C 4

Production of LPG From Natural Gas
CHAPTER 4
DESIGN ASPECTS
4.1PROCESS DESIGNING OF EQUIPMENTS
4.1.1 knock out drum: calculations
Input Data:
Total Inlet mass flow rate : 1,87,000 kg/hr
Operating pressure : 53 kg/cm2g
Liquid holdup time : 10 min
Operating temperature : 40 0C
Density of liquid : 992.2 kg/m3
Suggested thickness of mist eliminator, h5 : 0.150 m
Service option : H/C gas
Mist eliminator : Present
Viscosity (vapor) : 0.0112 cp
Viscosity (liquid) : 0.653 cp
Density (mixture) : 21.68 kg/m3
Calculations
1) Individual flow rates of inlet stream :

Vapor mass flow rate = 186936.42 kg/hr
Liquid mass flow rate = 63.5 kg/hr
2) Volumetric flow rates:
Vapor volumetric flow rate = 1.331m3/sec
65
Liquid volumetric flow rate = 1.77x10-5 m3/sec

3) Critical vapor velocity:
Vc = =
= 0.261 m/sec
4) Max allowable vapor velocity: This depends upon presence of mist
eliminator. For vessel
with mist eliminator Vmax = 1.7 Vc
= 1.7 *0.2377 = 0.4445 m/sec
5) The normal liquid holdup between LLL & HLL is given as,
VL = QL * t (for 10 min hold uptime)
= 2.98x10-6m3/hr
6) Reynolds Number, Re =
= 34745.15
Since this value lies in intermediate law so checking the settling velocity criteria for
intermediate region,
Newton’s law-(Particle size > ~ 1000 microns, C’ = 0.44, Re < 200,000)
Vt =
= 1.149m/s
So minimum Diameter of vessel,
Dmin = = 2.80m
7) Equivalent drum height between LLL and HLL (h L): since in this column water
removed is so small therefore taking hl = 200 x 10-3m
66
Height Below feed nozzle, h1 = 0.3*D

h1 = 0.3*2.80 = 0.765 m
a) Height of feed nozzle, h2 = NPS of feed Pipe*0.0254
h2 = 16x0.0254 = 0.4064 m
b) Height above feed nozzle, h3 = 0.45*D
h3 = 0.45*2.55 = 1.1475 m
c) Height above mesh pad, h4 = 0.15*D
h4 = 0.15*2.55 = 0.3825 m
d) Height of wire mesh pad, h5 = 100mm or 150mm
h5 = 0.125
10) Total Height (BTL-TTL),
11) Distance between tangent to tangent lines: This is the sum of all heights,
H = h1+h2+h3+h4+h5+hL
H = 0.765+0.4064+1.1475+0.3825+0.125+0.2 = 3.328 m
12) H/D ratio: H/D = 3.0264 / 2.55 = 1.308m

13) Nozzle Sizing:
Density of mixture (kg/m3) ρm = 21.68 kg/m3 (given)
V2m, in = = = 10.29 m/sec
Type of Inlet Device, ρm.V2m, in = 21.68 x 10.292 = 2089.23

(Condition: For feed nozzle, this value should be less than 2700)
For Vapor outlet nozzle, Vv =
= 13.44m/ sec
ρG .V2v = 21.68 x 13.442 = 3561.17kg/m sec2
(Condition: For Gas outlet nozzle, this value should be less than 3700)
For Liquid outlet nozzle, VL = =
67
= 0.0013m/sec
(Condition: downward Liquid velocity should be less than 1m/sec.)
68
4.1.2 Gas Phase pipe Line Sizing
Input Data
Vapor Fraction = 1.00
Mass Flow (kg/hr) = 1,87,000
Pressure (kg/cm2g) = 46.6
Temperature(oc) = 40
Viscosity(cp) = 0.01
Gas Density, ρG (kg/m3) = 21.68
Calculations
Outer Dia. = 18”x0.0254 = 0.4572 m

Internal dia. = 17.25”x0.0254 = 0.4381 m
Vol. Flow rate, Q (m3/sec) =
= 2.38m3/sec
Area, A (m2) =
= 0.151 m2
Velocity, V (m/sec) = Q/A = 1.468/0.151 = 9.729 m/sec
Reynolds No., Re =
= 9241086.877
Friction factor
69
Let f (1st iteration) = Put 0.00205 in above eqn.

So final friction factor, f = 0.00205 (using trial & error)
Fitting Details
Type (L/D) No. Equivalent Length

450 std Elbows (16) 0 16x0 = 0
900 std Elbows (30) 0 30x0 = 0
900 Long radius Elbow (16) 4 16x4 = 64
Tees: through Flow (20) 1 20x1 = 20
Tees: Branch Flow (60) 0 60x0 = 0
Check Valves, (100) 1 100x1 = 100
Gate Valves, (8) 6 8x6 = 48
Total (Σ) ∑(L/D) = 232
Table 4.1 Fitting details of valves
Fitting Details for gas line
Equivalent Length due to fittings =
= 0.4381x232 = 101.64 m
So, Total Length = 101.64 = 135.04 m
Frictional Head, Hf = (Darcy Weishback equation)
= 2.52m
∆Pf, (kg/cm2) =
= 5.46x10-3kg/cm2
Total line Loss, = 5.46x10-3 (100/135.04) = 0.004kg/cm2
4.1.3 Liquid Phase pipe Line sizing
Input Data
70
Liquid Flow rate (kg/hr) = 63.5

Liquid density, ρL (kg/m3) = 922.2
Liquid phase viscosity = 0.653 cp
Pipe Details:
Nominal Pipe Size = 10”

Schedule no. = 40
Calculations
Outer Dia. = 10”x0.0254 = 0.254m

Internal dia. = 8.065”x0.0254 = 0.2045m
Vol. flow rate = 1.91x10-5 m3/sec
Area, A (m2) =
= 0.033 m2
Velocity, V (m/sec) = Q/A = 1.91x10-5/0.033
= 5.797x10-4m/sec
Reynolds No., Re = =
= 167.4 (laminar flow)

Fitting Details
Type (L/D) No. Equivalent Length

450 std Elbows (6) 0 16x0 = 0
900 Long radius Elbow (6) 8 6x8 = 48
Tees: through Flow (2) 0 2x0 = 0
Tees: Branch Flow (6) 1 6x1 = 6
Check Valves, (10) 1 10x1 = 10
Gate Valves, (8) 3 8x3 = 24
Total (Σ) Σ (L/D) = 88
71
Table 4.2 Fitting details of valve
Fitting details of liquid lines
Equivalent Length due to fittings =
= 13.952 m
So, Total Length = 13.952 m
4.1.4 Pump
For carbon steel
Optimum pipe diameter dopt = 293 G0.53 ρ-0.37
As we know from material balance bottom of low pressure separator is 14,742.33 kg/hr
Mavg = M1x1 + M2x2 + M3x3 +…………MxXn
= 35.44kg/m3
Pipe handle material = 429.23* 37.83
= 16,236.86kg/hr
densityavg = Mavg * P/ R T
= 35.44* 31.36/ (0.0821 * 239.09)
= 56.62kg/m3
dopt = 293 * (3.73)0.53 * (56.62)-0.37
= 150.64 mm ~ 151
= 0.151 m
Thickness of pipe t = PiD/ (20σd + Pi) + C
= 34.3 x 10-4 * 151/ (20* 132+ 34.3 x 10-4) +2
= 2.2mm
Outlet dia of the pipe do = di + t
= 151 + 2
do = 153 mm
= 0.153 m
Schedule no. sh = PS * 1000 / σS
PS = Pi + 10% of Pi
72
= 34.3 x 10-4 + (34.3 x 10-4* 10)/100

= 5.28 N/m2
σS = σd + 10% of σd
= 120 + (120 * 10)/ 100
= 132 N/m2
Sh no. = (5.28 * 1000) /132
≈ 40
Suction line
Pipe – 0.49 & 1 m length
Elbow – 0.49 m dia
TEE-joint – 1
Discharge line:
TEE- joint
Pipe – 0.49 m dia. & 1 m length
TEE- joint – 1
Calculate the NPSH, only suction line considered

