Professional Documents
Culture Documents
Contents
Chapter 1: .....................................................................
................................................................................
. 6
Formaldehyde ...................................................................
............................................................................ 6
1.1 Introduction ..............................................................
.................................................................... 7
1.2
History .............................................................
.............................................................................. 7
1.2 Uses Of Formaldehyde ......................................................
........................................................... 8
1.4 Properties Of Formaldehyde ................................................
....................................................... 10
1.4.1 Formaldehyde Gas ........................................................
...................................................... 10
1.4.2 Formaldehyde Liquid ....................................................
...................................................... 10
1.4.3 Formaldehyde Solution ...................................................
.................................................... 11
1.5 Physical Properties .......................................................
............................................................... 12
1.6 Properties Of Monomeric Formaldehyde ......................................
............................................. 16
1.7 ............................................................................
...............................................................................
16
Chemical Properties ............................................................
.................................................................... 16
1.7.1 Reaction With Ammonia ....................................................
........................................................ 16
1.7.2 Cannizzaro Reaction ....................................................
........................................................ 17
1.8 Formaldehyde Occurance ....................................................
....................................................... 17
1.9 Health And Safety Aspects .................................................
......................................................... 17
1.9.1 Formaldehyde ............................................................
......................................................... 17
1.9.2 Methanol ................................................................
............................................................. 18
Chapter 2: .....................................................................
...............................................................................
20
Manufacturing ..................................................................
.......................................................................... 20
Processes Of ...................................................................
............................................................................. 20
Formalin .......................................................................
...............................................................................
20
2.1 Process Comparison And Selection Criteria .................................
............................................... 21
2.1.1 Natural Gas Process .....................................................
....................................................... 21
.......................................................... 62
5.2 Absorption Column Design ..................................................
....................................................... 63
5.2.1 Number Of Plates ........................................................
........................................................ 63
5.2.2 Diameter Of Column ......................................................
..................................................... 66
5.2.3 Pressure drop across plate ..............................................
.................................................... 69
5.2.3 Height of Column ........................................................
........................................................ 70
5.3 Distillation Column .......................................................
............................................................... 71
5.3.1 Calculation of Minimum Reflux ratio and Number of Plates ................
.............................. 71
5.3.2 Superficial velocity ....................................................
.......................................................... 74
5.3.3 Column Diameter .........................................................
....................................................... 75
3
5.3.4 Plate Pressure Drop .....................................................
....................................................... 76
Chapter 1
Formaldehyde
7
1.1 Introduction
Formaldehyde CH
2
O is the first of the series of aliphatic aldehydes. It is also
known as exomethane and methanol according to IUPAC system. Formaldehyd
e has
become an industrial chemical of outstanding importance. The formaldehyd
e industries
continue to expand in 1972,world production has reached a probable vol
ume of at least
7.? million metric tons (calculated as 37% soln).Because of its relati
ve low cost, high
purity, and variety of chemical reasons, fom1aldehyde has become one o
f the world's
most important industrial and research chemical. It is not only an Im
portant low. cost
chemical intermediate, it is also a synthetic tool like hydrogenation,
oxidation etc. In
formaldehyde, the carbonyl carbon in functional group of aldehyde is directly li
nked with
one hydrogen atom. Since pure monomeric formaldehyde is a gas at ordinary temper
ature
and cannot be readily handled in this state, it is marketed chiefly in the form
of aqueous
solutions containing 37% to 50% formaldehyde by weight.
In addition, solution of formaldehyde in methanol, propanol and butanol
arealso
available commercially.The standard 37% U.S.P soln.contains sufficient' m
ethanol (715% by weight) to prevent precipitation of polymer under ordinary cond
itions of
transportation and storage. A 40% aq.soln of methanol containing about 8% methan
ol is
called formalin used for the preservation of biological specimens.
Commercial forms of fom1aldehyde also include the polymeric hydrate, pa
ra
formaldehyde, HO (CH
2
O)nH. This is known as paraform or some times as
trioxymethylene. This polymer behaves chemically as a solid form of fomaldehyde.
The
cyclic timer, s-trioxane (a-trioxymethylene) is also
commercially avail
able as a special
form of formaldehyde. The so called alphapoly oxymethylene ,HO(CH
2
O)nH in which n
is greater than 100 may be regarded as the end product of the series.
1.2 History
Formaldehyde was first discovered by Russian chemist A.M. Butlerov in 1859.He
was working. with derivatives of methyl iodide, allowed the iodide to
react with silver
acetate and then hydrolyzed the resulting solution. A vapor with an
irritating
and
pungent odour was evolved, but because of a mistake in determining the vapor d
ensity,
Butlerov failed to identify it as formaldehyde. Although Butlerov failed to r
ealize that
he was dealing with forrpaldehyde, his description of its physical and chemical
properties
8
including the isolation of para formaldehyde which he called dioxymethy
lene and
synthesis of hexamethylene tetramine are unquestionable. Historically, fonnaldeh
yde has
been and continuously to be manufactured from methanol. A. W Von Holf
mann
synthesized formaldehyde deliberately in 1868 by the reaction of methanol and ai
r in the
presence of platinum catalyst, and definitely established its chemical
identity. Practical
-26.666 kcal
Heat capacity
8.461 cal/c
Entropy
52.261 cal/c
Formaldehyde Liquid
12
1.5 Physical
It
ol and ether.
is a powerful
liquid.
Properties
is colorless, pungent smelling gas readily soluble in water, alcoh
It
disinfectant and antiseptic. When condensed it yields a colorless
CH
2
O Content (%) 37 37 37 45 . 50
CH
3
OH Content (%) 1 5 1 0 1 1
'.
Boiling Point (OF) 210 208 206 211 211
Density at 18C:
lb/gal 9.29 9.29 9.09 9.47 9.70
g/ml 1.113 1.101. 1.089 1.135 1.150
Approx. expansion 0.0005 0.0006 0.0006 0.0006 0.0006
coefficient
Flash Point
o
F
o
C)
13
Table 1.2: Influence of methanol content on density and refractive index of 370
/0
formaldehyde.
10
15
20
1.0890
1.0764
1.0630
14
1.3772
1.3776'
1.3778
Flash Point
152
147
133
132
30 - 60 1.04
37 50
6
37
8
37
10
'37
12
37
16
60 1.21
60 1.82
25 2.45,
25 2.58
25 2.58
25 2.69
at -80oC
at -20C
point at
point
= 0.9151 gm/cm3
= 0.8153 gm/cm3
101.3 Kpa = -9 C
= -18 C
6HCHO + 4NH
3
(CH2) 6N
4
+ 6H
2
O
hexamethylene tetra amine
1.7.2 Cannizzaro Reaction
The reaction which involves the
self-oxidation and reduction
of formaldehyde into acids and alcohols in the presence of a strong base ( e.g N
aOH ) is
called Cannizzaro reaction, the reaction gives sodium formate and methanol
2HCHO + NaOH
3
OH
HCOONa + CH
rubber or PVC gloves, eczema can be avoided. All persons having forme
rly suffered
from eczema are discouraged from working with formaldehyde. Formaldehyde
gas
irritates the mucous membranes of the eyes, nose and throat. Its solution has a
hardening
or tanning action on the skin. Some persons are hypersensitive to formaldehyde a
nd even
a slight exposure may lead to severe reaction in such cases. For opt
imum safety,
formaldehyde solution should be handled in closed equipment where ever possible.
