.32 kg/hrMaterial InMaterial OutStream 21 = 13839.5 kg/hrTotal = 13839.5 kg/hr=Stream 22 = 13753.6 kg/hrStream 23 = 85.91 kg/hrTotal = 13839.5 kg/hrStream number212223Hydrogen (kg/hr)3.580.083.49CO (kg/hr)68.762.1666.60Propylene (kg/hr)1.181.090.09Propane(kg/hr)0.900.840.06n-butanal (kg/hr)13458.0313442.8815.16I-butanal (kg/hr)307.06306.550.51Total (kg/hr)13839.5013753.6085.91Material InMaterial OutStream 36 = 3283.17 kg/hrTotal = 3283.17 kg/hr=Stream 37 = 3178.46 kg/hrStream 38 = 104.70 kg/hrTotal = 3283.17 kg/hrStream number363738Hydrogen (kg/hr)140.18140.160.02CO (kg/hr)2481.102480.610.49Propylene (kg/hr)243.75240.862.89Propane(kg/hr)44.2643.630.62n-butanal (kg/hr)360.47262.6597.82I-butanal (kg/hr)13.4110.552.85Total (kg/hr)3283.173178.46104.70Page 15CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND FLASH SEPARATORStream number212223Hydrogen (kg/hr)3.580.083.49CO (kg/hr)68.762.1666.60Propylene (kg/hr)1.181.090.09Propane(kg/hr)0.900.840.06n-butanal (kg/hr)13458.0313442.8815.16I-butanal (kg/hr)307.06306.550.51Total (kg/hr)13839.5013753.6085.91Material InMaterial OutStream 36 = 3283.17 kg/hrTotal = 3283.17 kg/hr=Stream 37 = 3178.46 kg/hrStream 38 = 104.70 kg/hrTotal = 3283.17 kg/hrStream number363738Hydrogen (kg/hr)140.18140.160.02CO (kg/hr)2481.102480.610.49Propylene (kg/hr)243.75240.862.89Propane(kg/hr)44.2643.630.62n-butanal (kg/hr)360.47262.6597.82I-butanal (kg/hr)13.4110.552.85Total (kg/hr)3283.173178.46104.70Page 16CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND FLASH SEPARATORStream number363738Hydrogen (kg/hr)140.18140.160.02CO (kg/hr)2481.102480.610.49Propylene (kg/hr)243.75240.862.89Propane(kg/hr)44.2643.630.62n-butanal (kg/hr)360.47262.6597.82I-butanal (kg/hr)13.4110.552.85Total (kg/hr)3283.173178.46104.70Material InMaterial OutStream 17 = 14339.44 kg/hrStream 10 = 8712 kg/hrTotal = 23041.44 kg/hr=Stream 11 = 9201.94 kg/hrStream 19 = 13839.5 kg/hrTotal = 23041.44 kg/hrPage 17CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND MIXER1 82 3M - 1 0 12 82 7Stream number 18 23 27 28Hydrogen (kg/hr) 1.67 3.49 135.02 140.18CO (kg/hr) 32.20 66.60 2382.31 2481.10Propylene (kg/hr) 0.66 0.09 243.00 243.75Propane(kg/hr) 0.12 0.06 44.08 44.26n-butanal (kg/hr) 0.79 15.16 344.53 360.47I-butanal (kg/hr) 0.03 0.51 12.87 13.41Total (kg/hr) 35.46 85.91 3161.80 3283.17Material InMaterial OutStream 17 = 14339.44 kg/hrStream 10 = 8712 kg/hrTotal = 23041.44 kg/hr=Stream 11 = 9201.94 kg/hrStream 19 = 13839.5 kg/hrTotal = 23041.44 kg/hrStream number17101119Hydrogen (kg/hr)1.88549.04547.353.58CO (kg/hr)48.608162.968142.8068.76Propylene (kg/hr)201.830.00200.651.18Propane(kg/hr)43.610.0042.710.90n-butanal (kg/hr)13717.850.00259.8213458.03I-butanal (kg/hr)315.670.008.61307.06Total (kg/hr)14339.448712.009201.9413839.50Material In Material OutStream 18 = 35.46 kg/hr Stream 28 = 3283.17 kg/hrStream 23 = 85.91 kg/hrStream 27 = 3161.8 kg/hrTotal = 3283.17 kg/hr =Total = 3283.17 kg/hrPage 18CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND MIXER2 22 6M -1 0 24 03 9Stream number 22 26 39 40Hydrogen (kg/hr) 0.08 0.00 0.02 0.11CO (kg/hr) 2.16 0.07 0.49 2.72Propylene (kg/hr) 1.09 3.59 2.89 7.57Propane(kg/hr) 0.84 0.79 0.62 2.25n-butanal (kg/hr) 13442.88 485.72 97.82 14026.42I-butanal (kg/hr) 306.55 12.35 2.85 321.76Total (kg/hr) 13753.60 502.52 104.70 14360.82Material InMaterial OutStream 17 = 14339.44 kg/hrStream 10 = 8712 kg/hrTotal = 23041.44 kg/hr=Stream 11 = 9201.94 kg/hrStream 19 = 13839.5 kg/hrTotal = 23041.44 kg/hrStream number17101119Hydrogen (kg/hr)1.88549.04547.353.58CO (kg/hr)48.608162.968142.8068.76Propylene (kg/hr)201.830.00200.651.18Propane(kg/hr)43.610.0042.710.90n-butanal (kg/hr)13717.850.00259.8213458.03I-butanal (kg/hr)315.670.008.61307.06Total (kg/hr)14339.448712.009201.9413839.50Material InMaterial OutStream 41 = 14360.82 kg/hrTotal = 14360.82 kg/hr=Stream 42 = 13888.66 kg/hr Stream 43 = 59.10 kg/hr Stream 44 = 413.06 kg/hr Total = 14360.82 kg/hrMaterial In Material OutStream 22 = 13753.6 kg/hr Stream 40 = 14360.82 kg/hrStream 26 = 502.52 kg/hrStream 39 = 104.70 kg/hrTotal = 14360.82 kg/hr =Total = 14360.82 kg/hrPage 19CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND MIXER3 7M - 1 0 34 54 3Stream number 37 43 45Hydrogen (kg/hr) 140.16 0.11 140.27CO (kg/hr) 2480.61 2.69 2483.30Propylene (kg/hr) 240.86 5.62 246.47Propane(kg/hr) 43.63 1.59 45.23n-butanal (kg/hr) 262.65 29.23 291.88Material InMaterial OutStream 17 = 14339.44 kg/hrStream 10 = 8712 kg/hrTotal = 23041.44 kg/hr=Stream 11 = 9201.94 kg/hrStream 19 = 13839.5 kg/hrTotal = 23041.44 kg/hrStream number17101119Hydrogen (kg/hr)1.88549.04547.353.58CO (kg/hr)48.608162.968142.8068.76Propylene (kg/hr)201.830.00200.651.18Propane(kg/hr)43.610.0042.710.90n-butanal (kg/hr)13717.850.00259.8213458.03I-butanal (kg/hr)315.670.008.61307.06Total (kg/hr)14339.448712.009201.9413839.50Material InMaterial OutStream 41 = 14360.82 kg/hrTotal = 14360.82 kg/hr=Stream 42 = 13888.66 kg/hr Stream 43 = 59.10 kg/hr Stream 44 = 413.06 kg/hr Total = 14360.82 kg/hrI-butanal (kg/hr) 10.55 19.86 30.42Total (kg/hr) 3178.46 59.10 3237.57Material In Material OutStream 37 = 3178.46 kg/hr Stream 45 = 3237.57 kg/hrStream 43 = 59.10 kg/hrTotal = 3237.57 kg/hr = Total = 3237.57 kg/hrPage 20CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND STRIPPERStream number17101119Hydrogen (kg/hr)1.88549.04547.353.58CO (kg/hr)48.608162.968142.8068.76Propylene (kg/hr)201.830.00200.651.18Propane(kg/hr)43.610.0042.710.90n-butanal (kg/hr)13717.850.00259.8213458.03I-butanal (kg/hr)315.670.008.61307.06Total (kg/hr)14339.448712.009201.9413839.50Material InMaterial OutStream 41 = 14360.82 kg/hrTotal = 14360.82 kg/hr=Stream 42 = 13888.66 kg/hr Stream 43 = 59.10 kg/hr Stream 44 = 413.06 kg/hr Total = 14360.82 kg/hr?PPage 21CHAPTER 4 MATERIAL BALANCEMATERIAL BALANCE AROUND DISTILLATION COLUMNStream number 41 42 43 440.11 0.00 0.11 0.00Material InMaterial OutStream 41 = 14360.82 kg/hrTotal = 14360.82 kg/hr=Stream 42 = 13888.66 kg/hr Stream 43 = 59.10 kg/hr Stream 44 = 413.06 kg/hr Total = 14360.82 kg/hr?PCO (kg/hr) 2.72 0.00 2.69 0.02Propylene (kg/hr) 7.57 0.00 5.62 1.96Propane(kg/hr) 2.25 0.00 1.59 0.66n-butanal (kg/hr) 14026.42 13722.02 29.23 275.16I-butanal (kg/hr) 321.76 166.64 19.86 135.25Total (kg/hr) 14360.82 13888.66 59.10 413.06Page 22CHAPTER 5 ENERGY BALANCECHAPTER -5ENERGY BALANCEAccording to law of conservation of energy[Rate of Accumulation of Energy within system =Rate of Energy entering the system Rate of energy leaving the system + Rate of Energy generation]For steady state system there is no accumulation of mass or energy within system.So by modifying above equation, the energy balance around all equipments is as under.Forcaseofenergybalanceacrosseachequipmenttodeterminetheenthalpyof ?Pstreams we used reference temperature equal to 25 0C.ENERGY BALANCE AROUND THE COMPRESSOR K-101Propylene Gas P1= 101.325Kpa T1=25oCPropylene Gas P2= 2945Kpa T2=?Inlet flow rate = 209.7 kmol/hr = 0.0583 kmol/sInlet volumetric flowratem_T T P2