NPSH (A) = Pa/ρg – Pv/ρg – hfs - hs
hfs – head loss line to valves, joints, pipe in the suction line
Pa/ρg = 105/ (51.48 * 9.81)
=198 m
Pv/ ρg = (8*104) / (51.48 * 9.81)
=157 m
hfs for valve = 2* 0.17
= 0.34 m
hfs for elbow = 4 * 0.75
=3m
hfs for pipe = 4fLV2 / D*2g
V = Q / A = Q / {(π/4) d2}
=5.23m/s
Reynolds no. Re = DVρ/ µ
73
= 468341.87
i.e. the flow is turbulent
For turbulent flow and 104 < Re < 106
1/ = 2.5 ln + 1.75
On iteration it gives , f =0.0093

hfs for pipe
= 0.508m
Total hfs = 3.9 m
NPSH (A) =198– 157 – 3.9 – 5
= 31 m
Now applying bernoulli’s equation at &
P12/ρg + V12/2g + Z1 + η wp = P22/ρ g + V22/2g + Z2 + hfs
0 + 0 + η wp = P22/ ρ g + V22 / 2g + (Z2 – Z1) + hfs
0.7* wp = 6.8 / (51.48 * 9.8) + (4.76)2 / (2 * 9.81) + 8 + 3.8
= 21.37 m
= (9.8 * 21.37) m2/s2
= 209.693 m2/s2
Power supplied to the pump pump drive from an exit source
PB = ṁ w P
= 3.73* 190.63
= 782.177 J/s
Power delieverd to the fluid
Pf = ṁ ∆H = 4.1 * 172
=856.9 J/s
74
4.1.5 SHELL AND TUBE HEAT EXCHANGER
Calculations
Calculate all Properties at mean temperature.

Heat duty, QHc =
= 537.87 kW
Flow rate of cooling water, m =
= 12.76 kg/sec
Log mean temperature difference,
Where,
T1 = hot inlet temp, 0 C t2 = cold inlet temp, 0 C
T2 = hot outlet temp, 0 C t1 = cold outlet temp, 0 C
= = 22.40 0C
For Correction factor:
R =
= = 0.8
S =
75
= = 1.25
For corresponding values of S, & R, FT = 0.86

So ∆Tm, c = FT. ∆TLm
= 0.86*22.40 = 22.40 0C
Assuming Overall Heat transfer coefficient, = 3500Wl/m2 0C
General eqn for heat transfer across a surface
Q =
So area for heat transfer, A = = 201.036 m2
Tube side Coefficient:
Now consider 25.4 mm OD tubes and internal diameter is 19.05 mm & length 4.83 m.
Area for heat transfer, AT =
No. of tubes, Nt =
Nt =
= 1647.8
So the number of tubes taken as 335
Bundle diameter, Db = do
For 2 no. of passes, k1 = 0.249, n1 = 2.202

Db = 1134.59 mm
For fixed tube sheet, from graph 12.5 mm to be added
Shell diameter, Ds = 1209.39mm
76
Tube side flow area, at=
= 284.87 mm2
Tube side mass velocity, Gs =
= = 487.85 kg/m2 sec
Linear Velocity, us = = 0.484 m/sec
Reynolds no., Re =
= 11467.5
Prandtl no., Pr = =6.25
Nusselt no, = =
hi = 2584.637 w/m2 0C
Tube side Pressure Drop, =
For Np = 4,
= 29956.3Pa or N/m2
= .299 bar or .272x1.019 = 0.299 kgf/cm2a
Shell side heat transfer coefficient
77
Since Baffle, spacing can be taken as or maximum up to Shell ID.
No. of cross Passes = 23 (as Per PDS)

Tube pitch PT = 1.25*d0 = 1.25*25.4 =
31.75 mm
Taking baffle spacing as 219.89 mm
Shell side area, As =
= 0.052 m2
Mass Velocity, Gs = = 1081.63 kg/m2 sec
Equivalent diameter, de =
= 19.83mm
Reynolds no., Re =
= 7647.12
Prandtl no., Pr =
= 4.789
For 25 % baffle cut, if Re = 7647.12 gives jH = 1.144*10-3
Nusselt No, = =
(Source: coulson & Richardson, vol.-6, Heat exchanger, Page no. 691)
hs = 1252.30 w/m2 0C
Shell side Pressure drop, =
= 28810.94 Pa or N/m2 = 0.292 bar

78
Overall Coefficient
Fouling coefficient for mixture (tube side) hft = 5000 w/m2 oC

Fouling coefficient for water (shell side) = 2500 w/m2 o C
=
U0 = 564.50 w/m2 0C
Well above assumed value of 500 w/m2 oC
Over Design
% Design =
= *100
= 11.42% (within acceptable range)

4.1.6 SEPARATOR
Input Data:
Total mass flow rate : 100172.40kg/hr
Operating pressure : 53 kg/cm2g
Liquid holdup time : 10 min
Operating temperature : 25 0C
Density of liquid (BOTTOM) : 453 kg/m3
Suggested thickness of mist eliminator, h5 : 0.150 m
79
Service option : H/C gas

Mist eliminator : Present
Viscosity (vapor) : 0.0112 cp
Viscosity (liquid) : 0.088 cp
Density (mixture) : 94.12 kg/m3
Calculations:
1) Individual flow rates:
Vapor mass flow rate = 100172.40kg/hr
Liquid mass flow rate = 86509.698kg/hr
2) Volumetric flow rates:
Vapor volumetric flow rate = 0.398m3/sec
Liquid volumetric flow rate = 0.0530m3/sec
3) Critical vapor velocity:
Vc = =
= 0.1125 m/sec
Max allowable vapor velocity: This depends upon presence of mist eliminator. For
vessel
with mist eliminator Vmax = 1.7 Vc
= 0.2143m/sec
The normal liquid holdup between LLL & HLL is given as,
VL = QL * t (for 10 min hold uptime)
= 31.81m3
4) Reynolds Number, Re =
= 500.52
Since this value lies in intermediate law so checking the settling velocity criteria for
intermediate region,
80
V =
V = 1.437
which is greater than Vmax allowable vapor velocity.
5) So minimum Diameter of vessel,
Dmin = = 2.025 m
6) Suggested diameter of vessel, Dsug = 2.9 m
7) Equivalent drum height between LLL and HLL (hL):
hL = = 4.38m
a) Height Below feed nozzle, h1 = 0.3*D

h1 = 0.3*2.9 = 0.87 m
b) Height of feed nozzle, h2 = NPS of feed Pipe*0.0254
h2 = 16x0.0254 = 0.4064 m
c) Height above feed nozzle, h3 = 0.45*D
h3 = 0.45*2.9 = 1.305 m
d) Height above mesh pad, h4 = 0.15*D
h4 = 0.15*5.36 = 0.435 m
e) Height of wire mesh pad, h5 = 100mm or 150mm
h5 = 0.15m
10)Total Height (BTL-TTL), Distance between tangent to tangent lines: This is the
sum of all heights, H = h1+h2+h3+h4+h5+hL
H = 0.87+0.4064+1.3050+0.435+4.38 = 8.301m
11) H/D ratio: H/D = 7.5464/2.9 = 2.8622 m
12)Nozzle Sizing:
81
Density of mixture (kg/m3) ρm = 53.32 kg/m3 (given)
V2m, in = = 3.482m/sec
Type of Inlet Device, ρm.V2m, in = 53.32 x 3.4822 = 587.89