Danger of Fire:
Formaldehyde is inflammable under certain conditio
ns, e.g. as vapors
from strong formaldehyde solution or par formaldehyde. Throughout the. Formal
dehyde
factory smoking and open fires are therefore prohibited. The management of the f
actory
must consent to any welding work to be carried out in the factory premises.
1.9.2 Methanol
Danger to Health:
Methanol is toxic, methanol in liquid
or gaseous form is easily
absorbed by the body. It can penetrate the body in following ways:
a) As vapors by heating.
b) Through the mouth.
c) Through skin (particularly in case of cuts & scratches)
Once absorbed by body, methanol in increasing doses may lead to naus
ea, blindness,
mental disorder & finally to death. There is no 'safe_ dosage, and i
ndividual sensibility
differs to a high degree. When working with methanol the footing should be obser
ved:
a) Gloves of rubber or PYC should be worn.
b)
Should there be any danger of spatters or leaks, protective glas
ses
should be worn.
c) Methanol must be used. or stored exclusively in rooms where there
is
sufficient ventilation.
d) If methanol is spilled, the spot in question must immediately be cleaned
with a large quantity of cold water. Clothes which have been splashed
by
19
methanol must be removed immediately. If the eyes are spattered with
methanol, they must be washed for at least 30 minutes. It is also.
Recommended to call for a doctor. In critical cases, first aid may b
e
rendered. Take the patient out into the 9pen air; avoid further contact with
methano1.Keep him-warm and calm. Give him oxygen. In case breathing
fails, give him artificial respiration. If methanol has entered the mouth, give
the patient an emetic consisting of salt and water.
Danger of Fire:
Methanol in liquid or gaseous form is easily inflammable. In the vic
inity of sroan and
large storage tanks and near factories, smoking and open fires are st
rictly prohibited.
Together with air or oxygen, methanol vapors form an explosive mixture
. Safety
precautions to be taken when handling methanol "are the usual ones fo
r flammable
liquids. Inhalation of its vapors should be avoided. The maximum allow
able methanol
vapors concentration for 8 hours working period is 200 ppm of air. Blindness may
result
when methanol is absorbed into the blood stream through the skin or
through other
means.
20
Chapter 2
Manufacturing
Processes Of
Formalin
21
2.1 Process Comparison and Selection Criteria
To
day about all of the world's
commercial formaldehyde is manufactured from methanol and air by using
metal or
metal oxide catalyst but a portion is produced by the partial oxidation of lower
petroleum
hydrocarbons. The former procedure gives essentially pure formaldehyde c
ontaining
methanol and traces of formic acid as a primary product, where as th
e later gives a
mixture of lower aliphatic aldehydes, alcohols and acids which on refi
ning yield an
excessive group of petro-chemicals.
Although there are, other mcellaneous methods
for producing
formaldehyde including the hydration of carbon oxides, the pyrolytic de
composition of
formates etc... But they do not appear to have achieved commercial importance.
2.1.1 Natural Gas Process
Normally three methods are u
sed for the manufacturing of
formaldehyde from natural gas:
1)
Oxidation in gaseous phase by passing mixture of gas and air
over
catalyst.
2) Oxidation of natural gas by ozone.
3) Iodination of subsequent hydrolysis.
Formaldehyde is also synthesized by cracking of methane in electric di
scharge. Many
types of catalyst e.g. copper, nickel, cobalt, chromium, manganese, gol
d and silver are
used for production of formaldehyde. Maximum conversion of 60% to 70of
methane to
formaldehyde occurs in this process.
2.1.2 Methanol Process
Formaldehyde is produced by vapor
phase oxidation of
methanol in excess of air followed by absorption of water liquid methanol is v
aporized
in vaporizer
then it is mixed with compressed air. These mixed stre
ams are then
introduce into tubular reactor, filled with silver catalyst Heat is generated by
oxidation of
Methanol. In this process, 87.4% conversion of methanol to formaldehyde takes pl
ace. In
natural gas process, the conversion of low molecular weight hydrocarbon
s in the
oxidation step together with a complex separation system,
results in
energy-intensive
plant, that, with increasing fuel .costs, suffers economically when competing wi
th newer,
22
more selective manufacturing methods Hence the methanol process is pref
erred. In
natural gas process, maximum conversion of methane to formaldehyde is
60% to 70%
while in methanol process, conversion of methanol to formaldehyde is 85% . that
is why,
methanol process is preferred over natural gas process. No doubt, Pakistan is bl
essed with
a large quantity of natural gas which is a good raw material for th
e manufacturing of
formaldehyde but we prefer methanol to natural gas as it is fractione
d from petroleum
and is cheaper one though imported from Middle East up to some exten
t. Also, natural
gas sources are decreasing in Pakistan day by day, that is why, nowadays instead
of using
natural gas process we prefer to import methanol and methanol process
is used in our
country;
2.2 Catalyst Comparison for Methanol Process
Formaldehyde is manufactured
commercially from methanol and air by an older process using a metal catalyst an
d newer
one using a metal oxide catalyst. Reactor feed to former is on the methanol-rich
side of a
flammable mixture and virtually complete reaction of oxygen is obtained
, conversely,
feed to metal oxide catalyst is lean in methanol and almost complete
conversion of
methanol is achieved. Methanol process gives essentially pure formaldehy
de containing
traces of formic acid as a primary product. Two types of catalysts are currentl
y used for
methanol oxidation:
1) Iron Molybdenum oxide catalyst.
2) Silver or copper catalyst.
2.2.1 Iron Molybdenum Oxide Catalyst
We normally use I
ron Molybdenum oxide
catalyst for best efficiency. Unreacted methanol content in formaldehyde ranges
between
0.5-1.0percent in this case. Another reason is that we feed a specifi
c ratio of methanol
and air in reactor. If this ratio is between 7.5-35 it produces an explosive mix
ture. In case
of iron
molybdenum oxide catalyst this ratio is less than 7.5 there
fore less methanol is
used in this process. So this catalyst is more economical to use Initial cost of
this plant is
although high but cost of product is low. A typical metal oxide catalyst' has an
effective
life of 12 to 18 months. Compared to silver catalyst, it is much mo
re tolerant to trace
contamination. It requires less frequent change-outs but a longer down
time for each
replacement.
23
2.2.2
d on Iron
Molybdenum Oxide Catalyst.
2.3 Process Description
The PFD shows a process to produce
formaldehyde and.
water. Fresh methanol, Stream 2, at 30C and 14.7 psia mixes with recy
cled methanol,
Stream 15, at 68.3C a 16 psia. Stream: 3 (recycled and fresh methanol) is at 35.4C
and
14.7 psia. Pump, P-I01, raises the pressure up to 35 psia. Stream 4
enters a heat
exchanger where the methanol is vaporized. Stream 5 is then at 150C and 29 psia.