2 1

P

Wheren=0.0583 kmol/s1,R=0.0821 m3atm/kmol K P= 1 atmT=298.15 KV=1.356 m3/sFrom fig 3.6 Coulson Vol.6for this flow rate centrifugal compressor wouldbe used with efficiency EP=78%Page 23CHAPTER 5 ENERGY BALANCEOutlet temperaturem

_T T

P2

2 1

P

Where T1=25 oC P1=101.325KpaP2=2945 Kpa1,? ?P ???m -1 _

= 0.137=1.12T2 = 200.5 oCWork per kmol EP ,

n 1nZTR

n _

2 11W =1 1

n -1P1 , 1 ,

]Wheren 1 _= 1.16Z1=11- m ,R=8.314 kJ/kmolKBy putting valuesW=10622 kJ/kmolPower requirementPower W kmol/hEP13600= 793 KW = 0.793MWSimilarly by putting thevalues in Excel Data Sheet we can calculate the power of allcompressors which is given as:CompressorPower CompressorPower CompressorPowerK-102 0.129 MW K-105 0.694 MW K-108 0.289 MWK-103 1.024 MW K-106 0.004 MW K-109 0.119 MWK-104 0.794 MW K-107 0.114 MW K-110 0.022 MWPage 24CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND REACTORStream number 4 13 14 15Hydrogen (kg/hr) 0.00 547.35 3.55 135.02CO (kg/hr) 0.00 8142.78 80.79 2382.38Propylene (kg/hr) 8781.69 199.84 202.49 246.59Propane(kg/hr) 46.24 42.35 43.73 44.87n-butanal (kg/hr) 0.00 260.44 13718.63 830.25I-butanal (kg/hr) 0.00 8.63 315.70 25.22Total (kg/hr) 8827.91 9201.39 14364.90 3664.32Temperature 0C 105 45 120 120Pressure kPa 5010 5000 5000 5000Heat Flow kJ/hr 5.35E+06 -3.26E+07 -4.42E+07 -1.12E+07Heat Flow In Heat Flow OutStream 4 = 5.35E+06 kJ/hrStream 14 = -4.42E+07 kJ/hr Stream13= -3.26E+07 kJ/hr Stream 15 = -1.12E+07 kJ/hr Total = -2.72E+07 kJ/hr Total = -5.55E+07 kJ/hrCooling Duty Qp= -2.82E+07 kJ/hrPage 25CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND HEAT EXCHANGER E-101Stream number 2 3Hydrogen (kg/hr) 0.00 0.00CO (kg/hr) 0.00 0.00Propylene (kg/hr) 8781.69 8781.69Propane(kg/hr) 46.24 46.24n-butanal (kg/hr) 0.00 0.00I-butanal (kg/hr) 0.00 0.00Total (kg/hr) 8827.91 8827.91Temperature 0C 200 77Pressure kPa 2945 2925Heat flow kJ/hr 7.02E+06 4.90E+06Heat Flow In Heat Flow outStream 2 = 7.02E+06 kJ/hrStream 3 = 4.90E+06 kJ/hrCooling Duty Qp = -2.12E+06 kJ/hrPage 26CHAPTER 5 ENERGY BALANCETemperature of Cooling water in = 25 0C, Temperature of Cooling water out = 30 0C Mass Flow rate of cooling water= m = Q/(T.Cp) = 101313.7 kg/hrMass Flow rate of Steam= m = Q/ = 3957 kJ/kg. KSimilarlyfortheotherheatexchangerinflowsheetwecan calculatetheheat duty andmassflowrateof waterorsteamneed tocool orheatthe processfluidwith the help of spread sheet.For all these calculations we have used: Temperature of cooling water in= 25 oC Temperature of cooling water out = 30 oC Temperature of Steam in () = 120 oCTemperature of Steam out= 120 oCHeat Exchanger Heating/Cooling Duty kJ/hr CW/Steam Flow Rate kg/hrE-102 -3.53E+06 168899.54E-103 -2.65E+06 126794.26E-104 -2.76E+06 132256.42E-105 -9.15E+05 43786.35E-106 -2.72E+05 13022.23E-107 -8.15E+05 38983.59E-108 -3.13E+05 14979.65E-109 -2.41E+05 11553.60E-110 -2.96E+06 141596.05E-111 -9.12E+06 436456.74E-112 2.75E+06 694.97E-113 9.34E+06 2360.37Page 27CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND VAPOR LIQUID SEPARATORStream number 16 17 18Hydrogen (kg/hr) 3.55 1.88 1.67CO (kg/hr) 80.79 48.60 32.20Propylene (kg/hr) 202.49 201.83 0.66Propane(kg/hr) 43.73 43.61 0.12n-butanal (kg/hr) 13718.63 13717.85 0.79I-butanal (kg/hr) 315.70 315.67 0.03Total (kg/hr) 14364.90 14329.44 35.46Temperature oC 40 40 40Pressure kPa 4968 4968 4968Heat Flow kJ/hr -4.70E+07 -4.69E+07 -1.29E+05Heat Flow InHeat Flow OutStream 16 = -4.70E+07 kJ/hrStream 17 = -4.69E+07 kJ/hrStream 18 = -1.29E+05 kJ/hrTotal = -4.70E+07 kg/hr =Total = -4.70E+07 kg/hrPage 28CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND VAPOR LIQUID SEPARATORStream number 25 26 27Hydrogen (kg/hr) 135.02 0.00 135.02CO (kg/hr) 2382.38 0.07 2382.31Propylene (kg/hr) 246.59 3.59 243.00Propane(kg/hr) 44.87 0.79 44.08n-butanal (kg/hr) 830.25 485.72 344.53I-butanal (kg/hr) 25.22 12.35 12.87Total (kg/hr) 3664.32 502.52 3161.80Temperature oC 1.43E+01 1.43E+01 1.43E+01Pressure kPa 3.00E+02 3.00E+02 3.00E+02Heat Flow kJ/hr -1.21E+07 -1.68E+06 -1.05E+07Heat Flow InHeat Flow OutStream 25 = -1.21E+07 kJ/hrStream 26 = -1.68E+06 kJ/hrStream 27 = -1.05E+07 kJ/hrTotal = -1.21E+07 kJ/hr= Total = -1.21E+07 kJ/hrPage 29CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND VAPOR LIQUID SEPARATORStream number 21 22 233.58 0.08 3.49CO (kg/hr) 68.76 2.16 66.60Propylene (kg/hr) 1.18 1.09 0.09Propane(kg/hr) 0.90 0.84 0.06n-butanal (kg/hr) 13458.03 13442.88 15.16I-butanal (kg/hr) 307.06 306.55 0.51Total (kg/hr) 13839.50 13753.60 85.91Temperature oC 2.47E+01 2.47E+01 2.47E+01Pressure kPa 3.00E+02 3.00E+02 3.00E+02Heat Flow kJ/hr -4.64E+07 -4.61E+07 -3.14E+05Heat Flow InHeat Flow OutStream 21 = -4.64E+07 kJ/hrStream 22 = -4.61E+07 kJ/hrStream 23 = -3.14E+051 kJ/hrTotal = -4.64E+07 kJ/hr =Total = -4.64E+07 kJ/hrPage 30CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND VAPOR LIQUID SEPARATORStream number 36 37 38140.18 140.16 0.02CO (kg/hr) 2481.10 2480.61 0.49Propylene (kg/hr) 243.75 240.86 2.89Propane(kg/hr) 44.26 43.63 0.62n-butanal (kg/hr) 360.47 262.65 97.82I-butanal (kg/hr) 13.41 10.55 2.85Total (kg/hr) 3283.17 3178.46 104.70Temperature oC 80 80 80Pressure kPa 4990 4990 4990Heat Flow kJ/hr -1.06E+07 -1.03E+07 -3.28E+05Material In Material OutStream 36 = -1.06E+07 kJ/hrStream 37 = -1.03E+07 kJ/hrStream 38 = -3.28E+05 kJ/hrTotal= -1.06E+07 kJ/hrTotal = -1.06E+07 kJ/hrPage 31CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND MIXER1 82 3 M -1 0 12 82 7Stream number 18 23 27 28Hydrogen (kg/hr) 1.67 3.49 135.02 140.18CO (kg/hr) 32.20 66.60 2382.31 2481.10Propylene (kg/hr) 0.66 0.09 243.00 243.75Propane(kg/hr) 0.12 0.06 44.08 44.26n-butanal (kg/hr) 0.79 15.16 344.53 360.47I-butanal (kg/hr) 0.03 0.51 12.87 13.41Total (kg/hr) 35.46 85.91 3161.80 3283.17Temperature oC 40 25 14 15Pressure kPa 4968 300 300 300Heat Flow kJ/hr -1.29E+05 -3.14E+05 -1.05E+07 -1.09E+07Heat Flow InHeat Flow OutStream 18 = -1.29E+05 kJ/hrStream 28 = -1.09E+07 kJ/hrStream 23 = -3.14E+05 kJ/hrStream 27 = -1.05E+07 kJ/hrTotal = -1.09E+07 kJ/hr Total= -1.09E+07 kJ/hrPage 32CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND MIXER2226M-102 4039Stream number 22 26 39 40Hydrogen (kg/hr) 0.08 0.00 0.02 0.11CO (kg/hr) 2.16 0.07 0.49 2.72Propylene (kg/hr) 1.09 3.59 2.89 7.57Propane(kg/hr) 0.84 0.79 0.62 2.25n-butanal (kg/hr) 13442.88 485.72 97.82 14026.42I-butanal (kg/hr) 306.55 12.35 2.85 321.76Total (kg/hr) 13753.60 502.52 104.70 14360.82Temperature oC 25 14 74 25Pressure kPa 300 300 300 300Heat Flow kJ/hr -4.61E+07 -1.68E+06 -3.28E+05 -4.81E+07Heat Flow InHeat Flow OutStream 22 = -4.61E+07 kJ/hrStream 40 = -4.81E+07 kJ/hrStream 26 = -1.68E+06 kJ/hrStream 39 = -3.28E+05 kJ/hrTotal = -4.81E+07 kJ/hr =Total = -4.81E+07 kJ/hrPage 33CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND MIXER3 7M - 1 0 34 54 3Stream number 37 43 45Hydrogen (kg/hr) 140.16 0.11 140.27CO (kg/hr) 2480.61 2.69 2483.30Propylene (kg/hr) 240.86 5.62 246.47Propane(kg/hr) 43.63 1.59 45.23n-butanal (kg/hr) 262.65 29.23 291.88I-butanal (kg/hr) 10.55 19.86 30.42Total (kg/hr) 3178.46 59.10 3237.57Temperature oC 80 90 80Pressure kPa 4990 260 260Heat Flow kJ/hr -1.03E+07 -1.50E+05 -1.04E+07Heat Flow InHeat Flow OutStream 37 = -1.03E+07 kJ/hrStream 45 = 3237.57 kJ/hrStream 43 = -1.50E+05 kJ/hrTotal = 3237.57 kJ/hr=Total = 3237.57 kJ/hrPage 34CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND STRIPPERStream number 17 10 11 19Hydrogen (kg/hr) 1.88 549.04 547.35 3.58CO (kg/hr) 48.60 8162.96 8142.80 68.76Propylene (kg/hr) 201.83 0.00 200.65 1.18Propane(kg/hr) 43.61 0.00 42.71 0.90n-butanal (kg/hr) 13717.85 0.00 259.82 13458.03I-butanal (kg/hr) 315.67 0.00 8.61 307.06Total (kg/hr) 14339.44 8712.00 9201.94 13839.50Temperature oC 40 211 44 1154968 5000 4965 4990-4.69E+07 -2.92E+07 -3.26E+07 -4.35E+07Heat Flow InHeat Flow OutStream 17 = -4.69E+07 kJ/hrStream 11 = -3.26E+07 kJ/hrStream 10 = -2.92E+07 kJ/hrStream 19 = -4.35E+07 kJ/hrTotal = -7.61E+07 kJ/hrTotal = -7.61E+07 kJ/hrPage 35CHAPTER 5 ENERGY BALANCEENERGY BALANCE AROUND DISTILLATION COLUMNStream number 41 42 43 440.11 0.00 0.11 0.00CO (kg/hr) 2.72 0.00 2.69 0.02Propylene (kg/hr) 7.57 0.00 5.62 1.96Propane(kg/hr) 2.25 0.00 1.59 0.66n-butanal (kg/hr) 14026.42 13722.02 29.23 275.16I-butanal (kg/hr) 321.76 166.64 19.86 135.25Total (kg/hr) 14360.82 13888.66 59.10 413.06105 112 90 90280 300 260 260-4.54E+07 -4.37E+07 -1.50E+05 -1.33E+06Heat Flow InHeat Flow OutStream 41= -4.54E+07 kJ/hr Stream 42= -4.37E+07 kJ/hrReboiler Duty = 9.34E+06 kJ/hrStream 43= -1.50E+05 kJ/hrStream 44= -1.33E+06 kJ/hrCondenser Duty = 9.12E+06 kJ/hrTotal = -3.61E+07 kJ/hrTotal = -3.61E+07 kJ/hrPage 36CHAPTER 6DESIGN OF EQUIPMENTSCHAPTER -6DESIGN OF EQUIPMENTSCHEMICAL REACTORReactoristheheartofachemical plant.Chemicalreactorsare thevesselsthat aredesignedforachemicalreactiontooccurinsidethem.Thedesignofachemical reactor deals with multiple aspects of chemical engineering. Itis thejob of achemical engineertoensurethatthereactionproceedswiththehighestefficiency towardsthe desired output product, producing the highestyield of product while requiring the least amount of money to purchase and operate.Normal operating expenses include energy input,energy removal,rawmaterial costs,etc.energy changescancomeintheformofheatingorcooling,pumpingto increase pressure,frictional pressureloss.However, in searchingfor the optimum itis notjustthecostof thereactorthatmustbeminimized.Rather,theeconomicsof the overall process must be considered.Reactor SelectionWiththevarietyofreactorsavailable,someengineersbelievethatreactor classificationisnotpossible.Nomatterhowincompleteaclassificationmaybe, however,thedesignerneedssomeguidance,eventhough theremaybesomereactor typesthatdonotfitintoanyclassification.Accordingly,wewillclassifyreactors using the following criteria:1. Form of energy supplied2. Phases in contact3. Catalytic or noncatalytic4. Batch or continuousPage 37CHAPTER 6DESIGN OF EQUIPMENTSForm of Energy SuppliedIn hydroformylation of propylene we use thermal energy for reaction completion.Phases in ContactThenextconsiderationisclassifyingthereactorsaccordingtothephasesin contact.These are:1. gas-liquid2. liquid-liquid3. gas-solid4. liquid-solid5. gas-liquid-solidAfterspecifyingtheenergyform,thecatalystandthe phasesincontact,thenexttask istodecidewhethertoconductthereactioninabatchorcontinuousmode.Inthe batchmode,thereactants arechargedtoastirred-tankreactor(STR)andallowedto reactforaspecifiedtime.Aftercompletingthereaction,thereactorisemptiedto obtaintheproducts.Thisoperatingmodeisunsteadystate.Otherunsteady-state reactors are:(1)Continuousadditionof oneormoreof thereactantswithnoproductwithdrawal, and(2)Allthereactantsaddedatthebeginningwithcontinuouswithdrawalof product.At steady-state, reactants flow into and products flow out continuously without