(Condition: For feed nozzle, this value should be less than 2700)
For Vapor outlet nozzle, Vv =
= 3.6508m/ sec
ρv .V2v = 69.8x 3.65082 = 1023.33kg/m sec2
(Condition: For Gas outlet nozzle, this value should be less than 3700)
For Liquid outlet nozzle, VL =
= 0.967m/sec
(Condition: downward Liquid velocity should be less than 1m/sec.)
4.1.7 LPG Distillation Column
Tray Hydraulics
The design of a sieve plate tower is described below. The equations and correlations are
borrowed from the 7th edition of Perry’s Chemical Engineers’ Handbook and the
formulaes are taken from brownel young book. The procedure for the evaluation of the tray
parameters is iterative in nature. Several iterations were performed to optimize the design.
The final iteration is presented here.
1. Tray Spacing (Ts)

Choose tray spacing = 9” = 228.6mm
2. Hole Diameter (dh)
Choose hole diameter = 5mm
82
3. Hole Pitch (lp)

Choose hole pitch = 15mm, (triangular pitch)
4. Tray thickness (tT)
Choose tray thickness = 3mm
5. Ratio of hole area to perforated area (Ah/Ap)
= ½ (π/4.dh2)/[(√3/4). lp2] = 0.1008
6. Plate Diameter (Dc)

The plate diameter is calculated based on the flooding considerations
L/G{ρG/ρL}0.5 = 0.0207
From the flooding curve, for a tray spacing of 228.6mm,
Flooding parameter = 0.0582m/s
Unf = Csb x { σ/ 20 ) 0.2 [ (ρL - ρG) / ρG]0.5 = 2.8102 m/s
Actual velocity un= 0.8un,f = 0.8 x 4.4213 = 3.5370m/s
Net area available for gas flow (An)
Net area = Column cross sectional area – Downcomer area. An = Ac – Ad
Choose weir length (Lw) = 0.60(Column diameter, Dc) From the figure
Lw / Dc = 0.60
sin ( θc/2) = [( Lw/2) / (Dc/2) ] = 0.60
θc = 73.740
Ac = (π/4) Dc2 = 0.785Dc2
Ad = (π/4) Dc2 ( θc/3600) - (Lw/2) ( Dc/2). cos(θc/2)
= 0.1608 Dc2 - Dc2 x 0.1200 = 0.0408 Dc2
Since An = Ac -Ad
3.3352 = 0.785 Dc2 - 0.0408 Dc2
Dc = 2.1164 m
Ac = (π/4) Dc2 = 3.5179 m2
Ad = 0.1828 m2
Lw = 1.2698 m
7.Perforated plate area (Ap)

Aa = Ac - 2Ad = 3.1523m2
83
Perforated Area
Ap = Ac -2Ad - Acz = 2.6246 m2
Total Hole Area
Ah / Ap = 0.1008
Ah = 0.2646 m2
8. Total Hole Area

Ah = 0.1008Ap = 0.1008 x 2.6246 = 0.2646m2
Number of holes Nh = 13476
9. Choose the weir height (hW) as 12mm
10. Weeping Check
All the pressure drops calculated are represented as mm head of liquid on the plate. This
serves as a common basis for evaluating the pressure drops.
Notations used and their units:

hd = Pressure drop through the dry plate, mm of liquid on the plate
uh = Vapor velocity based on the hole area, m/s
how = Height of liquid over weir, mm of liquid on the plate
hσ = Pressure drop due to bubble formation, mm of liquid
hds = Dynamic seal of liquid, mm of liquid
hl = Pressure drop due to foaming, mm of liquid
hf = Pressure drop due to foaming, actual, mm of liquid
Df = Average flow length of the liquid, m
Rh = Hydraulic radius of liquid flow, m
uf = Velocity of foam, m/s
(NRe) = Reynolds number of flow
f = Friction factor
hhg = Hydraulic gradient, mm of liquid
hda = Loss under downcomer apron, mm of liquid
84
Ada = Area under the downcomer apron, m2

c = Downcomer clearance, m
hdc = Downcomer backup, mm of liquid
Calculations:
Head loss through dry hole
hd = head loss across the dry hole
= k1 + k2 (ρg/ρl) Uh2
where
Uh =gas velocity through hole area
k1, k2 are constants
For sieve plates
k1 = 0 and k2 = 50.8 / (Cv)2
Cv = 0.7419
k2 = 50.8 / 0.74192 = 92.77
Velocity through the hole area = Uh = 44.3409 m/s
hd = k2 [ρg/ρl] Uh2 = 42.16 mm
Height of Liquid Crest over Weir

how = 664Fw [(q/Lw)2/3]
q = liquid flow rate at top = 1.6224 x 10-3 m3/s
Fw = correction factor = 1.01
Lw = weir length = 1.2698 m
how = 7.90 mm clear liquid
Head Loss Due to Bubble Formation

hσ = 409 [ σ/ ( ρL.dh) ]
where σ = surface tension(mN/m)
dh =Hole dia
hσ = 409 [ 48.5 / ( 1052.2884 x 5)]
hσ = 3.77 mm clear liquid
85
( hd + hσ) = 42.16 + 3.77 = 45.93 mm , this is the design value

( hw + how) = 12 + 2.676 = 7.90 mm
Also, Ah/Aa = 0.0839
The minimum value of ( hd + hσ) required is calculated from a graph given in Perry ,plotted
against Ah/Aa. The minimum value as found is 8 mm. Since the design value is greater than
the minimum value, there is no problem of weeping.
Downcomer Backup
hdc = ht + hw + how + hda +hhg
ht = total pressure drop across the plate( mm liquid)
= hd + hl`
Hydraulic Gradient
The hydraulic gradient was evaluated through an iterative procedure involving flow
parameters of the liquid on the tray. The iteration yielded a value of 17.5mm. The large
hydraulic gradient is a characteristic feature of vacuum operated towers where the
additional hydraulic gradient is required to push the liquid hold up over the plate.
Head loss over downcomer apron

hda = 165.2 {q/ Ada}2
Take clearance, C = 0.5”
hap = hds - C = (28.9 – 25.4)/2 = 1.75 mm
Ada = Lw x hap = 0.0206 m2
hda = 165.2[1.802x 10-3/ 0.0206] 2 = 1.24 mm
ht = hd + hl` = 42.16+8.60 = 50.76 mm

hdc = ht+ hw + how + hda + hhg
=50.76+12+7.90+1.24+17.5 = 89.40 mm
h`dc = hdc / φ , where φ is the froth density.
= 89.4/ 0.5 = 178.8 mm
Which is less than the tray spacing of 228 mm. Hence no flooding in the enriching section.
86
Column Efficiency
Point Efficiency
Average Vapor rate = 35349.015 kg/hr
Average Vapor Density = 2.54 kg/m3
Active Area = 3.1523 m2
Df = (Dc + Lw )/2 = 1.6931 m
Average Liquid rate = 4581.75 kg/hr
Average Liquid Density =500.60 kg/m3
q = 1.7123 x 10 -3 m3/s
Tl = 313.45K and Tg = 313.15K
(µM)L = 0.7851 cp
( µM)G = 0.0143 cp
Diffusivity of the gas is calculated and is found out to be = 6.3003 x 10 -5 m2/s Similarly the
liquid diffusivity is calculated and found out to be = 3.2411 x 10 -9 m2/s.
Number of gas phase transfer units:
NG = KG.a.θG
KG.a = 316 Dg0.5 (1030f+867f2 )/ h0.5L
= 5262.2067 s-1
θG = (1-φ)hLAa/(1000φQ)
= 3.06552x10-3 s
NG = 5262.2067 x 3.06552x10-3 = 16.1314
Number of liquid phase transfer units

NL = KL.a.θL
KL.a = (3.875 x 10-3Dl)0.5(0.4UaρG0.5+0.17) = 2.7915 s-1
θL = (1-ε)hf Aa/(1000q) = 15.8263 s
NL = 2.7915 x 15.8263 = 44.18
87
Slope of equilibrium Curve

(m) top = 0.4933
(m) bottom = .6059
GM/LM = 35349.015/4581.75
λt = mt GM/LM = 0.8289
λb = mb GM/LM = 1.0181
λ= 0.9235
NOG = 1/ (1/NG + λ/ NL) = 3.4851
EOG = 1- e -NOG = 0.9694
Murphree Plate Efficiency
θL = 15.8263 sec
ZL = DC. Cos ( θc/2) = 1.6931 m
DE = 6.675 x 10 -3( Ua)1.44 + 0.922 x 10-4 x hL - 0.00562
= 0.0397 m2/s
Pecklet Number Npe = ( ZL)2/ ( DE.θL) = 4.5624
λEOG = 0.9235 x 0.9694 =0.8952
EMV/ EOG = 1.32
EMV = 1.32 x 0.9694 = 1.2796
Overall Efficiency ( EOC)
L/G{ρG/ρL}0.5 = 0.0094
at 80 % of the flooding value we have ψ = 0.40
Eα/ EMV = 1/(1 + EMV [ψ/(1- ψ)])
Eα = 0.6905
The overall efficiency is given by the equation :
EOC = log[ 1 + Eα( λ- 1) ] / log λ
EOC = 0.6819
Hence the actual number of trays can be calculated as :
{ Theoretical number of trays overall column efficiency }
= 35.45 / 0.6819 ≈ 52
Height of the enriching section can be calculated as
88
{ Tray Spacing x Actual number of trays } = 52 x 228 = 11856 mm.