Fresh
air is available at 25C and 14.7 psia in Stream 1. Compressor, C 101, raises the
pressure
to 35 psi a in Stream 5. This stream is then heated by medium-press
ure steam. The
temperature is raised to 150C in Stream 7. Stream 6 and Stream 7 mix at a pressu
re of
29 psia. The combined mixture is at 149.6C and 28 psia in Stream 8.
The reactor
converts 87.4% of the methanol. The exit reactor temperature is 343 C. The metal
oxide
catalyst that has approximately uniform activity over a One year period, and cat
alyzes the
oxidation reaction.
CH
3
OH + 0.5 O
2
HCHO + H
2
O
Heat is removed by making high-pressure steam from boiler feed water.
The outlet,
Stream 9, is at 343C and 25 psia. A valve drops the pressure of thi
s stream to 5 psia
before. it enters the absorber T -101. Fresh water is sent through the T -101 at
30C and
20 psia. T -101 is set to absorb 99% of the' formaldehyde that enters. Stream
13 is then
heated to 102C before entering T -102, the formalin distillation column T -101 re
covers
a 37 wt% solution of formaldehyde in water. Most of the methanol is
recovered in the
24
distillate. Stream 15, the distillate, is recycled back to the inlet
of fresh methanol at
68.3C and 16 psia. The bottoms Stream 16 is pumped, by P-I03, up to
38.5 psia for
storage. Deionized water at 30C in Stream 18 is added to. Achieve the 37 wt% solu
tion
of formaldehyde in water. Storage of formalin is tricky. At high temperatures, u
ndesirable
polymerization of fomaldehyde is inhibited, but fom1ic acid formation is favored
. At low
temperatures acid fom1ation is inhibited, but polymerization is favored.
With 2 wt%
methanol, the storage tank contents must be maintained between 35C and 45C.
25
Chapter 3
Material Balance
Calculations
26
3.1 Mass Balance Calculation Reactor
F = 100 Kgmol/hr
CH
3
OH =
0.2982
O
2
=
0.1459
CH
2
O =
0.00001477
H
2
O
=
0.0472
N
2
=
0.5511
Total
=
1.00
A
CH
3
OH
O
2
CH
2
O
= ?
H
2
O
= ?
N
2
= ?
Reaction:
3
OH + 0.5O2
CH
CH
2
O + H
2
O
27
Basis: 100 Kgmol/hr of F
N
2:
(0.5511) 100
N2
.
A
X
N2
.
A
=
55.11Kgmol/hr
Reactor Conversion
= 87.4%
HCHO Produced:
29.28 kgmol CH
3
OH 1 Kgmol CH
2
O Produced 0.874
1 Kgmol CH
3
OH Produced
=
2
O
26.06Kgmol CH
2
required for oxidation of Methanol:
29. 82 kgmol CH
3
OH 0.5 Kgmol O
2
required 0.874
1 Kgmol CH
3
OH reacted
= 13.03 kgmol O
2
required
Unreacted O
2 =
14.549 13.03
= 1.56 Kgmol O
2
H
2
O Formed
29.82 kgmol CH
3
OH
1 Kgmol H
2
O 0.874
1 Kgmol CH
3
OH reacted
= 26.06 Kgmol H
2
O
29
Water present already in feed = 0.472 kgmol
Total Water
= 269.06 + 0.472
= 26.532 kgmol
A
3
OH
2
=
+ O
+ CH
2
O
2
O
2
+ H
+ N
CH
3.76 +
A
1.56 + 26.06
113.02 Kgmol/hr
30
2.2 Absorption Column
W = 211 Kgmol/hr
H
2
O = 1.0
3
OH = 0.0369
247.388Kgmol/hr
CH
O
2
= 1.56
CH
2
O
= 0.259
H
2
O
= 190.42
N
2
= 55.11
A
=
113.022 kgmol/hr
CH
3
OH = 0.0332
CH
3
OH = ?
O
2
= 0.0138
CH
2
O
= ?
CH
2
O
= 0.2305
H
2
O
= ?
H
2
= ?
+ 26.532
+ 55.11
O
= 0.2347
N
2
= 0.4876
31
CH
3
OH:
X
CH3 OH, B
=
0.99 (.0332113.022)
= 3.68064 Kgmol/hr
CH
2
O:
X
CH2O, B
=
0.99 (.2305113.022)
= 25.795 Kgmol/hr
For stream B:
Species Kgmol/hr Kg/hr Weight %
CH
3
OH 3.68064 117.78
CH
2
O 25.795 773.85 44 (assumed)
H
2
O 471.158 848.84
Total 76.68 1740.476
B
G
G
G
H
2
O:
=
=
=
=
76.68 Kgmol/hr
A + W B
113.022 + 211 76.68
247.388 Kgmol/hr
X
H2O,G
= X
H2O,A
+ X
H2O,A
X
H2O,B
X
H2O,G
= 190.426 Kgmol/hr
In terms of fraction
CH
3
OH = 0.048
CH
2
O
= 0.3364
H
2
O
= 0.615
32
3.3
Distillation Column
=
CH
3
OH = ?
CH
2
O = ?
H
2
O
= ?
76.68 Kgmol/hr
CH
3
OH = 0.048
3
OH
= ?
CH
2
O
2
O
= 0.3364
H
2
O
2
O
= 0.615
= ?
CH
CH
= ?
= ?
X
H2O,C
X
H2O,R
= .6418 Kgmol/hr
For stream R
50000 Mton
1 year
1000 kg
= 6250 kg/hr
Yr
8000 hr
1 Mton
Avg Mol. Wt
= 30(0.261) + 18 (0.738)
= 21.114 kg /kgmol
6250 kg
= 296.012 Kgmol/hr
Hr
25.92kg
1 kgmol
Original (18)
26.141Kgmol/hr
= 176.90(w)/676.71
Thus, (19)
= 72.4785 + 26.141
(19)
= 98.62 kgmol/hr
Stream(14):
(13) = (14)
Stream(15):
76.68 Kgmol (14) Produce (15)
= 4.203 Kgmol
1
//
//
= 4.203/76.68
313.1713
//
//
= 4.203/76.68 313.1713
Stream (15)
= 17.166 Kgmol/hr
Stream(16):
76.68 Kgmol (14) Produce (16)
= 72.4785 Kgmol
1
//
//
= 72.4785/76.68
313.1713
//
//
= 72.7485/76.68 313.1713
Stream (16):
= 296.01 Kgmol/hr
Stream(17):
(16)
= (17)
38
Stream(18):
72.4785 kgmol (16) needs (18)
= 26.141 kgmol
1
//
//
//
= 26.141/72.478
296.01 //
//
//
= 26.141/72.478 296.01
(18) = 106.76 Kgmol/hr
Stream(19):
Thus
(19) = (17) + (18)
(19) = 402.775 kgmol/hr
Stream(1):
100 Kgmol (8) needs (1)
= 471.71/676.71 100 = 69.7
1 //
//
//
= 69.7/100
408.414 //
//
= 69.7/100 408.414
Stream (1) = 283.724 Kgmol/hr
Stream(2):
100 Kgmol (8) needs (2) = 176.9/676.71 100 = 26.14
1
//
//
// = 26.14/100
408.414
//
//
= 26.14/100 408.414
Stream (2) = 106.58 Kgmol/hr
39
Stream(3):
(3) = (2) + (15)
(3) = 106.58 + 17.166
Stream (3) = 123.74 Kgmol/hr
I) Stream(3) = Stream(4) = Stream(6) = 123.74
II) Stream(1) = Stream(5) = Stream(7) = 283.72
Check:
Stream (6) + Stream (7) = Stream (8)
123.74
+
283.72
=
408.414
407.4
=
408.414
40
Chapter 4
Energy Balance
Calculations
41
(1) n
air
=
283.724 kgmol/hr
So,
Adiabatic Compression:
1
1 1
2 2
T P
T P
T
T
| |
=
|
\ .
