Production of ethanol Production of ethanol

From syngasFrom syngas

Design presentationDesign presentation

Done by:Done by: SARA BADER AL- SARA BADER AL-SAFISAFI

Supervised by:Supervised by:

Prof. M. fahimProf. M. fahim

My equipmentsMy equipments

1-Reactor 1-Reactor

2-Condenser 2-Condenser

3- Separator 3- Separator

First reactor First reactor

R-101(fixed bed reactor)R-101(fixed bed reactor)

The main reaction :The main reaction :2CO+4H2 2CO+4H2 CH3CH2OH+H2O CH3CH2OH+H2O

•Assumption taken to design reactor:Assumption taken to design reactor:

**to calculate conversion I assumed that this is the only reaction for to calculate conversion I assumed that this is the only reaction for

producing ethanolproducing ethanolethanol out =1834 ibmole/hr=X * CO in/2ethanol out =1834 ibmole/hr=X * CO in/2

X=12.6%X=12.6%

* * there is 3 reactor in parallel having same conversionthere is 3 reactor in parallel having same conversion

Design equationDesign equation

Rate lowRate low

ra = - k pH2^0.9*pCO^-0.76ra = - k pH2^0.9*pCO^-0.76

Where:Where:

PCO=Ca*R*T=ca0*(1-x)*(T/To)/(1+ex)*R*TPCO=Ca*R*T=ca0*(1-x)*(T/To)/(1+ex)*R*T

PH2=Cb*R*T=ca0*(θB-b/ax)*(T/To)/(1+ex)*R*TPH2=Cb*R*T=ca0*(θB-b/ax)*(T/To)/(1+ex)*R*T

V=Faoƒdx/-ra= Faoƒ(1/k *Pco*Ph2)V=Faoƒdx/-ra= Faoƒ(1/k *Pco*Ph2)

Taking space velocity 4000 and volume of one reactor Taking space velocity 4000 and volume of one reactor

176.05m2 176.05m2 from SRI reportfrom SRI report

Then rate constant Then rate constant k= 4.516 k= 4.516 kmole/volume^0.86/hrkmole/volume^0.86/hr

Taking L/D= 4 Taking L/D= 4

L=15.3m & D=3.8mL=15.3m & D=3.8m

Cost of one reactor=842400 US$Cost of one reactor=842400 US$

Cost of 3 reactor=2527200 US$Cost of 3 reactor=2527200 US$

From actual plant cost=8186400 $ From actual plant cost=8186400 $

Catalyst:Catalyst:

Taking catalyst to be cobalt Taking catalyst to be cobalt oxideoxide

And assuming prosity =o.4And assuming prosity =o.4

density = 1830 kg/m3density = 1830 kg/m3

Weight of catalyst =(1- Weight of catalyst =(1- porpsity)*volume*density=193304.54 kg porpsity)*volume*density=193304.54 kg

catcat

Condenser E-103Condenser E-103

Objective: Objective:

**To condense alcohol mixture and water **To condense alcohol mixture and water by cooled them to 140Fby cooled them to 140F

** using 3 condenser with same flow rate** using 3 condenser with same flow rate

Design equation Design equation

Inlet T=187.8 oC Inlet T=187.8 oC

Outlet T=60 oCOutlet T=60 oC

Using cooling water with inlet t=25 oC Using cooling water with inlet t=25 oC

Outlet t=50 oC Outlet t=50 oC

Qh = mh *Cp * (T1-T2)Qh = mh *Cp * (T1-T2)∆∆Tlm =(T1-t2)-(T2-t1) / ln((T1-t2)/(T2-t1))Tlm =(T1-t2)-(T2-t1) / ln((T1-t2)/(T2-t1))Ft is correction factor using figure and Ft is correction factor using figure and R=(T1-T2)/(t2-t1)R=(T1-T2)/(t2-t1)S=(t2-t1)/(T1-t1) S=(t2-t1)/(T1-t1) ∆∆Tm = Ft * ∆TlmTm = Ft * ∆TlmAssuming u to be 700 then provisional Assuming u to be 700 then provisional area =A= Q / U * ∆Tmarea =A= Q / U * ∆Tm