Process & Detail Design of Stripping Section:-
Tray Spacing = ts = 152.4mm = 6 "

Hole Diameter = dh = 5 mm
Hole Pitch = lp = 15 mm
Tray Thickness = tt = 3 mm
Ah/Ap = Total Hole Area / Perforated Area
= ½ (π/4 . d2H) / (√3/4). lp2
= 0.1008
Plate Diameter ( Dc)

Based on entrainment flooding, L/G{ρG/ρL}0.5 has to be evaluated at a pt where the group is
maximum
L/G{ρG/ρL}0.5 = 0.0207
Unf = Csb x { σ/ 20 )0.2 [ (ρL - ρG) / ρG]0.5
Unf = 2.8102 m/s
U Net vel. = Un = 0.7286 Unf = 2.0475 m /s
The odd value of the % flooding is taken so as to make the diameter of the stripping
section equal to that of the enriching section. This ensures a considerable saving in
mechanical design and fabrication without affecting the efficiency substantially.
Maximum flow rate of vapor = Vapor flow rate( max. at bottom ) / vapor density
= 6.8284 m/s
An = 6.8284 / 2.0474 = 3.3352 m2
Lw / Dc = 0.60
sin ( θc/2) = [( Lw/2) / (Dc/2) ] = 0.60
θc = 73.740
Ac = (π/4) Dc2 = 0.785 Dc2
Ad = (π/4) Dc2 ( θc/3600) - (Lw/2) ( Dc/2). cos(θc/2)
= 0.1608 Dc2 - Dc2 x 0.1200
= 0.0408 Dc2
89
Since An = Ac -Ad
3.3352 = 0.785 Dc2 - 0.0408 Dc2
Dc = 2.1164 m
Ac = (π/4) Dc2 = 3.5179 m2
Ad = 0.1828 m2
Lw = 1.2698 m
Active Area ( Aa)
Aa = Ac - 2Ad
= 3.1523 m2
Perforated Area
Ap = Ac -2Ad - Acz - Awz
Ap = 2.6246 m2
Total Hole Area

Ah / Ap = 0.1008
Ah = 0.2646 m2
Number of holes Nh = 13476
Weir Height
Take a weir height of 12 mm.
Weeping check
hd = head loss across the dry hole
= k1 + k2 (ρg/ρl) Uh2
For sieve plates
k1 = 0 and k2 = 50.8 / (Cv)2
Cv = 0.7476
k2 = 50.8 / 0.74762 = 90.89
Weeping check is done at a point where the gas velocity is the least. Here the velocity of
the vapor is minimum at the top of the enriching section. Hence volumetric flow rate of the
gas = 6.456 m3/s
90
velocity through the hole area = Uh = 6.456 / hole are(Ah) = 24.3991 m/s
hd = k2 [ρg/ρl] Uh2 = 12.77 mm
Height of Liquid Crest over Weir

how = 12.6746 [(q/Lw)2/3]
q = liquid flow rate = 1.2727 m3/s
Lw = weir length = 1.2698 m
how =12.6746[(1.2727/1.2698)(2/3)] = 8.4691 mm clear liquid
Head Loss Due to Bubble Formation

hσ = 409 [ σ / ( ρL.dH) ] = 409 [ 23.0104 / ( 500.60 x 5)] = 3.76 mm clear liquid
( hd + hσ) = 16.52 mm , this is the design value
( hw + how) = 20.47 mm
Also, Ah/Aa = 0.0839
The minimum value of ( hd + hσ) required is calculated from a graph plotted against Ah/Aa.
The minimum value as found is 8 mm. Since the design value is greater than the minimum
value we proceed using the same value for further calculations.
Downcomer Backup
hdc = ht + hw + how + hda +hhg
ht = total pressure drop across the plate( mm liquid)
= hd + h l
The hydraulic gradient was iteratively evaluated and found to be equal to 10.5 mm. The
large gradient is again prominent as described before.
Loss under Downcomer

hda = 165.2 {q/ Ada}2
Take clearance = 0.5” = 12.70 mm
hap = hds - c = 25.47-12.70 = 12.77 mm
Ada = Lw x hap = 0.0162m2
hda = 4.51mm
ht = hd + hl
91
=12.77 + 10.83
= 23.60 mm
hdc = ht+ hw + how + hda + hhg
= 23.60+12+8.47+4.51+10.50
= 59.08mm
h`dc = hdc / ρ , where ρ is the froth density.
= 59.08 / 0.5 = 118.2 mm which is less than the tray spacing of 152.4 mm. Thus flooding
check is fulfilled satisfactorily for the enriching section.
Column Efficiency
Point Efficiency
Number of gas phase transfer units:

NG = KG.a.θG
KG.a = 316 Dg0.5 (1030f + 867f2 )/ hL0.5 = 578.3924 /s
θG = (1-ε) hL Aa /(1000εQ) = 4.8271 x 10-3 s
NG = 2.8180
Number of liquid phase transfer units:

NL = KL.a.θL
KL.a = (3.875 x 108 DL)0.5 (0.4 Ua ρG0.5 + 0.17)
= 0.9852 /s
θL = (1-ε) hf Aa / (1000q) = 15.2361 s
NL = 15.0161
Slope of equilibrium Curve

(m) top = 0.6509
(m) bottom = 2.1875
λt = mt GM / LM = 0.5572
λb = mb GM / LM = 2.4905
92
λ= 1.5238
NOG = 1 / (1/NG + λ/ NL) = 2.1914
EOG = 1- e -NOG = 0.8882
Murphree Plate Efficiency

θL = 15.2361 sec
ZL = DC. Cos ( θc/2) = 1.6931m
DE = 6.675 x 10-3( Ua)1.44 + 0.922 x 10-4 x hL - 0.00562
= 0.0151 m2/s
Pecklet Number Npe = ( ZL)2/ ( DE.θL) = 12.4599
λ EOG = 1.6314
EMV/ EOG = 1.60
EMV = 1.4211
Overall Efficiency ( EOC)

L/G{ρG/ρL}0.5 = 0.0193
at 72.58 % of the flooding value we have ψ = 0.35
Eα / EMV = 1 / (1 + EMV [ψ/(1- ψ)])
Eα = 0.8051
The overall efficiency is given by the equation :
EOC = log[ 1 + Eα( λ- 1) ] / log λ
EOC = 0.8125
Hence the actual number of trays can be calculated as : { Theoretical number of trays
overall column efficiency }
= 13 / 0.8125 ≈ 16
Height of the enriching section can be calculated as ( Tray Spacing x Actual number of
trays )
= 16 x 152.4 = 2438.4 mm.
Summary of the Distillation Column
Enriching section
93
Tray spacing = 228.6 mm , Column diameter = 2.1164 m