a change in concentration and temperature in the reactor.Oursystemisgas-liquid.Soforgasliquidcontinuousflowwecanusetank reactor or tubular counter current reactor. Now we have to select either CSTR or PFR. There are twoideal modelsfor developingreactor-sizing relationships:the plugflow andtheperfectlystirred-tankmodels.Intheplug-flowmodel,thereactantsflowingthrough the reactor are continuously converted into products. During reaction there isResidence Time sPage 38CHAPTER 6DESIGN OF EQUIPMENTSno radial variation of concentration, backmixing or forward mixing. In a perfect STR, thereactantsarethoroughlymixedsothattheconcentrationofallspeciesandtemperature are uniform throughout the reactor and equal to that leaving the reactor.106105104Batch ReactorBackmix ReactorCascadeBackmix10310210Tubular Reactor110-110-4 10-310-210-1 1 10 102 103Production Rate kg/sFrom Reaction time and Production we have selected the CSTR for our process.Page 39CHAPTER 6DESIGN OF EQUIPMENTSCSTR (Continuous Stirred-Tank Reactor)InaCSTR,oneormorefluidreagentsareintroducedintoatankreactor equippedwithanimpeller w hilethereactoreffluentisremovedcontinuously.The impellerstirsthereagentstoensurepropermixing.Thecontentsofthereactorsare completelymixedsothatthecompletecontentsofthereactorsareatthesame concentration andtemperatureas theproductstream.Sincethereactorisdesignedfor steadystate,theflowratesoftheinletandoutletstreams,aswellasthereactors conditions,remainunchangedwithtime.Simplydividingthevolumeofthetankby theaveragevolumetricflowratet hroughthetankgivestheresidencetime,orthe average amount of time a discrete quantity of reagent spends inside the tank.In short CSTR has following properties.Mixing of reactantsGood temperature controlHigh heat and mass transfer efficienciesUseful for slow reactions requiring large hold up timeUniform composition though out the reactorDistribution of catalystIn our process carbon monoxide, hydrogen and propylene are converted to n-butyraldehyde in an aqueous phase containing a water soluble rhodium catalyst. The reaction,therefore,system consistsofthreedifferentphases:theaqueousphase,the organicphaseandthegasphase.Ithasbeenshownthatmasstransferplaysan importantroleinthisreactionsystem.Inordertotransferthegas tothereactionsite and to make the separate organic phase as dispersed phase we need agitation.Keeping these points in view CSTR has been selected.AgitationAgitationisameanwherebymixingofphasescanbeaccomplishedandby whichmassandheattransfercanbeenhancedbetweenphasesorwithexternal surfaces.Initsmostgeneralsense,theprocessofmixingisconcernedwithall combinations of phases of which the most frequently occurring ones are.Gases with gasesPage 40CHAPTER 6DESIGN OF EQUIPMENTSGases with liquidsGases with granular solidsLiquids into gasesLiquids with granular solidsPastes with each otherSolids with solidsThedimensionsoftheliquidcontentof avesselandthedimensionsand arrangementofimpellers,bafflesandotherinternalsarefactorsthatinfluencethe amountof energy requiredfor achievingthe required amount of agitation or quality of mixing.Theinternal arrangementsdependon theobjectivesof theoperation:whether itis to maintain the homogeneity of reactingmixture or to keep a solid suspended or a gasdispersedortoenhanceheatormasstransfer.Abasicrangeofdesignfactors,however can be defined to cover the majority of cases, for example as in figure.GaseousProductLiquidProductFeedThe VesselA dishedbottom requiresless powerthan aflatone. When asingleimpelleris to be used, a liquid level equal to the diameter is optimum, with the impeller located at the center for all liquid systems. Economic and manufacturing considerations,however often dictate higher ratios of depth to diameter.Page 41CHAPTER 6DESIGN OF EQUIPMENTSBafflesExceptat very high Reynolds numbers,baffles are needed toprevent vortexing androtationoftheliquidmassasawhole.Abafflewidthone-twelfththetank diameter,W=D/12; alength extendingfrom onehalf theimpellerdiameter,d/2,from the tangentline atthebottom to theliquidlevel,butsometimes terminatedjustabove thelevelof theeyeof theuppermostimpeller.Whensolidsarepresentorwhenheat transferjacketisused,thebafflesareoffsetfromthewalladistanceequaltoone sixth,W/6thebaffleswidth.Fourradial bafflesatequal spacing arestandard; six are only slightlymoreeffective,andthreeappreciablylessso.When themixershaftis locatedoff center,theresultingflowpattern hasfewerswirls,andbafflesmaynotbe needed, particularly at low viscosities.Draft TubesAdrafttubeisacylindricalhousingaroundaslightlylargerindiameterthan Partial pressure of PropyleneConcentration of RhodiumPECRh= 13.5 bar= 0.92 mol/m3Concentration of LigandsCLig= 22.08 mol/m3as CRh:CLig = 1:24Conversion of ReactionXA= 95%Initial Flow rate of PropyleneFA0= 58 mol/secTemperature of ReactionT= 393.15 KReaction PressureP= 50 barRate of Reaction Volume of Reaction Volume of CatalystrA Vr Vcat= 0.485 mol/m3.sec= FA0 x XA/rA = 110.63 m3= 16.38 m3Page 45theimpeller.Itsheightmay belittlemorethanthediameter of theimpelleroritmay extendthefulldepthoftheliquid,dependingontheflowpatternthatisrequired. Usuallydrafttubesareusedwithaxialimpellerstodirectsuctionaredischarge streams.Animpellerdrafttubesystembehavesasanaxialflowpumpofsomewhat lowefficiency.Itstoptobottomcirculationbehaviorisofparticularvalueindeep tanks for suspension of solids and for dispersion of gases.Impeller