Where = 1.4
P1 = 101.3 kPa
P2 = 241.2 kPa
T1 = 298 K
T2 = 382 K
= 283.724 [28.09(382-298+ 0.1965x 10
-2
(382
2
-298
2
) +
2
0.4799 x 10
-5
(382
3
-298
3
) 1.965 x 10
-9
(382
4
- 298
4
)]
3
H = W
& compressor
= 85%
So,
696086.6
819772.5 820
0.85
Ws kJ MJ = =
42
]
=
-2
283.724[28.09(423-382) + 0.1965x10
(423
2
-382
2
)
2
+ 0.4799x10
-5
(423
3
-382
3
) - 1.965x10
-9
(423
4
-382
4
)]
3
3
= 283.724 [1151.69+32.247+31.9-5.267]
H
air
= 343518.83kJ
Since
(h
7
h
5
)
=
q5-7
=
m
S
Now, Medium pressure steam is at 1200 kPa & at this pressure
S
= 1984.3 kJ/kg
Thus:
m
m
43
=
343518.83kJ
1984.3kJ/kg
=
141.5kg/hr
H2O
=
T = 53.23
q
H2O
= 1.948 (29.526-8.8999x 10
-3
T + 3.8083x 10
-5
T
2
)
= 1.948 (29.526 2.982 + 4.2768 1.228)
= 1.948 (29.59)
T+ n
= 3068.24 + 80469.85
= 83538.094 kJ
44
q
CH2O
=
.0060939
[34.4260 T
-2
2
-2.9779x10
2
T +
4 7
3 4
1.5104x10 -1.2733x 10
3 4
T T
]
=
11.875 + 156.9 = 168.8 kJ
Q
= q
CH4O
+
q
H2O
+
q
CH2O
Q
= 5071691.357 kJ/hr =
-4
Btu
1kJ
1J
hr
Q
=
Since:
n (h
6
-h
4
4809992.083 Btu/hr
kJ
1000J
9.484 X 10
) = Q
4-6
= m
At 1200 kPa = 1984.3 kJ/kg
So,
m
m =
5071691.357 kJ/kg
1984.3 kJ
2555.9 kg/hr
(Mass of Steam)
45
4.4
Here
T
c
= Critical temp
T
b
= boiling point
L
v,b
= Latent heat at normal b.p
Thus:
L
H2O
= 40683
0.38
647.3 361.73
647.3 373
L
H2O
= 41308.96kJ/kgmol
n
H2O
= 80469.85 kJ
L
CH2O
= 40683
0.38
408 361.73
408 253.8
L
CH2O
=
25748.67 kJ/kmol
n
CH2O
= 126.74kJ
46
L
CH3OH
= 40683
0.38
512.6 361.73
512.6 337.6
L
CH3OH
= 38452.768
n
CH3OH
= 4682993.423 kJ
4.5 Energy Balance across Reactor (R-101)
Reactants
423k
Reactant
298 K
H
=
1
+ H
2
+ H
3
For H
Products
616k
Products
298 K
H
1
H
1
=
H
CH3OH
= 121.7856 [40.046 (T
2
T
1
)
( )
-2
2 2
2 1
3.8287x10
T -T
2
+
( ) ( )
4 7
3 3 4 4
2 1 2 1
2.4529x10 2.1679x 10
T -T T -T
3 4
]
T
2
- T
1
=
298-423
= -125k
( )
2 2
2 1
T -T
=
298
2
-423
2
= -90125k
( )
3 3
2 1
T -T
3
-423
3
=
( )
4 4
2 1
-49223375k
298
T -T
=
4
-423
4
= -2.42x10
10
k
298
47
=
H
CH3OH
=
-729926.8655 kJ/hr
H
CH2O
=
.0060939
[34.4260 (T
2
- T
1
)
( )
-2
2 2
2 1
-2.9779x10
T -T
2
+
( ) ( )
4 7
3 3 4 4
2 1 2 1
1.5104x10 -1.2733x 10
T -T T -T
3 4
]
H
CH2O
=
.0060939
[-4303.25+1341.916-2478.2+770.3]
H
CH2O
=
-28.45 kJ/hr
H
N2
=
2
T
1
224.142 [29.342(T
)
( )
-3
2 2
2 1
-3.595x10
T -T
2
+
( ) ( )
5 9
3 3 4 4
2 1 2 1
1.006x10 -4.311x 10
T -T T -T
3 4
]
H
N2
= -817555.70 kJ/hr
H
O2
= 59.582 [29.526(T
2
T
1
)
( )
-8
2 2
2 1
-8.899x10
T -T
2
+
( ) ( )
5 8
3 3 4 4
2 1 2 1
3.808x10 -3.262x 10
T -T T -T
3 4
]
H
O2
= -221471.06 kJ/hr
H
H2O
= 1.948[33.933(T
2
-T
1
)
( )
-3
2 2
2 1
-8.4186x10
T -T
2
+
( ) ( )
5 8
3 3 4 4
2 1 2 1
2.9906x10 -1.7825x 10
T -T T -T
3 4
]
H
H2O
= -8269.53 kJ/hr
48
Thus,
H
1
H
CH3OH
+
H
CH2O
+
H
N2
+
H
H2O
+
H
O2
H
1
=
-1777251.612 kJ/hr
For H
2
(From data)
( H
f
)
CH3OH
= 121.7856 (-201170)
= -24499609.15 kJ/hr
( H
f
)
CH2O
= .0060939
(-115920)
= -706.405 kJ/hr
( H
f
)
H2O
= 1.948 (-241800)
= -471026.4 kJ/hr
Thus,
H
2
= -24971341.96 kJ/hr
For H
3
H
3 =
T
2
- T
1
=
616-298 = 318
( )
2 2
2 1
T -T
=
616
2
-298
2
= 290652
( )
3 3
2 1
T -T
3
-298
3
616
= 207281304
( )
4 4
2 1
T -T
4
-298
4
= 1.36x10
11
49
616
H
CH3OH
= 121.7856[40.046 (T
2
T
1
)
( )
-2
2 2
2 1
3.8287x10
T -T
2
+
( ) ( )
4 7
3 3 4 4
2 1 2 1
2.4529x10 2.1679x 10
T -T T -T
3 4
]
H
CH3OH
= 2039746.835 kJ/hr
H
CH2O
= .0060939
[34.4260 (T
2
- T
1
)
( )
-2
2 2
2 1
-2.9779x10
T -T
2
+
( ) ( )
4 7
3 3 4 4
2 1 2 1
1.5104x10 -1.2733x 10
T -T T -T
3 4
]
H
CH2O
= 77.55 kJ/hr
H
N2
= 224.142 [29.342(T
2
T
1
)
( )
-3
2 2
2 1
-3.595x10
T -T
2
+
( ) ( )
5 9
3 3 4 4
2 1 2 1
1.006x10 -4.311x 10