Weir length = 1.2698 m , Weir height = 12 mm
Hole diameter = 5 mm , Hole pitch = 15 mm, triangular
Tray thickness = 3 mm , Number of holes = 13476
Flooding % = 80
Stripping section
Tray spacing = 152.4 mm , Column diameter = 2.1164 m
Weir length = 1.2698 m , Weir height = 12 mm
Hole diameter = 5 mm , Hole pitch = 15 mm, triangular
Tray thickness = 3 mm , Number of holes = 13476
Flooding % = 72.58
4.1.8 Molecular sieve bed
Q = flow rate kmol/hr = 8362.2530kmol/hr

Vo = volumetric flow rate
Co = Initial concentration ,kmol/l
Ce = final concentration , kmol/l
T = Temperature,52 deg Celsius
Density of mixture = 53.72 kg/m3
Vo = (kg/hr)/density = 169711/53.72 = 3159.177
Co = 8365.33903/3159.1772 = 2.64794*10-3 kmol/l
Ce = 8362.2530/3159.1772 = 2.7469*10-3kmol/l
Density of bottom mixture at 52 C temperature = 42.35kg/m3
Density of top mixture at = 16.75kg/m3
For molecular sieve bed design
m/q = Co-Ce/q = Co-Ce/KfCo1/n
94
Kf = freundlich capacity factor = 24

1/n=1.6129
n =freunldich intensity parameter = .62
M/Q = 4.9682*10-4 sieve/l
Calculation for diameter
q = {2.40D*D*K*P*(pl-pg).5}/ Z (T+460)p g.5]

8362.2530 = 4829.70*D*D
Therefore D = 1.315m
For vertical sieve separator
L/D ratio lies b/w 3-8ft And height or length of separator is upto 6ft
D = 4.317 ft = 1.312m
H = L = 6ft = 1.828
Length must be 1.5 times of diameter
Liquid capacity
W = 1440 vl/t Vl = 0.1399D*D*H

t = time ,hr (10-12min)
vl =.4390 w = 3160.8
Volume = 3.14*D*D*H/4
Volume = 2.4636
EBCT = empty bed time volume/q
Specific throughtput m3/g = Q/M = 2012.2014(m3/g)
Volume of water treated = water removed upto less than 1ppm
Bed life = 5 year
4.2 MECHANICAL DESIGNING OF EQUIPMENTS
4.2.1 SHELL AND TUBE HEAT EXCHANGER:-
95
(a) Shell side details:-
Material: carbon steel

Number of shell passes: 2
Working fluid: water
Working pressure: 15.5333 kg/cm2.g
Design pressure : 20 kg/cm2.g
Inlet temperature: 55.80C
Outlet temperature: 400C
Permissible stress for carbon steel: 95N/mm2
Shell inner diameter: 1153.8 mm
(b) Tube side details:-
Number tubes: 1678

Number of passes: 4
Outside diameter: 25.4 mm
Inside diameter: 19.05 mm.
Length: 4.83m
Pitch triangular: 13/16 inch
Working pressure: 5.293kg/cm2
Design pressure: 10 kg/cm2.g
Inlet temperature : 330C
Outlet temperature: 400C
SHELL SIDE:-
1. Shell thickness:-
ts= PD/(2fJ+P)
= (15.5333*1153.8)/(2*95*0.85+5.293)
= 0..107 mm
Minimum thickness of shell must be = 6.0 mm
Including corrosion allowance shell thickness is 8mm
2. Head thickness:-
96
Shallow dished and torispherical

Since Rk = 6%Rc
w = 1/ 4 x ( 3 + √(Rc / RK )
= 1/ 4 x ( 3 + √Rc / .06 Rc )
= 1.77
t = PRcW/2fJ
= 15.5333 *1153.8 *1.77/(2 *95 *0.85)
= 0.196 mm.
Minimum shell thickness should be 10mm including corrosion allowance.
3. Transverse Baffles:-
Baffle spacing =0.2 *shell ID= 0.2*1153.8= 230.76mm
4. Tie Rods and spacers:-
Tie rods are provided to retain all cross baffles and take support plates accurately.
For shell diameter, 500-1200mm
Diameter of Rod = 18mm
Number of rods=4
5. Flanges:-
Design pressure=18 kg/cm2.g

Flange material IS= 2004-1962, class 2
Bolting steel= 5% Cr-Mo steel
Gasket material= asbestos composition
Shell inside diameter = 1153.8mm.
Shell thickness= 8mm=go
Outside diameter of shell= 1169.8 mm
Allowable stress of flange material= 1019.36 kg/cm2.g
97
Allowable stress of bolting material = 1406.72 kg/cm2.g
6. Determination of gasket width:-
do/di = [(y-P*m)/(y-P*(m+1))]0.5
y = minimum design yield seating stress = 25.5 MN/m2
m = gasket factor = 2.75
do/di = [(25.5-5.293 x2.75)/(25.5-5.293x(2.75+1))]0.5
do /di = 1.077
do = 1.077 *0.11538= 0.1242 m
Mean gasket width = (0.1242 -0.11538)/2 = .0044 mm.
Taking gasket width of N= 0.0044 m
do= 0.1242 m.
Basic gasket seating width, bo = 5mm
Diameter of location of gasket load reaction is
G= di + N=0.11538+0.0044 = 0.11978 m
7. Estimation of Bolt loads:-
Load due to design pressure

H= πG2P/4
= 3.14 *11.9782 *15.533/4= 1749.39 kg/cm2.g
Load to keep joint tight under operation
b = 2.5 (b0)0.5 = 6.12mm.
Hp= π*G*(2*b)*m*p
= 3.14 *11.978 * (2 *0.612) *2.75 *15.5333
= 1966.5 kg/cm2.g
Total operating load
98
Wo =H+ Hp
=1749.39 + 1966.5
=3715.89 kg/cm2.g
Load to seat gasket under bolting condition
Wg = π*G*b*y
= 3.14 * 0.11978 * 6.12 * 10-3* 25.5
= 58695.601 kg/cm2.g
Wg>Wo, controlling load=58695.601 kg/cm2.g
8. Calculation of optimum bolting area:-

Am=Ag=Wg/Sg
= 58695.601 /138
= 4253304.42 cm2
Calculation of optimum bolt size
Bolt size, M18 X 2
Actual number of bolts = 20
Radial clearance from bolt circle to point of connection of hub or nozzle and back of
flange,
R = 0.027 m
C =ID + 2*(1.415*g + R)
=1.1538 +2*[1.41 *0.008+0.027]
= 1.23036 m
Bolt circle diameter = 0.80163 m.
Using bolt spacing Bs = 45mm
C = n *Bs / 3.14 =20* 0.045 / 3.14 = 0.286
Hence C = 0 .286
Calculation of flange outside diameter
bolt diameter = 18 mm.
A= C+ bolt diameter +0.02
=0.286 +0.018+0.02
= 0.324 m.
99
9. Calculation of flange thickness:-

t2 = CF Y / (B SF)
SF is the allowable stress for the flange material
K =A/B = 0.764/0.446 = 1.71
For K = 1.71 Y = 4.4
Assuming CF =1
t2 = 1 *4.4/ (0.446 * 100)
t= 0.314 m
Actual bolt spacing BS = π*C/n = (3.14)*(0.286)/(20) = 0.044 m
11. Channel and channel Cover:-

th= Gc√(KP/f)
= 119.78 *√(0.25 *15.5333/95)
= 20.65 mm
th= 28.65 mm including corrosion allowance
12. Tube sheet thickness:-
tts=FG√(0.25P/f)
= 1 *0.11978√(0.3 *15.5333/95)
= 0.029 m
tts= 8.029 mm including corrosion allowance.
14. Saddle support:-