TypesThetypicalimpellersusedintransitionalandturbulentmixingarelistedin Table6-1.Thesehavebeendividedintodifferentgeneralclasses,basedonflow patterns,applications,andspecialgeometries.Theclassificationsalsodefine application types for which these impellers are used. For example, axial flow impellers areefficientforliquidblendingandsolidssuspension,whileradialflowimpellers are best used for gas dispersion. Up/down impellers canbe disks and plates, are consideredlow-shearimpellers,andarecommonlyusedinextraction columns.The pitchedbladeturbine,althoughclassifiedasanaxialflowimpeller,issometimesreferred to as a mixed flow impeller, due to the flow generated in both axial and radialPage 42CHAPTER 6DESIGN OF EQUIPMENTSdirections.AboveaD/Tratioof0.55,pitchedbladeturbinesbecomeradialflowimpellers.Flow Pattern ImpellerAxial Flow Propeller, Pitched Blade Turbine, HydrofoilsRadial FlowFlat-blade Impeller, Disc Turbine (Rushton), Hollow-blade TurbineHigh ShearCowles, Disc, Bar, Pointed blade ImpellerSpecialtyRetreat Curve Impeller, Sweptback Impeller, Spring ImpellerUp/Down Disks, Plate, CirclesImpeller SizeThis depends on the kind of impeller and operating conditions described by the Reynolds,Froude,andPowernumbersaswellasindividualcharacteristicswhose effects have been correlated. For the popular turbine impeller, the ratio of diameters of impellerandvessel fallsin the range,d/D = 0.3 0.6, thelower valesathigh rpm,in Partial pressure of PropyleneConcentration of RhodiumPECRh= 13.5 bar= 0.92 mol/m3Concentration of LigandsCLig= 22.08 mol/m3as CRh:CLig = 1:24Conversion of ReactionXA= 95%Initial Flow rate of PropyleneFA0= 58 mol/secTemperature of ReactionT= 393.15 KReaction PressureP= 50 barRate of Reaction Volume of Reaction Volume of CatalystrA Vr Vcat= 0.485 mol/m3.sec= FA0 x XA/rA = 110.63 m3= 16.38 m3Page 45gas dispersion.Impeller LocationExpertopinionsdiffersomewhatonthisfactor.Asfirstapproximation,the impellercanbeplacedat1/6theliquidleveloffthebottom.In somecasesthereis provisionforchangingthepositionoftheimpellerontheshaft.Foroff-bottom suspensionofsolids,amimpellerlocationof1/3diameteroffthebottommaybe satisfactory.Aruleisthatasecondimpellerisneededwhentheliquidmusttravel more than 4 ft before deflection.Impeller SelectionForgasdispersionradialflowimpellersarecommonlyusedsofrom tablewe have selected flat blade impeller.Modeling of mass transfer and chemical reactionThemodelthatisusedinthissectiontakesboththemasstransferandthe chemical reaction into account. The governing equations that determine the flux of the three gasses (A = H2, B = CO and E = propylene) into the aqueous liquid phase are:Page 43CHAPTER 6DESIGN OF EQUIPMENTSPartial pressure of PropyleneConcentration of RhodiumPECRh= 13.5 bar= 0.92 mol/m3Concentration of LigandsCLig= 22.08 mol/m3as CRh:CLig = 1:24Conversion of ReactionXA= 95%Initial Flow rate of PropyleneFA0= 58 mol/secTemperature of ReactionT= 393.15 KReaction PressureP= 50 barRate of Reaction Volume of Reaction Volume of CatalystrA Vr Vcat= 0.485 mol/m3.sec= FA0 x XA/rA = 110.63 m3= 16.38 m3Page 45From theseequationsthefluxof thedifferentgassesintotheliquidcanbe calculatedaccording to:The average flux in time can be determined using the penetration model:In the reactor model a constantpartial pressureof the gaseous reactants was assumedandtheoveralllossofCO,H2andpropylenefromtheliquidphase is neglected.Inthesteady statethefluxesofallcomponentsarethenequaltothe total reaction rate in the solution:Thebulkconcentrationsofthethreedifferentreactants canbedetermined from this equation.Page 44CHAPTER 6DESIGN OF EQUIPMENTSKineticsThekineticsofthehydroformylationreactioninthepresenceofa RhCl(CO)(TPPTS)2/TPPTScomplexcatalystwereexperimentallydeterminedby Yang et al. Partial pressure of PropyleneConcentration of RhodiumPECRh= 13.5 bar= 0.92 mol/m3Concentration of LigandsCLig= 22.08 mol/m3as CRh:CLig = 1:24Conversion of ReactionXA= 95%Initial Flow rate of PropyleneFA0= 58 mol/secTemperature of ReactionT= 393.15 KReaction PressureP= 50 barRate of Reaction Volume of Reaction Volume of CatalystrA Vr Vcat= 0.485 mol/m3.sec= FA0 x XA/rA = 110.63 m3= 16.38 m3Page 45(2002).Theseauthors variedthepropyleneconcentration,theinitial pressure,the H2/COratio,thetemperature,therhodiumconcentrationandtheligand torhodium ratioin an orthogonal experimental design to obtain the following rate expression:The constants are defined in Table 6.2:SIZING OF CSTRInsizingofCSTRfirstofallweshouldhaverateexpression6.7which,wehave already developed.VOLUME OF REACTORPartial pressure of HydrogenPA = 17.1 barPartial pressure of Carbon monoxide PB = 19.4 barCHAPTER 6DESIGN OF EQUIPMENTSHead VolumeVH= 12.70 m3Volume of ReactorV = 139.7 m3LENGTH AND DIAMETERFor CSTR Length to diameter ratio is 1. So L/D = 1SinceV = ( / 4) L D2 =127 m3WhereL = Length of the reactorD = Diameter of the reactorAfter putting L/D = 1 calculated thatLength L = 5.45 mDiameterD = 5.45 mWALL THICKNESSForthecalculationofwallthicknesswehavetocalculatethetotalpressure which is the sum of static pressure inside the reactor.Static Pressure can be calculated as:Static pressure = Ps = g hPutting the values and found thatPs = 940 9.81 5.45 = 50196 Pa = 50.19 kPaPressure in the reactor P1 = 5000 kPaTotal pressure = Pt= Ps+ P1 = 50.19 + 5000 = 5050.19 kPa Maximum allowableinternal pressure = 1.1 P = 5555 kPa For cylindrical Shells thickness of wall can be found as:t