T -T T -T
3 4
]
H
N2
= 2099308.59 kJ
H
H2O
= 1.948[33.933(T
2
-T
1
)
( )
-3
2 2
2 1
-8.4186x10
T -T
2
+
( ) ( )
5 8
3 3 4 4
2 1 2 1
2.9906x10 -1.7825x 10
T -T T -T
3 4
]
H
H2O
= 21481.589 kJ/hr
H
O2
= 59.582 [29.526(T
2
T
1
)
( )
-8
2 2
2 1
-8.899x10
T -T
2
+
( ) ( )
5 8
3 3 4 4
2 1 2 1
3.808x10 -3.262x 10
T -T T -T
3 4
]
H
O2
= 5730459.37 kJ/hr
50
Thus,
H
3
=
H
CH3OH
+
H
CH2O
+
H
N2
+
H
H2O
+
H
O2
H
3
= 4733659.924 kJ/hr
Hence:
H
=
H
1
+
H
2 +
H
3
H
=
- 22014933.6 kJ/hr
Across Reactor:
Q = mc
p
(T
b
-25) +m
Cp of steam at 380k &1200 kPa is
=
4.18 kJ/kgmol.k
T
B
= 461.11k = 187.96
0
C
Q = m (4.18 (461.11-298) + 1984.3)
= m (2666.09)
m =
22014933.65
2666.09
m = 8257.35kg/hr
51
4.6 Heat Exchanger Duty (E-103)
Stream (13) = 313.1713 kgmol/hr
CH
3
OH = .485 = 15.18
CH
2
O
= .3364 = 105.35
H
2
O
= .615 = 192.6
T
14
- T
13
= 22k
T
14
2
- T
13
2
= 16016k
T
14
3
- T
13
3
= 8747398k
T
14
4
- T
13
4
= 4.2x10k
T
14
= 375k
T
13
= 353k
H
CH3OH
= 15.18 [881-306.6+715.2-227.63]
H
CH3OH
= 16120.7 kJ/hr
H
CH2O
= 105.35[757.372-238.4+440.4-133.7]
H
CH2O
= 86984.54 kJ/hr
H
H2O
= 192.6[746.5-67.4+87.2-18.7]
H
H2O
= 143987.76 kJ/hr
H
=
H
CH3OH
+
H
CH2O
+
H
H2O
H
= 247093 kJ/hr
n (h
14
- h
13
) = q
13
- q
14
= m
m
247093
1984.3
m
= 124.52 kg/hr
52
Chapter 5
Equipment Design
53
5.1 Reactor Design
Reactor conversion
87.4%
(Methanol Formaldehyde)
Isothermal Reactor
= 246.3
o
C (519.3K)
Pressure = 182.6Kpa
5.1.1 Volume of the Catalyst
Basic performance equation for Plug Flow Rector is:
1
(V)
=
XAf
dX
A
or
C
Ao
XAf
dX
A
F
AO
0
-r
A
0
-r
A
The rate expression for methanol- formaldehye system is:
-r
m
=
K
1
Pm
1+k
2
Pm
Here
Where
519.3K
log
10
k
1
= 10.79 1
5640
0.8492
T
log
10
k
2
= 11.43 -
3810
2
T
from (2)
Pm V = nRT
A
RT
So,
-r
m
Pm = C
=
k
1
C
A
RT
RT k
1
CA
12394
1+k
2
C
A
RT
RT (1/RT + k
2
CA)
Put in eq (1) we have
54
AO
XAf
1/RT + k
2
C
A
dX
A
0
k
1
C
A
Now:
C
=
A
C
AO (
1-X
A)
(1 +
A
X
A
)
CH
3
OH + 0.5O
2
HCHO + H
2
O
Here
A
=
xA = 1
- V
xA = 0
=
2 - 1.5
0.333
V
xA= 0
1.5
Now, total no. of moles entering.
n = 408.4135 kmol/hr
PV
o
=
nRT
V
O
=
nRT
P
V
o
= 408.4135x8.314x519.3
182.6
V
o
= 9656.6 m
3
1hr
V
o
= 160.9 m
3
/min
hr
Now:
60 min
F
methanol
=
121.78kgmol
methanol
=
2.02 kgmol /min
1hr
F
hr
55
Thus:
60 min
Ao
=
Fm =
2.02
Vo
160.9
C
Ao
=
0.0126
Kmol
m
3
From (3)
Ao
XAf
1/RT + k
2
C
A
dX
A
0
k
1
C
A
Put
1 =
RT
0.00189
8.314x519.3
k
1
= 0.8492
k
2
= 12394
AF
= 0.874
& X
= C
AO
0.874
0.00189+12394
A
dX
A
0
0.8492 C
A
Since C
A
=
C
AO
(1-XA)
So (4) becomes:
(1+0.33
XA
)
AO
= C
0.874
(1+0.33X
A
)
(0.00189(1+0.33X
A
)+12394C
AO
(1-X
A
))
dX
A
0
C
AO (1-XA)
(1+0.33X
A
)
Put C
AO
= 0.0126
& simplify
= 1.178
0.874
0.00189(1+0.33
X
A) +0.0126x12394
(1-X
A
)
dXA
0
(1-X
A
)
56
Solving integration
=
0.874
0.00189+(1+0.33
X
A)
dX
A+ 156.16
0.874
(1-XA)
A
(-X
A
0.874
)
0
dX
(1-X
A
)
0
(1-XA)
0
= 0.00189 [
0.874
1
dX
A
+ 0.33
0.874
1
dX
A
]
+56.16x(0.874)
0
1-X
A
0
1-X
A
= 0.00189 [
In (1X
A)
0.874
+ 0.33
0.874
1-1+
X
A
d
X
A
]
+136.5
0
1- X
A
= 0.00189[-[In(1-0.874)-In (1)]]+0.33[
0.874
1 d X
A
0.33
0.874
1-1 X
A
]
+136.5
0
A
1- X
A
= 0.00189 (2.07)+0.33[-In (1-XA)
0.874
- X
A
0.874
] + 136.5
0
0
= 0.0039+0.33 (2.07-0.874)+ 136.5
= 0.39+ 136.5 = 136.9
Thus:
= 1.178x136.9 = 160.78
Kmol
kg.hr
3
m
3
Kmol
1- X
950kg
= 0.1692 hr
= 10.15min
57
= C
AO
W
F
AO
W =
AO
=
W =
10.15x2.02
C
1627.9 kg
AO
0.0126
Vol. of catalyst =
Wt
of catalyst
Ca
950
V = 1.7 m
3
5.1.2 Catalyst
Dimensions
Diameter of catalyst
= 3mm
Voidage
Let
// //
Density
= 55% -65%
= 60% = 0.60
= 950kg/m
3
Volume of vessel
B
= ?