Material: carbon steel
Total length of shell: 4.88 m
Diameter of shell: 1153.8 mm
Knuckle radius: 6% of crown radius =26.28 mm
Total depth of head (H) = √(Doro/2)
100
= √(1153.8 *576.9/2)
H = 576.9 mm
A= 0.5 R = 0.5 * 1153.8/2 = 576.9 mm.
weight of vessel and contents = weight of (shell + tube)
density of the steel = 7600 kg/m3.
Weight of shell = π*D * 4.61* 7600
=126933.0456 kg
15. Longitudinal Bending Moment:-
M1 = Q*A[1-(1-A/L+(R2-H2)/(2AL))/(1+4H/(3L))]
Q = W/2(L+4H/3)
= 126933.0456/2 *(4.88 +4 *0.5769/3)
= 321921.24 kg m
M1 = 308.5 kg-m
16. Bending moment at centre of the span:-
M2 = Q*L/4[(1+2(R2-H2)/L)/(1+4H/(3L)) - 4A/L]
M2 =458 kg-m
17. Stresses in shell at the saddle:-
(a) At the topmost fibre of the cross section
f1 =M1/(k1πR2 t) k1=k2=1
= 43.95 kg/cm2
The stresses are well within the permissible values.
Stress in the shell at mid point
f2 =M2/(k2πR2 t)
= 42.95 kg/cm2
Axial stress in the shell due to internal pressure
fp= PD/4t
= 15.5333*1153.8/( 4* 8)
= 560.072kg/cm2
101
f2 + fp = 603.022 kg/cm2
the sum f2 and fp is well within the permissible values.
4.2.2 LPG Distillation Column
Diameter of the tower (Di) = 2.1164 m

Working pressure = 13.05 kg.cm2 G
Design pressure (pe) = 14.06 kg.cm2 G
Working temperature = 40 oC
Design temperature = 50 oC
Shell material – IS: 2002-1962 Grade I Plain Carbon steel
Permissible tensile stress (ft) = 93.195 MN/m2
Elastic Modulus (E) = 1.88 x 105 MN/m2
Insulation thickness = 75 mm
Density of insulation = 5.64 KN/m3
Tray spacing:
Enriching section: 9”
Stripping section: 6”
Top disengaging space = 0.5 m
Bottom separator space = 1.0 m
Weir height = 12 mm
Down comer clearance = 0.5”
Height of support = 2 m
1. Shell minimum thickness

Considering a torispherical head, head dish:
hi= 0.4101m
Tangent to tangent length = 6.4350+ 2/3 (0.4101) = 6.7048m
D/L = 0.3155 => K = 0.232
P(allowable) = KE (t/D)2.46
0.1 = (0.232) (1.88 x 105) (t/2.1164)2.46
t = 10.79 mm, take 12 mm (standard)
102
Check for Plastic deformation

P = 2 f (t/D) (1+1.5U(1 - 0.2D/L)) / (100t/D)
U = 1.5% (for new equipment)
Substituting the values, we get P(allowable) = 0.224 MN / m2
The allowable pressure is greater than the design pressure. Hence, the thickness
is satisfactory with respect to plastic deformation.
2. Head Design
A torispherical head of the following parameters is chosen:
Crown radius (Rc) = Di = 2.1164m
Knuckle radius (Rk) = 10% of Rc
= 0.21164 m
t = thickness of the head =12mm
Pressure at which elastic deformation occurs

P(elastic) = 0.366 E (t/ Rc)2
= 2.2121 MN/ m2
The pressure required for elastic deformation, P(elastic) > 3(Design Pressure)
Hence, the thickness is satisfactory. The thickness of the shell and the head are made
equal for ease of fabrication.
3. Shell thickness at different heights

At a distance ‘X’ m from the top of the shell the stress are;
3.1. Axial Stress: (compressive)

fap = pi Di / [ 4(ts – C)]
= 4.4 N/m2
3.2. Compressive stress due to weight of shell up to a distance ‘X’

fds = [π/4 * ( Do2 – Di2 ) ρs X] / [π/4 * ( Do2 – Di2 )
103
= ρs X = 0.0077 X N/mm2
3.3. Compressive stress due to weight of insulation

fd(ins) = [π Dins tin ρins] / [ π Dm (ts – C )]
fd(ins) = [2290.4 * 75 * 0.0564X] / [2174.9 * (12)]
= 0.0358 X N/mm2
3.4. Stress due to the weight of the liquid supported

fl = Wl / [π ts (Di + ts)]
Enriching section
F(liq) = ((X-top space)/TS+1) (π d2/4) ρL
= 14157.8X – 3842.4
fd(liq) = 0.1727X – 0.0469
Stripping section
F(liq) = ((X-top space)/TS+1) ( π d2/4) σL+ 14157.8X – 3842.4
= 35394.6X – 84145.2
fd(liq) = 0.4383X – 1.0250
3.5. Stress due to the weight of the attachments
The total weight of the attachments
Wa = (26700 + 1400X) N
fa = Wa / [π ts (Di + ts)]
= 0.3256 + 0.0171X N/mm2
The total dead load stress, fw acting along the axial direction of shell at
point is given by:
fw = fds + fd + fl + fa
Enriching section: fw = 0.2787+0.2333X
Stripping section: fw = -0.6994+0.4989X
3.6. wind loads

Stress due to wind,
104
fwx = [1.4 pw X2] / [π Do (ts – C)]

where pw is the wind pressure, which is = 1300 N/mm2
fwx = [1.4 * 1300 X2] / [ π * 21404 *(1.2 )]
= 0.0226 X2 N/mm2
Taking joint efficiency as 0.8
(Total force, tensile) = jf(max) = jf(allowable)
Enriching section
0.0226 X2 + 4.4 – (0.2787 + 0.2333X) = ft max= 0.8(93.195)
X = 64m
Hence, the entire tower can be constructed keeping the same 12mm thickness
Stripping section
0.0226X2 – 4.4 - (-0.6994 + 0.4989X) = 0.8(93.195)
X = 68.1 m
Hence, the 12mm thickness is sufficient for the stripping section also.
Design of Support
Skirt Support
D = 2.1164 m
Minimum weight of the vessel with attachments:
W(min) = π (D+t) t (H) γs + 2(shell weight)
= 55.9773 kN
W(max) = W(shell) + W(insulation) + W(water during test) + W(attachments)
= 41.1913+18.4986+226.1696+29.7526
= 316kN
Period of vibration at minimum dead weight is:
T(min) = 6.35 x 10-5 (H/D)1.5(W(min)/t)0.5 = 0.0362 < 0.5s So, K = 1.0
Period of vibration at maximum dead weight load:
T(max) = 6.35 x 10-5 (H/D)1.5 (W(max)/t)0.5
= 0.0860 < 0.5 So, K = 1.0
Skirt
Stresses due to wind load
P(wind)=k.K.p(wind).H.D
105
p(wind) = 1 kN/m2
k = 0.7 for cylindrical surface. H=8.7048 m
For minimum weight condition, D = 2.1164 m
P(wind), min = (0.7) (1) (1000) (8.7048) (2.1164) = 12896 N
For maximum weight condition, D = 2.1164 + 2(0.075) = 2.2664 m

P(wind),max = (0.7) (1) (1000) (8.7048) (2.2664) = 13810 N
Minimum wind moment

M(wind), min = P(wind),min x H/2 = 12896 (8.7048/2) = 56.13 KJ
Maximum wind load

M(wind),max = P(wind),max x H/2 = 13810 (8.7048/2) = 60.11 KJ
Assuming a small skirt thickness, D(in) = D(out) = 2.1164 m
σzwm,min = 4(M(wind),min) / ( π D2t)
= 4 (56.13 x 10-3) / (π x 2.11642 x t) = 0.0160 / t MN/m2
σzwm, max = 4(M(wind),max) / ( π D2 t)
= 4(60.11 x 10-3) / ( π x 2.11642 x t) = 0.0171 / t MN/m2
Minimum and maximum dead load stresses

σzw,min = W(min)/( 3.14 x d x t)
= 55.9773 x 10-3 / (3.14 x 2.1164 x t) = 0.0084/t MN/m2
σzw,max = W(max) / ( 3.14 x d x t)
= 316 x 10-3 / (3.14 x 2.1164 x t) = 0.0475/t MN/m2
Maximum tensile stress without any eccentric load