P riSE j0.6P+ CcPage 46CHAPTER 6DESIGN OF EQUIPMENTSWheret = minimum wall thickness, mP = maximum allowable internal pressure, kPari = inside radius of shell before corrosion allowance is added, mS = maximum allowable working stress, kPaCc = corrosion allowance and its value is taken 3 mmEj = efficiency of joints expressed as a friction and its value is 0.85Putting the values of all variablet

5555 2.72(96105.2 0.85) (0.6 5555)+ 0.003t = 132.9 + 3.0 = 135.9 mmOUTSIDE DIAMETEROutside DiameterD0 = Di + 2t = 5.45 + 2(0.135.9) = 5.72 mREACTOR HEADThere are three types of head:1. Ellipsoidal head2. Torispherical head3. Hemispherical HeeadEllipsoidalheadisusedforpressuregreaterthan150psigandforlessthanthatpressure we use Torispherical head. Thats why we have selected Ellipsoidal head.Head thickness = tH =P D D i2S E j 0.2P D+Cc =5555 x 5.452 x 137895x 0.85(0.2 x 5555 )+.003= 132.74 mmPage 47CHAPTER 6DESIGN OF EQUIPMENTSAGITATOR DESIGNViscosity of Mixture at 393K = = 0.45 cpShape Factors areS1 = D/T = 1/3S2 = E/T = 1/3S3 = L/D= 1/4S4 = W/D = 1/5S5 = J/T= 1/10Agitator Dimensions are:Impeller DiameterImpeller Height above Vessel floorDE= T/3= T/3= 1.82 m= 1.82 mLength of Impeller BladeWidth of Impeller BladeL W= 0.25D= D/5= 0.45 m= 0.36 mPage 48CHAPTER 6DESIGN OF EQUIPMENTSWidth of Baffle J = T/10 = 0.54 mLength of Sparger Ls = T/3 = 0.36 mFor Gas-liquid-liquid mixture and reaction with heat transfer: Tip Velocity = 10 20 ft/secTip Velocity = 5 m/secTip Velocity = x Da x NForm this equation we can fine speed of Impeller as:Speed of Impeller N = 5/( x 1.82) = 53 RPMPOWER CALCULATIONSPower required by the impeller is given by following equationP =NP x x N3 D5WhereP = Power, wattsNp = Dimensionless power number= average density, Kg/m3N = no. of revolutions per min of impeller, RPM D = diameter of the impeller, mPower number is related with the Reynolds number of the impeller.REYNOLDS NUMBER:Reynolds no. of impeller is given by following equationPage 49CHAPTER 6DESIGN OF 2EQUIPMENTSN NDaReN Re= 6.04 106ForsuchahighReynoldsnumber,whichisgreaterthan105weusetherelationfor power requirement as:PowerP = KT x N3 x D5 x /gcKT from literature for six blade disc turbine = 5.75Putting these values in above equation we get: PowerP = 7346 Watts = 9.9886 hp Power consumption by gas spargerGas mass flow rate= 8828 kg/hrCompressor efficiency= 0.78Pressure difference due to sparger= 10 kPaGas density = 19.8 kg/m3Power consumption by sparger = (mG x x P)/GPower consumption by sparger = 0.966 watts = 0.0013hpTotal Power consumption = (0.0013+9.9886) = 9.989 hpItisassumedthatgearderiverequires5%oftheimpellerhorsepowerandsystem variations require a minimum of 10% of this impeller horsepowerThusActual minimum motor horsepower =impeller required hp/0.85= 9.989/0.85 = 11.75 hpm2Page 50CHAPTER 6DESIGN OF EQUIPMENTSSHAFT DESIGNContinuous average rated torque on the agitator shaft,Tc = (hp x 360 x 60)/ (2 N)= (11.75 x 360 x 60)/ (2 x 53)= 775.5 Kg mPolar modulus of the shaft,Zp = Tm/fsTm= 1.5 Tcfs shear stress = 550 kg/cm2Zp = (1.5 x 776 x 100) /550= 211.5 cm3d3/16 = 211.5d= 10 cm Diameter of shaft= 10 cm Force, Fm= Tm/3.61Rb Rb Radius of bladeFm = (1.5 x 158 x 100) / (3.61 x 45)= 711.6 KgMaximum bending momentumM = Fm x l.3= 701 x 1.3= 925 Kg-mEquivalent bending momentMe=12 [M + M1+T2]22Me=2 [925 + 925+(776 1.5)]Me= 1206 kg. mThe stress due to equivalent blendingF= Me/ZZ= d3 / 32 = x 103 / 32 = 98.13F= (1206 x 100)/98.13= 1229 Kg/cm2This is within the allowable limits of stress.Overhang of agitator shaft between bearing and agitator I = 130 cmPage 51CHAPTER 6DESIGN OF EQUIPMENTSModulus of elasticityE = 19.5 x 105 kg/cm2Shaft deflection = (Fm x I3)/(3E x x D4/64) = 0.54 cmHUB AND KEY DESIGNHub diameter of agitator = 2 x shaft diameter= 20 cmLength of the hub= 2.5 x 36.3 = 90.82 cmLength of key = 1.5 x shaft dia = 15 cmHEAT TRANSFER IN REACTORCooling Jacket area available A = DH + D2/4= ( x 5.42 x 5.42) + ( x 5.422 /4)= 153.29 m2CW inlet temp = 28 oC CWoutlettemp=33 oC Approaches;T1= 120 28 = 92T2= 120 33 = 87LMTD = 89.47 0C Heat, removable by jacketQ = UATM= 590 x 153.29 x 89.47 = 2.9e+7 KJ/hrThis heat is Sufficient, so we can use jacketNow Cooling water Flow rate can be calculated as: Heat to be remove from reactor = 2.82 x 107m = Q/( CpTM) = 77892 kg/hrPage 52CHAPTER 6DESIGN OF EQUIPMENTSSPECIFICATION SHEETIdentificationItem ReactorItem Number R-101Number of Item 1Operation ContinuousType Continuous Stirred Tank ReactorDesign DataVolume 139.71 m3Width of baffles 0.545 mLength 5.45 m Impeller above bottom 0.363 mDiameter 5.45 m Length of sparger 1.089 mNumber of Baffles 4 Speed of impeller 52.6 RPMType of Impeller Disc turbine Diameter of shaft 10 cmNumber of blades 6 Hub diameter 20 cmWall thickness 135.9087 mm Length of hub 90.82 cmHead thickness 132.7441 mm Length of key 15 cmImpeller Diameter 1.82 m Power requirements 11.75 hpLength of blade 0.45 m Jacket area 153.29 m2Width of Blade 0.363 m Water requirements 77891.86 kg/hrPage 53CHAPTER 6DESIGN OF EQUIPMENTSHEAT EXCHANGER DESIGNA Heat Exchanger is aheattransfer device thatis usedfor transfer of internal thermal energy between two or more fluids available atdifferent temperatures. In most oftheexchangersthefluidsareseparatedbyaheattransfersurfaceandideallydont mix with each other.CLASSIFICATION OF HEAT EXCHANGERIn general industrial heat exchangers are classified according to their:ConstructionTransfer processesDegrees of surface compactnessFlow arrangementsPass arrangementsPhase of the process fluidHeat transfer mechanismSELECTION CRITERIA FOR HEAT EXCHANGERSTheselectionprocessincludesanumberoffactors,dependinguponheattransfer application. These are as follows:SpaceOperating temperatureEfficiency Flow ratesAvailabilityFlow arrangementsEase of construction.Intended applicationOperating pressure Fouling tendenciesMaterial Compatibility Types and phases of fluidsMaterial of construction