V
B
-V
P
= 0.6
V
B
V
B
-1.7
= 0.6 = V
B
0.6
= V
1627.9
V
B
=
1.7
V
B
0.4 V
B
=
1.7
V
B
=
3
4.25m
58
Diameter of tube
= 3in
// // //
=
12
Length of table
3 =
Vol. of tube
2
L
1
= 3.141 x
2
x 6.096
0.25ft = 0.0762m
= 20ft = 6.096m
Di
(0.0762)
4
4
= 0.027m
3
No. of tubes
= V
B
=
4.25
v
t
0.0277
= 153 tubes
Pitch
= 1.25 x O. D
k
1
)
1/n
1
D
o
= outer dia
= 3.5in = 88.9 = 0.0889m
For f=1 pass & square pitch
59
k
1
= 0.215
&
1
=
2.207
D
B
=
0.0889
153
)
1/2.207
0.215
D
B
= 1.74 m
= 1742 mm
D
S
=
B
D
S
= 1742 + 27.4
D
S
=
1769.4mm
D
27.4 + D
S
=
dia of inside shell = 1.76m
5.1.3
Pressure Drop
Using Ergun Eq
P
150 (1-e)
2
( x u
c
)
1.75 (1-e ) ( x u
c
2
)
l
3
d
2
e
3
d
Here
1 = 6.096m
D = 0.003m
e = 0.6
= Viscosity of fluid = N.s = 0.02 cp = 0.00002
N.s
60
m
2
m
2
u
c
= Superficial velocity of fluid = m
s
S = density of fluid = 1.25
kg
m
3
M
L
= 0.2982 (32) + 0.1459 (32) + 0.0001477 (30) + 0.00472 (18) + 0.5511 (28)
M
L
= 29.7
kg
kgmol
S = 182.6 kpa 29.7 kg
Kmol
= 1.25 kg
8.314
519.3
P =
1505.18 Uc + 8231.48 Uc
2
Uc = ?
Area of tube /4 d
2
=
/4 (1.76)
2
= 2.43 m
2
Thus, superficial of fluid
G = 408.4135
hr
kmol
kmol
29.7kg
3600s
G = 3.3 kg/s
61
U
C
=
3.3 kg
3
s
1.25 kg
2.43m
2
Uc = 1.08 m
s
Put in (1)
P
2
= 11615.7 Pa
= 11.615 kpa 14.7psi
101.3 kpa
1hr
= 1.68 Psi
5.1.4
= 1.82 bar
N/ mm
Design temp
0
= 400C
= 70
N/ mm
2
Thus:
5.1.5 Cylindrical Section
e
3
= PiDi
= 0.22 x 1.76x10
2fPi
2x70-0.22
= 2.51mm
2.51+0.75x20
18 mm
63
5.2 Absorption Column Design
W = 861.752 Kg-mol/hr
Equilibrium relationship = y = x(solute free) y = mx
At bottom of tower
1
1
0.2305
0.2305 . .
0.299
1 0.2305 . . . .
461.591 / 0.128 / sec
y
so
SMF solute mole fraction
y
SFG mole fraction solute free gas
A Kgmol hr Kgmol
=
= = =
= =
2
2
1
1 2
1
1 2
1
1
0.00105
0.00105
0.00105
1 0.00105
(Souders and Brown equation)
1
.
1.86
0.9964
1
7.83
N
N
N
N
y
y
y y
y mx
Absorption Factor
W
mA
N
o o
o
o
o
o o
o
+
+
+
+
= =
= =
=
= =
=
3
3
62.4 /
0.0332(32) 0.0138(32) 0.2305(30) 0.2317(18) 0.4876(28)
26.3 /
1.35 *26.3
0.044 /
0.7302*1108
L
g
g
g
lb ft
M
lb lbmol
PM
atm
lb ft
RT
p
p
=
= + + + +
=
= = =
64
65
=
=
Actual Velocity
0.7
7.899 / sec
m
v v
v ft
=
=
66
5.2.2 Minimum Diameter Of Column
4*0.128*2.2*26.3
*0.044*11.28
4.36 ft
t
=
=
Minimum Diameter of Column
5.36 ft =
Tower diameter:
Tray area used by one downcomer = 8.8%
For 40mm wide supporting ring, because between sports of 50mm wide disengaging
and disturb zones, these areas total => 0.222m
2
2 2
2
5.36 *1
1.62
3.280
. / 4(1.62 ) 2.06
0.088* 0.088*2.06
0.18
d
d
ft m
m
ft
active area m
A Area
A m
t
= =
= =
= =
=
68
Total area
Actual Tower diameter
= 1.83m
_ 2
0.44 0.5
_ 4.5
_
0.05
_
0.69
v
r mm
tray thickness mm
hole dia mm
hole area
active area
C
t = =
= =
=
=
69
5.2.3 Pressure drop across plate
Length of weir is
2
2
2
2
0.186
11.28 0.044
0.186
0.69 62.3
0.035 _ _
( )
min
2 , 0.70
t d l
o v
d
v L
d
d
l w ow
w
h h h
U
h
C
h
h inch of liquid
h h h
assu g
h inch
p
p
|
|
= +
| || |
=
| |
\ . \ .
| |
| |
=
| |
\ .
\ .
=
= +
= =
3
3
2/3
2/3
4.35 *1
1.62 1.62
2 2*3.2008
2.14
861.752 *1 *18 *1
1 *60min*1 *100
0.258 / min
43.4
0.258
43.3
2.14
10.59
W
L
L
L
ow
W
d ft m
L
ft
m
Kgmol hr Kg m
q
hr Kgmol Kg
q m
q
h
L
mm
| |
| |
= =
|
\
.
\
=
=
=
|
=
|
|
\
|
=
.
|
|
\ .