Area of one tube = L* do *πArea of one tube = L* do *π

Where L = tube length Where L = tube length

do=tube outside diameter do=tube outside diameter

Number of tubes = provisinal area / area of Number of tubes = provisinal area / area of one tubeone tube

Shell Ds = Db + Bundle diametrical Shell Ds = Db + Bundle diametrical clearanceclearance

Where Where Db = (do)*( Nt / K1)^ (1/n1)Db = (do)*( Nt / K1)^ (1/n1)

Bundle diametrical clearanceBundle diametrical clearance

From fig 12.10 From fig 12.10

Overall heat transfer coefficient= Overall heat transfer coefficient=

1/Uo =(1/ho) + (1/hod) + ( 1/Uo =(1/ho) + (1/hod) + ( do(ln(do/di))/2kw) + (do/di) * (1/hid) + do(ln(do/di))/2kw) + (do/di) * (1/hid) + (do/di) * (1/hi)(do/di) * (1/hi)

Outside coefficient(fouling factor)=hod Outside coefficient(fouling factor)=hod

Inside coefficient(fouling factor) =hid Inside coefficient(fouling factor) =hid

Pressure drop Pressure drop

ΔPt = Np [ 8jf (L/di)(µ/µw)^(-m) +2.5 ] ΔPt = Np [ 8jf (L/di)(µ/µw)^(-m) +2.5 ] ρut²/2 ρut²/2 where where

ΔPt = tube side pressur drop (N/m²)(pa) ΔPt = tube side pressur drop (N/m²)(pa)

Np = number of tube side passes Np = number of tube side passes

ut = tube side velosity (m/s) ut = tube side velosity (m/s)

L = length of one tube L = length of one tube

Jf=tube side friction factorJf=tube side friction factor

ΔPs = 8jf (Ds/de)(L/Lb)( ρus^2/2)(µ/µw)^(-ΔPs = 8jf (Ds/de)(L/Lb)( ρus^2/2)(µ/µw)^(-0.14) where:0.14) where:

Lb : baffle spacingLb : baffle spacing

Jf: shell side factor from RE and figJf: shell side factor from RE and fig

Result:Result:

for 3 condenserfor 3 condenser cost=591300$ cost=591300$

591300

separatorseparator

Objective:Objective:

to separate vapor from liquid which is to separate vapor from liquid which is alcohol mixture alcohol mixture

AssumptionAssumption

1- vertical separator1- vertical separator

2- using demister pad 2- using demister pad

3- 4 separator are used with same flow rate3- 4 separator are used with same flow rate

Calculation Calculation

1-Settling Velocity1-Settling Velocity

Ut =0.07*(rL-rv)/rv^.5)Ut =0.07*(rL-rv)/rv^.5)

2-Volumetric flow rate= mass flow/density2-Volumetric flow rate= mass flow/density

3-Using demister pad us=ut 3-Using demister pad us=ut

Dv=(4*Vv/3.14*us)^.5 Dv=(4*Vv/3.14*us)^.5

4-Liquid depth hv=volume held up /vessel 4-Liquid depth hv=volume held up /vessel area area

5-Volume of cylinder using Dv5-Volume of cylinder using Dv6-Thickness= (p*ri)/((s*Ej)-(0.6*p))+co6-Thickness= (p*ri)/((s*Ej)-(0.6*p))+coTotal height= hv+Dv/2+Dv+0.4+DV/2+Dv/2Total height= hv+Dv/2+Dv+0.4+DV/2+Dv/27-Area of vessel=2*3.14*Dv/2*ht7-Area of vessel=2*3.14*Dv/2*ht8-Volume of metal= thickness* area8-Volume of metal= thickness* area 9-Weight of metal=volume*density9-Weight of metal=volume*densityCost= 89800US$Cost= 89800US$For 4 separator= 359200For 4 separator= 359200

Result Result for 4 separatorcost=359200$for 4 separatorcost=359200$