Fabrication techniqueOperational maintenanceOverall economyPage 54CHAPTER 6DESIGN OF EQUIPMENTSThermalrequirementandrepairpossibilitiesMaintenance, inspection,cleaning, extension,Environmental, health, and safety considerations andregulationsPerformance parameters-- thermal effectiveness andpressure dropsINDUSTRIAL APPLICATIONS OF HEAT EXCHANGERSHeatexchangersarecommonly usedinawidevariety ofindustrial,chemical, and electronics processes to transfer energy and provide required heating or cooling.Industrial types of heat exchangers are common in everyday equipment such asBoilersReaction vessels. Cooling towersFurnaces ChillersCoolersRefrigeratorsEvaporators CondensersDryers Pre heaters DistillationInfact,every airconditioning system and refrigeration system has atleasttwo heat exchangers o nefor the cooling side, and one toexpel the heat. In themajority of chemical processes heatis either given out or absorbed, and fluids must often be either heated or cooled in a wide range of plant.SHELL AND TUBE HEAT EXCHANGERSIn processindustries,shellandtubeexchangersareusedingreatnumbers,far more than any other type of exchanger. More than90-95% of heatexchangers usedin industryareoftheshellandtubetype.Theshellandtubeheatexchangersarethework horses of industrial process heat transfer.They are thefirstchoicebecause of well-established procedures for design and manufacturefromawidevariety ofmaterials,manyyearsof satisfactory service,and availabilityofcodesandstandardsfordesignandfabrication.Theyareproducedin thewidestvarietyofsizesandstyles.Thereisvirtuallynolimitontheoperatingtemperature and pressure.Page 55CHAPTER 6DESIGN OF EQUIPMENTSWe employed shell and tube heat exchanger due to following reasons:It occupies less space.Its maintenance is easy.Its compactness is more.They can tolerate dirty fluids.It is used for high heat transfer duties.These are mostly employed in industry.Means of directing fluid through the tubes.Means of controlling fluid flow through the shell.Used where large heat transfer surfaces are requiredConsideration for ease of maintenance and servicing.Inlet Temperature= T1= 120 0COutlet Temperature= T2= 40 0CConsideration for differential thermal expansion of tubes and shell.It can be fabricated with any type of material depend up fluid properties.They can be operated at higher temperature difference b/w coolant and gas.ShellandTubeheatexchangersareusedonapplicationswherethedemands on high temperatures and pressures are significant.Shell and tube (or tubular)heat exchangers are used in applications where high temperatureandpressuredemandsaresignificant. Theseheatexchangersconsistofa bundleof parallelsanitary tubes with theends expandedintubesheets.Thebundleis containedinacylindrical shell.Connectionsare such thatthetubes can contain either the productor the media,depending upon theapplication. Themajorlimitation is that they cannotbeusedtoregenerate, butthey can transferlots of heatdue tothesurface area.Therearemany differenttypesordesignsofshellandtubeheatexchangersto meet variousprocessrequirements.ShellandTubeheatexchangerscanprovide steadyheattransferbyutilizingmultiplepassesofoneorbothfluids.Tubularheat exchangers arealsoemployedwhenfluidcontainsparticlesthatwouldblockthechannels of a plate heat exchanger.Page 56CHAPTER 6DESIGN OF EQUIPMENTSDESIGN STANDARDS FOR SHELL AND TUBE HEAT EXCHANGERSThere are two major standards for designing shell and tube heat exchangers:TEMA standardsASME StandardsTEMA STANDARDSTheStandardsoftheTubularExchangerManufacturersAssociation(TEMA) describethesevariouscomponentsofshellandtubeheatexchangerindetail.An STHEisdividedintothreeparts:thefronthead,theshell,andtherearhead.Figure illustratestheTEMAnomenclatureforthevariousconstructionpossibilities. Exchangersaredescribedby thelettercodesforthethreesectionsforexample;a Inlet Temperature= T1= 120 0COutlet Temperature= T2= 40 0CBFLexchangerhasabonnetcover,a two-passshellwith alongitudinalbaffle,anda fixed tube sheet rear head.CLASSIFICATION OF SHELL AND TUBE HEAT EXCHANGERSThree principal types of shell and tube heat exchangers are:Fixed tube-sheet exchangersU-tube exchangersFloating head exchanger.GENERAL DESIGN CONSIDERATIONSThe points for designing a shell and tube heat exchanger are:Flow rates of both streams inlet and outlet temperatures of both streams.Operating pressure of both streams. This is required for gases, especially if the gas density isnotfurnished; itisnotreally necessary for liquids, as their properties do not vary with pressure. Allowablepressuredropforbothstreams.Thisisaveryimportantparameterfor heat exchanger design. Generally, for liquids, avalue of0.50.7kg/cm2is permittedpershell. Ahigherpressuredropisusuallywarrantedforviscous liquids, especially in the tube side. For gases, the allowed value is generally 0.050.2 kg/cm2, with 0.1 kg/cm2 being typical.Page 57CHAPTER 6DESIGN OF EQUIPMENTSFoulingresistanceforbothstreams.Ifthisisnotfurnished,thedesignershould adopt values specified in the TEMA standards or based on past experience.Physical properties of both streams. Theseincludeviscosity, thermal conductivity, density, and specific heat, preferablyat both inlet and outlet temperatures. Viscositydatamustbesuppliedatinletandoutlettemperatures,especiallyfor liquids,sincethevariation with temperaturemaybeconsiderableandisirregular (neither linear nor log-log).Heatduty.Theduty specifiedshouldbeconsistentforboth theshell sideandthe tube side.Inlet Temperature= T1= 120 0COutlet Temperature= T2= 40 0CTypeofheatexchanger.If notfurnished,the designercan choose thisbasedupon the characteristics of the various types of construction described earlier. In fact, the designer is normally in a better position than the process engineer to do this.Linesizes.Itis desirabletomatch nozzle sizeswithlinesizes toavoid expanders orreducers.However,sizingcriteriafornozzlesareusuallymorestringentthan for