EXECUTIVE SUMMARY

Waste from a reactor is to be processed to separate methane (CH4) from ethanol and pxylene. The stream is sent to a flash tank where practically all the methane is separated as vapor and then compressed before being sent to a tank farm for storage from where it can be offloaded using a train (Block flow diagram can be found in Appendix A). The following report outlines the design of the storage tanks and the tank farm. A material and mass balance was first done to calculate the amount of CH4 that needs to be stored per day and this yielded an answer of 1054.57 kmol CH4 including an extra capacity of 4 hours in case the train is delayed. The tank farm constructed consisted of 32 Carbon Steel, AS 1548-7-430 class 2B vessels, each with the capacity of 58.95 m3. The tanks were arranged in 4 rows of 8 tanks each with bypass lines in case of maintenance work. The drawing of a single tank is given in Appendix C and the outlay of the tank farm is given in Appendix D. The design temperature was calculated to be 1540 KPa while the design temperature was set at 50OC. Australian Standards were referred to while designing the tank and all fittings and accessories to ensure safety and efficiency. The vessel was designed with semiellipsoidal end caps as they are optimum for a pressure vessel. The outer diameter of the tank was 2896mm while the inner diameter was 2952mm; hence the thickness of the vessel and the end caps was 28mm. This includes a corrosion allowance of 1.96mm. The length of the vessel was 10.398m, which gives the aspect ratio of 3.52 which is close to the optimum ratio of 3. Appendix B shows the equipment specification sheet. The inlet and outlet nozzles were set at DN25 schedule 80 and DN100 schedule 40 respectively while the drainage pipe was selected DN200 schedule 40. A manhole of 0.5m diameter was also designed for the vessel. The vessel was designed in horizontal position with 2 saddles for support. For safety and control a pressure and temperature indicator was added along with a spring pressure relief valve set at 1.5 MPa. Fire alarm and safety systems were also recommended. A number of managerial and safety issues were also discussed.

1.0

INTRODUCTION

Storage of chemicals is one of the most common and important issues in the design of a processing facility. A good design is one that is economical and practical but at the same time does not comprise on safety in any way. Equipment for pressurized, flammable gasses need to designed with even more consideration to safety due to the increased risk it poses. The following report details the design of a tank farm for the storage of methane (CH4) separated from a waste stream using a flash drum. The methane is to be stored so that it is transported every 24 hours.

2.0

MASS AND MATERIAL BALANCE CALCULATIONS

A mass and material balance needs to be done around the system to know the amount of methane that needs to be stored (NB: block flow diagram of process is given in Appendix A). Flow rate of waste stream = 21,000 kg/hr Composition: 15 mol% methae 15 mol% ethanol (CH4) (EtoH) MW[1]: 16.04 kg/kmol MW[1]: 46.07 kg/kmol MW[1]: 106.17 kg/kmol

70 mol% p-exylene (Pex) MWavg = (MWi)(molesi) + (MWj)(molesk)+.

= (0.15x16.04) + (0.15x46.07) + (0.70x106.17) = 83.64 kg/kmol Overall Molar flow rate = = 251.10 kmol/hr

Now given the assumption that the ethanol and p-xylene exit the bottom of the flash tank (T1) at 25 OC and 1 atm pressure (i.e. no vapor phase for these components in the flash tank) and that methane is insoluble in the liquid, it can be assumed that all methane that enters the system exits from the top of the flash tank and that the top stream out of the flash tank is pure methane (~99.99%).

6.3 APPENDIX C: DRAWING OF SINGLE TANK

6.4 APPENDIX D: COMPLETE TANK FARM LAYOUT

6.4 APPENDIX E: METHANE COMPRESSIBILTY GRAPH