=
10.59 *1 / 25.4
0.416
( )
0.70(2 0.416)
1.69 _ _
1.69 0.035
1.72 _ _ *25.4 / 1
43.86 _ _
ow
ow
l w ow
l
t l d
h mm inch mm
h inch
h h h
h
inch of liquid
h h h
inch of liquid mm inch
mm of liquid
|
=
=
= +
= +
=
= +
= +
=
=
70
5.2.3 Height of Column
A rough estimate of the height of column is
(No. of stages + 2) tray spacing
2 is added to compensate for top/bottom clearances
= (8 + 2) 24in
= 240 in
= 6.1 meter
71
5.3 Distillation Column
Light key component =
CH
3
OH =
A
Heavy key component =
H
2
O
=
B
R
f
= ratio of the key component in the liquid part of the feed
X
nl
= Pinch composition of the light key component
0.615
12.81
0.048
fB
f
fA
x
r
x
= = =
12.81
(1 )(1 ) (1 12.81)(1 0)
0.927
0.927
0.0724
12.81
1.265
f
nl
f i fh
nl nA
nA
nB ml
f
AB
r
x
r x
x x
x
x x
r
o
o
= =
+ + E + +
= =
= = = =
=
1 0.615 0.268
1.265( )
0.265 1 0.927 0.0724
0.43
1
1
1.2
0.43 1.2
0.516
m
m
dA dB
m AB
AB nA nB
m
R
R
x x
R
x x
R R
R
R
o
o
=
=
=
=
=
=
72
(
) (
0.556
log ( ) ( )
1
log
0.615 0.656
log ( ) ( )
0.268 0.0138
1
log1.265
19
From Eq 15.4
( )
0.75 1
1 1
52
A B
D B
B A
m
AB
D B
m
m
m m
x x
x x
N
N
N
N N R R
N R
N stages
o
+ =
=
=
=
From Eq (15.6) (Peter & Timmerhaus)
2
( )
log 0.206log ( ) ( )
( )
D HK LK B
F
B LK HK D
N
x x B
N D x x
=
73
Eq1
Eq2
By solving eq1 & 2
N
B
= 33
N
D
= 32
Thus feed enters the column 33 stages above the bottom stage.
immer)
(Peter & T
=
= +
= +
17.23 0.43 7.40
7.40 17.23 24.63
7.40 313.17 320.50
320.50 295.96 24.61
n
n m
n n
m
m m
kgmol
L D R
hr
kgmol
V L D
hr
kgmol
L L F
hr
kgmol
V L W
hr
=
= +
= +
=
74
=
=
=
=
+
+
=
=
=
=
V
m
=
n
=
L
m
=
L
n
=
V
24.63 kgmol/hr x 1kg/27.804kgmol
0.8858 kg/hr
=
=
14.46kg/hr
2.66kg/hr
atm
P psia atm
psi
lb
M
lb
R
T R
p = =
= =
=
=
=
( ) From R.K SINNIOT vol.6
2
1
14.3469 1.06
0.8858 927.46
0.552
0.268 1.00916
0.0126
0.8858 568.65
0.05
0.09
w v
LV
m l
LV
LV bottom
LV top
bottom
top
L
F
L
F
F
F
K
K
p
p
=
=
=
= =
=
=
3
0.8858
0.877
1.00916
kg
m
hr s
=
0.8858
1.06
0.835 B
3 2
2
0.877 0.513
0.59
1.707 0.86
0.835 0.707
0.80
1.18 0.88
Top m m
Bottom m
= = =
= = =
568.65 1.00916
0.09 2.134
1.00916
927.46 1.06
0.05 1.47
1.06
2.134 0.8 1.707
1.47 0.8 1.18
f top
f bottom
top
bottom
m
U
s
m
U
s
m
U
s
m
U
s
= =
= =
= =
= =
75
5.3.3 Column Diameter
= A
B
= 0.707m
2
Assuming hole dia
= =
2
2
0.1*0.513 0.0513
0.1*0.707 0.0707
t
b
A m
A m
= =
= =
0.0513
13.15 14
0.0039
(R.K.SINNIOT)
0.0707
8.8 19
0.0039
Top holes
Bottom holes
= = =
= = =
76
Total area covered by holes = 1042x0.0039 = 4.0638m
2
Height of column =
(no. of plates-1) plates spacing + top free space + hold
up
Assume hold up & top free space as 18in same as plate spacing :
= (65-1)18in + 18in + 18in
Height of Column
5.3.4 Plate Pressure Drop
2.54 1
1188
1 100
30
cm m
in
in cm
h m
=
=
2
0
2
0
2
2
51( )( )
1.707 1.00916
51( )( )
0.89 568.65
D L
v
D
l
D
h h h
u
h
c
h
p
p
= +
=
=
( )
0.70
L w ow
h h h |
|
= +
=
77
For weir height h
W
= 50mm
h
Top
= 51.445mm of liquid
Same procedure for bottom feed as did for top feed
= 0.1150 mm of liq
For weir height h
W =
50mm
= 43.28 mm
= 66mm
h
Bottom
= 66.11mm of liquid
2
3
2
3
43.4( )
1.62 ( )
2
0.86
1.62 0.696
2
0.877
43.4( )
0.696
22.96
( )
(22.96 50)0.7 51.072
51.072
L
ow
w
top
w
w
ow
ow
ow w l
l
Top d l
V
h
L
d
L
L m
h
h mm
h h h
h
h h h
|
=
=
= =
=
=
+ =
+ =
=
= +
78
5.4 Heat Exchanger Design E-101:
5.4.1 Heating Area, Number of Tubes
F
= 5902.3lb/hr
T
1
=
0
F
370.2
T
2
=
370.20
0
F
t
2
=
0
F
1
=
0
F
302.2
t
96
F
Hot fluid =
0
F in shell side
8607.7 lb/ hr
Cold fluid
3
OH + CH
2
O + H
2
O
in tubes
CH
= 1500 Btu/ hr
E-101
79
3)
(1)
Heat balance
(2)
LMTD
= Q
= 4809992.086 Btu
hr
1
-
2
LMTD
_________ = 148F
ln(
1
/
2
)
Here
1
= 370.2 - 302 = 68
0
F
2
= 370.2 - 96 = 274.2
0
F
Thus: LMTD = 148
0
F
For steam F
T
= 1.0
T
m
= LMTD * F
T
= 148
0
F
(3) t
C
= average of temp of cold stream
0
F
From table let the selected
U
D
= 75
(range 50 -100)
(Overall design coefficient)
198.5
Now:
Q = U
D
A t
m
80
Here t
m
= true mean temperature difference LMTD = 148
0
F
So,
A =
here Q = 4809992.08
UD t
m
hr
Btu
A
2
4809992.08 = 433.3 ft
75 x 148
Length of tube
= 16 ft
Flow area
t
= 0.1963 ft
2
no. of tubes per shell
=
433.3
1 x 16 x 0.1963
103 tubes
OD tubes 1
1
4
1.25 inch
Shell ID = 17
1
4
(table 9)
112 tubes
le 9)
81
Corrected Area
2
(table 10)
So
Corrected U
D
= 3920605
2
.F
= 69.27 Btu/hr.ft
148 469.14
(tab
= 0.0827ft
82
G
t
=
339019.2
lb
hr.ft
2
(6) at
Tavg = 199
0
F
= 0.33 cp x 2.42
= 0.7986
lb/ft.hr
ID
0.67 in
12
R
et
= D
T
G
T
/
0.0558 x 339019.2
0.7986
64609
lb
hr ft
2
(6)
0
F
At Tavg
370.2
(Methanol + H
2
O)
= 0.0155 x 2.42
= 0.0375 1b/ft.hr
De = 0.99 inch = 0.0825 ft
83
Re
t
=
(7) At Re =
(From table)
J
H
23685
23685
( fig 28)
160
(8)
=
Cp
2.03Btu/1b.