σz (tensile) = σzwm, min - σzw,min
= 0.016/t – 0.0084/t = 0.076/t MN/ m2
Taking a joint efficiency of 0.7 (Double welded butt joint, class 3 construction)
σz (tensile) = fJ = 93.195 x 0.7 = 65.2365 MN/m2
106
65.2365 = 0.0076(1000/t)
t = 0.11maintenance
Maximum compressive load
σz (compressive) = σzwm, max + σzw,max
= 0.0171/t + 0.0475/t = 0.0646/t
substituting,
σz (compressive) = 0.125E(t/D)
= 0.125(1.88 x 105) (t / 2.1164) = 1.1104 x 104t
equating,
t2 = 0.0646 / (1.1104 x 104)
t = 2.4 mm
As per IS 2825-1969, minimum corroded skirt thickness = 7mm
Design of skirt bearing plate
Maximum compressive stress between bearing plate and foundation:
σC = W(max)/A + M(wind),max/Z
W(max) =319 KN
A = 3.14(D-l)l
D =outer diameter of skirt = 2.1164m
L = outer radius of bearing plate – outer radius of skirt
M(wind),max = 60.11 KJ
Z = 3.14 R2 l
R = (D-l) / 2
In calculating A, it is assumed that the bearing plate ID is no much less than the ID of the
skirt.
σC = 0.316 / (3.14l(2.1164-l)) + 0.06011 x 4 / (l(2.1164 - l)2)
Allowable compressive strength of the concrete varies from 5.5 to 9.5 MN/m2.
Taking σC = 5.5 , and equating,
l = 11.8 mm ,Since this is very small, a standard length of l=80 mm is chosen.
Thickness of the bearing plate
t(bp) = l (3 σC / f)0.5
l = 80 mm
σC = Maximum compressive load calculated for l = 80 mm
107
= 0.848 MN/m2
f = allowable stress = 93.195 MN/m2
t(bp) = 13.2 mm.
Take a standard thickness of 14 mm .As the bearing plate thickness is less than 20 mm,
gussets are not required.
Rolled angle bearing plate of 14 mm thickness is used. (80 x 80 x 14)
σ(min) = W(min)/A – M(wind)/Z
= 0.056 / (3.14 (2.1164 - 0.08) (0.08) – 0.05613 / (3.14 (2.1164 - 0.08) 2(0.08))
= 0.1094 - 0.0539
= 0.0555 MN/m2
R = 0.42 D(bp), where D(bp) is the outer diameter of the bearing plate.
j factor = W(min)R/(M(wind),min)
= (0.056) (0.42) (2.1164 + 2 x 0.08) / (0.05613) = 0.9539
j < 1.5
hence, anchor bolts are required.
Design of anchor bolts
P(bolt).N = σ (min)A
= (0.0555) (3.14 x (2.1164 - 0.08) x 0.08) = 0.0284 MN
Hot rolled plain carbon steel is selected for bolts. (f = 53.5 MN/m2)
(Area of bolts)f = P(bolt)N = 0.0284 MN
Area of bolts = 0.0284 / 53.5 = 5.3084 x 10-4 m2
Choose M 16 x 1.5 bolts. Area = 133 mm2 ,Number of bolts = 4.
Trays
The trays are standard sieve plates throughout the column. The plates have 13476
holes of 5 mm dia arranged on a 15 mm triangular pitch. The trays are supported on
purloins.
Nozzles
Nozzles are required for compensation where a hole is made in the shell. The following
nozzles are required:
1. Vapor discharge
Nozzle diameter = 0.1D = 211.64 mm , t = 10 mm
2. Reflux Inlet
108
Nozzle diameter = 126 mm , t = 10 mm

3. Feed Inlet
4. Reboiled vapor Inlet
5. Liquid Bottoms Outlet
All nozzles are provided with a standard compensation pad of 30 mm thickness.
This small compensation is sufficient.
4.3 Specification Of Major Equipments:-
4.3.1 knockout drum

Feed gas knock out drum separates out any liquid (water amines etc.) from the feed
gas .Feed gas is available from common sweet gas header. Feed gas is taken under pressure
control with a battery limit pressure .
Knock out drum specification:
Design pressure : 53 kg/cm2

Design temperature : 25°C
4.3.2 Molecular sieve bed
Feed gas from the dryer inlet knock out drum goes through feed gas dryers where the
moisture content is reduced below 1ppm. Molecular sieves are used as desiccant in dryers.
Feed gas drying section consists of two molecular sieve beds. One dryer is used for drying
while the other during that period is under regeneration. During drying the flow of gas is
from top to bottom (downward) and the same is from bottom to top upward during
Regeneration operation.
Molecular sieve bed specification:

109
4.3.3 Feed gas filter

Feed gas filters are provided in the downstream of feed gas dryers to remove any fine moil
sieves particles escaping from feed gas dryer along with the dry compressed gas.
Feed gas filter specification :

4.3.4 Chiller
Filtered gas is routed to feed gas chiller and is cooled to -39 0C
The feed gas from chillers is sent to HP separator and the liquid condensed is separated.
Liquid is sent back to LEF column for fractionation via Multi-Heat exchanger, while
vapour from HP separator is expanded isentropically in expander section of Expander
Compressor. Liquid condensed is separated out in LP separator and sent to LEF column for
Fractionation via Multi-heat exchanger. Vapours from LP separator are lean gas and are
sent to LEF Condensers to partially condense the LEF overhead vapours.
chiller specification :
Design temperature : -45°C
4.3.5 High Pressure Separator(HPS)

In this column the feed stream(gas phase) gets separated into two phases i.e. overhead
vapors and the bottom liquid by reducing the momentum of the incoming stream.
HPS specification :
4.3.6 Low Pressure Separator(LPS)

Again in this column the inlet stream which is gas phase gets converted into two outlet
products i.e overhead gas and the bottom liquid .since the inlet stream is coming at low
pressure which named it as a low pressure column.
110
LPS specification :
4.3.7 Pump specification :

Design temperature : -40.23°C
4.3.8 Compressor specification :
4.3.9 Liquid phase pipe line specification :

Design pressure : 50kg/cm2
Design temperature : 45 °C
Diameter : 0.254 m
4.3.10 Gas phase pipe line specification :

Design pressure : 46.6 kg/cm2
Design temperature : 40 °C
Diameter : 0.4572 m
4.3.11 LEF Column

Liquid from HP& LP separator under level control cascaded with flow after exchange of
cold in feed gas chiller is mixed & then fed to LEF column. The column has a total of 40
valve trays. The column operates at a pressure of 28.2 kg/cm 2g at the top. Reflux is
generated by condensing a part of overhead vapours in LEF Condenser by using LP
separator overhead vapours and fed to the column top by Reflux Pump under flow control.
Lean gas is generated as LEF column overhead vapours with main constituents of methane,
ethane & little amount of Propane. Cold from uncondensed LEF column overhead vapours
is recovered in feed gas chiller and the lean gas is then used for regeneration of feed gas
111
dryers. Thermo siphon type LEF column reboiler is Provide at LEF column bottom using
LP steam. Liquid from LEF column bottoms is withdrawn at approximately 97 0C and feed
to LPG column
LEF column specification :

PARAMETERS TOP BOTTOM
pressure , kg/cm2 30.6 26.5
Temperature , °C 5 97.5
Flow rate, kg/hr 62368.11 38883.91
Vapor 1 0
Table 4.3 LEF column Specification
4.3.12 LPG Column
Bottom liquid from LEF column is taken to LPG column. This column has overall 52 tray
(valve type) and is designed to separate LPG (Propane & Butane) from heavier
Components. LPG Product is withdrawn as overhead liquid Product from reflux drum
under level control & is sent back to column through LPG column reflux pumps under
flow control.Provision for diverting of off spec NGL to the crude stabilization unit has also
been kept, in case of NGL rundown temperature goes higher than 50 0C due to fouling of
rundown cooler or LPG Column temperature going down due to any operational failure.
LPG column specification :
PARAMETERS TOP BOTTOM

pressure , kg/cm2 16 14
Temperature , °C 68.4 130
Flow rate, kg/hr 36061.14 2,882.89
Vapor 1 0
Table 4.3 LPG column Specification
112
4.3.13Specification sheet of Heat Exchanger:
Identification: Date: 31st march,2010