lines, especially for the shell side inlet.Nozzlesizesmustsometimesbeonesize(orevenmoreinexceptional circumstances) larger than the corresponding line sizes, especially for small lines. Maximumshelldiameter.Thisisbasedupontube-bundleremovalrequirements andislimitedby cranecapacities.Suchlimitationsapply only toexchangerswith removabletubebundles,namelyU-tubeandfloating-head.Forfixed-tubesheet exchangers,the only limitation isthemanufacturers fabrication capability andthe availabilityof componentssuchasdishedendsandflanges.Thus,floating-head heat exchangers are often limited to a shell I.D. of 1.41.5 m and a tube length of 6 m or 9 m, whereas fixed tube sheet heat exchangers can have shells as large as 3 m and tube length up to 12 m or more.Materials of construction.If the tubes and shell are made of identical materials, all componentsshouldbeof thismaterial.Thus,only theshellandtubematerialsof constructionneedtobespecified.However,iftheshellandtubesareof different metallurgy,thematerialsofall principal componentsshouldbespecifiedtoavoid anyambiguity.Theprincipalcomponentsare shell(andshellcover),tubes,channel (and channel cover), tube sheets, and baffles.Page 58CHAPTER 6DESIGN OF EQUIPMENTSTube sheets may be lined or clad.TUBE SIDE AND SHELL SIDE FLUID ALLOCATIONThe criteria for fluid allocation in shell and tube heat exchangers are:Specific pressure drop.The most corrosive to be tube sideThe higher pressure fluid to be tube side.Shell side boiling or condensation is usually preferred.Inlet Temperature= T1= 120 0COutlet Temperature= T2= 40 0CSevere fouling fluids shall be allocated the side which is accessible.PRELIMINARY THERMO- HYDRAULICS DESIGN STEPSFollowing are the Coulsons Design Steps for shell and Tube Heat ExchangerDefining heat-transfer rate, fluid flow-rates and temperatures.Collect physical properties data.Decide the type of exchanger.Select a trial value for the overall coefficient U.Calculate the LMTD required.Calculate the area required.Calculate the individual coefficientsCalculatetheoverallcoefficientandcomparewithtrialvalue.Ifthecalculated valuediffers significantly from estimatedvalue, substitute the calculated valuefor estimated value.Calculatetheexchangerpressuredrop,ifunsatisfactory,changeexchanger configuration.THERMO-HYDRAULICS CALCULATIONS SHELL SIDE DATARaw Butanal dataProcess ConditionsPage 59CHAPTER 6 DESIGN OF EQUIPMENTSMean temperature = Tm 80 oCMass Flow Rate = mh= 31420 kg/hrPhysical PropertiesSpecific Heat = Cp = 1.923 kJ/kgoCThermal Conductivity = k = 0.125 W/m oCDensity = = 866 kg/m3Viscosity = = 0.34 x10-3 kg/m.sTUBE SIDE DATACooling Water dataInlet Temperature = t1 = 30 oCOutlet Temperature = t2 = 37 oCMean temperature = tm = 33.5oCPhysical PropertiesSpecific Heat = Cp = 4.23 kJ/kg oC Thermal Conductivity = k = 0.61 W/m oCDensity = = 1015 kg/m3Viscosity = = 0.72 x10-3 kg/m.sDESIGN CALCULATIONSCalculation of Heat DutyFrom Energy Balance across heat exchanger E-14 we have Heat load q = 2.76 x 106 kJ/hrMass flow rate of water needed = 93300 kg/hrCalculation of LMTDCalculate the LMTDT logmean=T1 T2T 1ln (T 2 )Page 60CHAPTER 6DESIGN OF EQUIPMENTST logmean=83 1080Correction Factor Calculationln (10 )= 34.5 0CR= [Th,i - Th,o] / [Tc,o- Tc,i] R= 11.4P= [Tc,o - Tc,i] / [Th,i-Tc,i] P= 0.08Correction Factor F = 0.89Corrected LMTD= 30.7 0CSELECTION OF HEAT EXCHANGERSelectionCriteriaaccordingto,PlantdesignandEconomicsforChemicalEngineers by Max Peter1. Heat Duty of Exchanger q= 2.76 x 106 J/s2. Mass cooling water needed m= 93300 kg/hr3. Log mean temperature difference (LMTD)= 30.72 oC4. Average Value of UD [ = 1245 W/m2K5. Area at average overall heat transfer coefficient=50 m2For this area :Approx. Cost of multiple-pipe heat exchanger= $16500Approx. Cost of U-tube Heat exchanger= $ 9095Approx. Cost of fixed tube heat exchanger= $ 18190Approx. Cost of floating head heat exchanger = $ 55000The most suitable from these exchangers is U-tube heat exchanger.Assumption of overall dirt Heat Transfer CoefficientAssume:Ud = 700 W/m2 KTube SpecificationsStandard tube specification are taken from D.Q.Kern, Tabel 10Page 61CHAPTER 6DESIGN OF EQUIPMENTSTube side dimensions(cold fluid)BWG=14OD=0.019mID=0.0148mInside Surface Area/m=0.047m2/mTriangular pitch= 0.0254mNo.of passes=2Tube Wall Thickness = 0.0021mTUBE SIDE CALCULATIONSFlow AreaFlow area/tube=AC = 0.00017 m2Heat Transfer Area for assumed UDArea=A = 35.64 m2Outside surface Area of TubeOutside surface Area = Aot = 3.14 do L= 0.292 m2For this area number of tubes = A/A0t = 122 tubes Nearest number of tubes from literature = 138 tubes Corrected Heat Transfer Coefficient Udc = 619 W/m2 K Corrected Heat transfer area = AC= 40 m2Mass VelocityVelocityGt = mc/ (AC x no oftubesper pass)= 93300/(0.00017 x 69 x 3600)= 2209 kg/m2-sVt= Gt/(density)Page 62CHAPTER 6DESIGN OF EQUIPMENTSHeat Transfer Coefficient= 2209/1015= 2.18 m/s (within the range)hi from literature for water= 10000 W/m2K hi,o = hi x (ID/OD) = 7787 W/m2 K Reynolds NumberReynolds number= Gt ID/ = 2209 x 0.0148/0.00072= 45519 (turbulent flow)SHELL SIDE CALCULATIONSFlow AreaMass Velocity (Gs)ACS= (ID x Pd x Lb)/Pt= (0.54 x 0.108 x 0.00635)/0.0254= 0.0145 m2GS = mh/(flow area x 3600)= (14380)/(0.0145 x 3600)= 532 kg/m2sViscosity at Wall TemperaturetViscosity at wall temperature = w = 0.00042 kg/msEquivalent Diameter of ShellDe = 4(0.86 x P 2- 3.14 x D02/4)/(3.14 x D0)Reynolds NumberDe = 0.01805 mRe= (Gs x De)/ = (532 x 0.01805)/0.00034= 28270 (turbulent region)Page 63CHAPTER 6DESIGN OF EQUIPMENTSPrandtl NumberPr = (Cp x )/k=3.06 x 0.00034/0.000124= 8.33Heat transfer coefficienth

= 0.36 x (k/Di) x (Re)0.55 x (Pr)0.33 ( / w )0.14= 1399.5 W/m2KOverall Clean Heat transfer coefficient UCh i ,o h oUC =h i ,o+ h oUC = 1186 W/m2KOverall Dirt Heat transfer coefficient UD RD factor from literature = 0.0006 m2K/W Using this RD value and clean coefficient:UD= 693 m2K/WCheck for Assumed UDCheck for UD0