K
= 0.0187 Btu/hr ft
2
.F
(table 5)
(9)
i
h
=
h
i
= j
h
(K/D)(Cp/K)
1/3
= 180 Btu/hr.ft
2
.F
h
io
= (hi)(I.D/O.D)
= 120.6Btu/hr.ft
2
.F
Re
s
= Ds Gs = 0.0825x 64609 = 3.45in
.0375
Re
s
=
141198.4
(7)
Re
J
H
=
(8)
240
= 141198.4
1/3
= .47
K
2
0.0187 Btu/hr ft
.F
C
(table 5)
0.47 Btu/1b.F
9)
O
h
=?
h
O
=
1/3
s
D
S
=
240
* 0.47*.0187
0.0792
h
o
= 190 Btu/hr.ft
2
.F
84
U
c
= (h
io
h
o
)/( h
io
+h
o
)
=
73.9 Btu/hr.ft
2
0
F
R
d
= (U
c
U
D
)/(U
c
U
D
) =
2
0.00083hr.ft
0
F/Btu
5.4.2 Pressure Drop Calculations
Re
SHELL SIDE
= 141198
f =
2
/in
2
( fig 29)
0.012
ft
T
avg
= 370.2
0
F
S =
(table 6)
D
s
= 17.25/12 = 1.44 ft
Number of crosses :
N+1
12 (L/B)
= 55.6
P
S
=
( ) ( )
s s
10
e
f G D N 1
5.22 10 S s D
+
u
=.0914Psia
TUBE SIDE
= 23685
Re
f
= 0.0002
T
avg
=
199
0
F
S
0.8
P
t
=
( ) ( )
2
1
10
f G L no. of passes
5.22 10 S D
= 0.0006 Psia
85
5.5 Pump Calculations
capacity
Mass flow rate in of pump
Average Densit y
3
= 3931.878kg/hr
= 794.91 kg/m
3
/hr =4. 95 m
3
/hr
= 21.7 GPM
h =
35ft
Efficiency
= 80 - 0.0285(H) +3.78*10
-4
(H) (GPM) - 2.38*10
-7
(H) (GPM)
10.66m
2
+
5.39*10
-4
(H)
2
- 6.39*10
-7
(H)
2
(GPM) + 4*10
-10
(H)
2
(GPM)
2
= 80 - 0.0285(35) +3.78*10
-4
(35) (21.7) - 2.38*10
-7
(35) (21.7)
2
+ 5.39*10
-4
(35)
2
6.39*10
-7
(35)
2
(21.7) + 4*10
-10
(35)
2
(21.7)
2
= 79%
Power = (GPM) P / (1715) (Efficiency)
= (21.7)(14)/(1715*0.79)
Power = 0.32 hp
86
NPSH
Pump specific speed
Ns = (RMP) (GPM)
0.5
/ (H)
0.75
= (2500) (21.7)
0.5
/ (35)
(Ns):
0.75
= 810.8077
IMPELLER DIAMETER:
D
2
= (1840(Kv) (H))
0.5
/RPM
(From Graph between Kv and Ns)
Kv = 0.99
D
2
= 1840*0.99*35
0.5
/2500
= 4.31 inch
EYE DIAMETER:
(From graph between D
1
/ D
2
& Ns)
D
1
/ D
2
= 0.399
D
1
=1.722 inch
Impeller Eye Area:
Eye Area= (/4) D
1
2
= (/4)* 1.722
2
= 2.33 inch
2
Suction Eye velocity:
CM
1
= 0.321*(GPM)/Eye Area
= 0.321*21.7 / 2.33
= 3.2
87
Peripheral Velocity of Impeller:
U
t
= (Eye Dia)*(RPM/229)
= (1.722)*(2500/229)
= 18.8
From graph between CM1 & U
t
NPSH =8ft = 2.43m
Specification Sheet
Item Pump
Type Cent ri fugal
Operat i on Cont i nuous
Densi t y 794. 91kg/ m3
Mat eri al of Const ruct i on Carbon St eel
Power 0. 32hp
NPSH 2. 43 m
88
Reference graph
89
90
91
92
93
94
95
Chapter 6:
Instrumentation
&
Process Control
96
6. INSTRUMENTA TION AND PROCESS CONTROL
Proper process instrumentation is of primary importance of smooth operation in
modern
large capacity plants. Automatic operation and control of process param
eters is a
necessity for process units, where extreme working conditions are prevalent. Kee
ping in
view the economic factors and the process constraints some control loops, indica
ting and
recording appliances are recommended. Flow controllers at proper interva
ls through out
this section are also proposed to cause the required production rate.
6.1 Reactor
The most important aspect in the reactor operation
is the ri.1aintenance
of air to methanol ratio. This is particularly important for safety purposes. It
is therefore
recommended that a ratio control1er be employed to regulate both flow rates. Con
trolled
97
Methanol (C
ontrolled Stream)
Ratio Control System for Air Methanol
It is recommended that the inlet temperature and pressure of the feed mixture be
indicated
and recorded. Recording process conditions is also recommended.
6.2 Heat Exchanger
Heat exchangers are inherently stable op
erating units. Extensive
t
c
u
b
epend on
the composition analyzers. It is possible that such measuring devices
are either very
costly or of very low reliability for' an industrial environment (failing quit
e often or not
providing accurate measurements). In such cases we can measure the temperature
of the
liquid at various trays along the length of the column quite reliably
, using simple
thermocouples. Then using the material and energy balances around the
trays of the
column and the thermodynamic equilibrium relationships between liquid an
d vapor
streams, we can develop a mathematical relationship that gives us the compositio
n of the,
distillate if the temperatures of some selected trays are known.
100
Chapter 7
Cost
Estimation
101
7.1 Cost of Reactor (R-101)
From Figure 13-14 (6), For Jacketed and Agitated Reactor
For Capacity = 1.6 m
3
Purchased cost = $ 10500 (Jan-2002)
Catalyst used = 1400 kg
Price of Catalyst used = $ 200 /kg
Price of Catalyst used = $ 280000
7.2
77m
I.22m
(6),
vertical column = $ 6000
Diameter = 4 ft= I.22m & for sieve trays, From Figure 15-13 (6),
Installed Cost per tray = $ 500
Installed Cost for 7 trays = $ 3500
(Floating head Heat Exchanger) From Figure 14-19 (6),
Purchased cost = $ 6500
102
7.7
For capacity =0.063 m3/s (Centrifugal pump) From Figure 12-23 (6),
Purchased cost = $ 2000
7.8
UNIT
COST ($)
Feed Pump (P-I01) 2000
Direct Cost
Item
% age $
Purchased + Delivered 100 243100
cost
Purchased equipment 47 114257.
/
installation
Instrumentation and 36 87516
controls installed
Piping installed
68 165308.
Electrical
11 26741
Building
18 43758
Yard improvement 10 24310.
Service facilities 70 170170
(installed)
.
Land (already available) 0.0 0.0
Total
851060
105
BIBLIOGRAPHY
106
BIBLIOGRAPHY
1 D.Q.Kern (1950), "Process Heat Transfer", McGraw Hill Book Co.
14. Perry, R.M., Green, D.W', Moloney, J.O. (1984) "Perry Chemical
Engineers Hand Book" 6th Edition McGraw Hill Book Co. Newe
York
15.
16.
20.
21.
110