Item: Heat Exchanger
Item No. – HE-01 By: India Petrochem Ltd.
Function: Production of high pressure steam using hot syngas in vaporizer.
Operation: Continuous
Type: Horizontal
Fix tube sheet
Area - 182.76 m2
Design Data:
Chemicals Handled Exchanger Length Exchanger Diameter
Water HC 1.24meter
4.83 meter
Shell side: Fluid Handled: Hydrocarbon

Temperature in / out : 55 deg c / 50 deg c
Tube Side: Fluid Handled: Water
Temperature in / out: 25 deg cel / 35 deg c
Operating Pressure:- 16 bar
Utilities:- Process Water
Required Delivery Date: 10th June, 2010
4.4 Major Engineering Problems
4.4.1. Transportation Problem: The major problem in LPG industries is the

transportation of the product at various places because it takes a lot of care in
transportation .LPG leakage can cause many problems such as explosion, inhaling
problems etc.
113
4.4.2. Potential Health Effects: LPG may cause mild short lasting discomfort to eyes.
Rapid release of gases which are liquids under pressure may cause frost burns of exposed
tissues (skin, eye) due to evaporative cooling. Rapid release of gases which are liquids
under pressure may cause frost burns of exposed tissues (skin, eye) due to evaporative
cooling.
Chronic Exposure: May cause central nervous system disorder (e.g., narcosis involving
a loss of coordination, weakness, fatigue, mental confusion and blurred vision.
4.4.3. Storage Problems: Keep away from flame, sparks, excessive temperatures and
open flame. Use approved containers. Keep containers closed and clearly labeled. Empty
or partially full product containers or vessels may contain explosive vapors. Do not
pressurize, cut, heat, weld or expose containers to sources of ignition. Store in a well-
ventilated area. Keep away from food, drink and animal feed. Keep in a dry place. Keep
away from heat.
4.4.4. Raw Material Availability: since here we are producing LPG from natural gas
therefore the problems associated with its availability in the nature gradually decreasing
day by day.Therefore it becomes a global issue for its availability.
4.4.5. Disposal Problem: Liquid release is only expected to cause localized, non-persistent
environmental damage, such as freezing. Biodegradation of this product may occur in soil
and water. Volatilization is expected to be the most important removal process in soil and
water. This product is expected to exist entirely in the vapor phase in ambient air. Dispose
of container and unused contents in accordance with federal, state and local requirements.
4.4.6. Leakage Problems: Since LPG is a gas so the hards of its leakage increases
therefore carrying pipes need a regular checking in order to avoid leakage because the
chances of a gas leakage is more .and if once due malfunctioning of the pipe gas leaks it
becomes a huge problem for the industry. So proper care must be taken during handling of
LPG.
114
4.4.7Piping must be wrought iron or steel, brass, copper, aluminum alloy Piping must met
ANSI standards. The use of threaded cast iron pipe fittings is prohibited .In most of petro-
chemical industries carbon steel is used .It is important to ensure thermal protection during
initiation of the event. However Vessel legs are usually fireproofed with concrete.
4.4.8. Operating Conditions: To maintain the high temperature as well as low

temperature is quiet a typical job. Pressure is also very high so it becomes necessary and a
tough job to maintain the required conditions for the manufacturing of LPG.
HOW TO OVERCOME THE PROBLEMS
1. Regular inspection of the equipments must be done.

2. Strict stock control is required to provide up to date information on leakage and other
losses
3.Accurate records must be maintained so that similar problems can be prevented in the
future.
4.Hygiene and safety instructions must be followed.
5.The oven/furnace burner operating system should be operated by trained
persons only. The specified no. of LPG cylinders should be attached to the manifold.
6. The manifold and LPG cylinders should be kept open to atmosphere/ fresh air and away
from electrical connections/cables.
7. Make sure to ‘ON’ all the control valves of the LPG pipeline.
8. Carry out the leak test (soap test) once in 15 days and make necessary
repairs for the same.
9. The temperature setting on the temp. Controller should be done according to the process
requirement only. Excess temperature setting may cause hazards.
10. In case of hazards switch ‘OFF’ the control system and LPG supply
quickly or always shut off the LPG supply by the nearest valve to the
burner .
11. Do not change the setting of Main & low pressure regulator, solenoid
control valves, air damper on the burner-blower etc. unnecessarily.
115
12. Ensure good working of solenoid valves.

13. Observe the full indication of sequence controller on control panel.
116

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Production of LPG From Natural Gas

4.1PROCESS DESIGNING OF EQUIPMENTS

4.1.1 knock out drum: calculations

1) Individual flow rates of inlet stream :

Liquid volumetric flow rate = 1.77x10-5 m3/sec

Height Below feed nozzle, h1 = 0.3*D

12) H/D ratio: H/D = 3.0264 / 2.55 = 1.308m

V2m, in = = = 10.29 m/sec

Type of Inlet Device, ρm.V2m, in = 21.68 x 10.292 = 2089.23

For Vapor outlet nozzle, Vv =

For Liquid outlet nozzle, VL = =

4.1.2 Gas Phase pipe Line Sizing

Outer Dia. = 18”x0.0254 = 0.4572 m

Vol. Flow rate, Q (m3/sec) =

Let f (1st iteration) = Put 0.00205 in above eqn.

Type (L/D) No. Equivalent Length

Table 4.1 Fitting details of valves

Fitting Details for gas line

Equivalent Length due to fittings =

Frictional Head, Hf = (Darcy Weishback equation)

Liquid Flow rate (kg/hr) = 63.5

Nominal Pipe Size = 10”

Outer Dia. = 10”x0.0254 = 0.254m

= 167.4 (laminar flow)

Type (L/D) No. Equivalent Length

Table 4.2 Fitting details of valve

Fitting details of liquid lines

Equivalent Length due to fittings =

= 34.3 x 10-4 + (34.3 x 10-4* 10)/100

Calculate the NPSH, only suction line considered

On iteration it gives , f =0.0093

4.1.5 SHELL AND TUBE HEAT EXCHANGER

Calculate all Properties at mean temperature.

Flow rate of cooling water, m =

For Correction factor:

For corresponding values of S, & R, FT = 0.86

So area for heat transfer, A = = 201.036 m2

Tube side Coefficient:

For 2 no. of passes, k1 = 0.249, n1 = 2.202

Tube side flow area, at=

Tube side mass velocity, Gs =

= = 487.85 kg/m2 sec

Linear Velocity, us = = 0.484 m/sec

Prandtl no., Pr = =6.25

Tube side Pressure Drop, =

= .299 bar or .272x1.019 = 0.299 kgf/cm2a

Shell side heat transfer coefficient

Since Baffle, spacing can be taken as or maximum up to Shell ID.

No. of cross Passes = 23 (as Per PDS)

Shell side area, As =

Mass Velocity, Gs = = 1081.63 kg/m2 sec

Shell side Pressure drop, =

= 28810.94 Pa or N/m2 = 0.292 bar

Fouling coefficient for mixture (tube side) hft = 5000 w/m2 oC

Well above assumed value of 500 w/m2 oC

= 11.42% (within acceptable range)

Service option : H/C gas

6) Suggested diameter of vessel, Dsug = 2.9 m

7) Equivalent drum height between LLL and HLL (hL):

a) Height Below feed nozzle, h1 = 0.3*D

11) H/D ratio: H/D = 7.5464/2.9 = 2.8622 m

Density of mixture (kg/m3) ρm = 53.32 kg/m3 (given)

Type of Inlet Device, ρm.V2m, in = 53.32 x 3.4822 = 587.89

q = {2.40DDKP(pl-pg).5}/ Z (T+460)p g.5]

W = 1440 vl/t Vl = 0.1399DDH

Baffle spacing =0.2 shell ID= 0.21153.8= 230.76mm