SIZING OF BENZENE WATER WASH SYSTEM & PERFORMANCE EVALUATION OF RECYCLE GAS COMPRESSORS IN LAB FE PLANT

Report Submitted

by

DishaGardi
Under the guidance of Mr. S. Rangarajan

Reliance
Industries Limited

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CERTIFICATE
This is to certify that this report is a bonafide record of the project work titled Sizing of Benzene water wash system & Performance evaluation of recycle gas compressors in LAB FE plant completed successfully by Ms. DishaGardi, MPSTME, Mumbai.

Mr. S. Rangarajan CTS - LAB RIL, Patalganga.

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Acknowledgement

I feel indeed fortunate and privileged that I have got this rare opportunity to carry out my training at an esteemed organization like RIL.

It is indeed a matter of great pleasure to express my sincere gratitude towards Ms. Mankirat Kaur & Ms. Pallavi Joglekar whose encouragement, cooperation and guidance and keen supervision and support at every stage of training inspired me in pursuing and completing the project. I will be forever grateful to them, for under their guidance, I learned the correct tact and the never-say-die attitude.

I also heartly thank the Head of Chemical Department and the faculty Supervisor, Dr.AnantJhaveri for his valuable support and the friendly atmosphere of education provided by him and guidance in my endeavor to work on the project that will enhance my capabilities for my future studies and career.

I would also like to acknowledge my sincere thanks to Mr.HareshOcchaney, Mr.Vasant Warke and Mr. S Rangarajan who had mentored me during the training period. I would also like to thank all the plant people who have provided me with the required knowledge and information. I would also like to thank Mr.GaneshanShankar,HR Manager of the company for his help and guidance without which the training would not have been possible.

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OBJECTIVES The objectives of the training were:  To understand the modern technologies applied for designing a chemical process plant.  To develop an understanding of the working environment of the chemical industry.  To build on the knowledge gathered in the college and understand its practical application.  To get an insight to the modern chemical industry in the developing Indian economy.

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INDEX Sr.no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Contents PROJECT-1 Introduction Study of LAB process Alkylation unit Developed scheme Scheme description Calculation Specification sheets PROJECT-2 Introduction Dew point Performance Evaluation of GB-601 A/B Flash calculation for 1st stage Performance Evaluation of GB-602 A/B/C Flash calculation for 1st stage Flash calculation for 2nd stage Flash calculation for 3rd stage Flash calculation for 4th stage Safety measures in LAB plant

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COMPANY INFORMATION Reliance Industries Limited, found by Dhirubhai H. Ambani , is Indias largest private sector enterprise, with businesses in the energy and materials value chain. Groups annual revenues are in excess of US$ 28 billion. The flagship company of RIL is a Fortune Global 500 company and its largest private sector company in India. Backward vertical integration has been the cornerstone of the evolution and growth of Reliance. Starting with textiles in the late seventies, Reliance pursued a strategy of backward vertical integration in polyesters, fibre intermediates, plastics, petrochemicals, petroleum refining and oil and gas exploration and production to be fully integrated along the materials and energy value chain. Reliance enjoys global leadership in its businesses, being the largest polyester yarn and fibre producer in the world and among the top ten producers in the world in major petrochemical products. Major Group Companies are Reliance Industries Limited (including main subsidiary Reliance Retail Limted ) and Reliance Industrial Infrastructure Limited.

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LAB (Linear Alkyl Benzene) Process Overview Introduction: The linear alkylbenzenes produced from C10-C13 linear olefins are useful detergent intermediates and can be readily sulfonated to yield linear alkylbenzensulfonates.

HF acid catalyst C10C13 olefins + Benzene Sulfonation Linear Alkyl benzene (LAB)

Linear alkyl benzene (LAB)

LAB sulfonates

These compounds constitute the active ingredients of many household detergents. They are surface-active compounds (surfactants), which are combined with various builders (often inorganic salts) to make up a detergent formula. Builders LAB sulfonates Typical Detergent formulation: LAB sulfonates Sodium tripolyphosphate Sodium silicate Sodium sulfate Water Carboxymethylcellulose 25wt%. 40 wt% 10 wt % 16 wt % 8 1 wt% wt %

House hold Detergents

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History: During 1940s and 1950s, the detergent market was primarily captured by dodecylbenzene (DDB), a product formed by alkylation of Benzene with propylene tetramer. It was found that detergent formed by this, was giving poor biodegradability of detergent

Propylene tetramer + Benzene (Low biodegradability)

Dodecylbenzene (DDB)

Thus LAB introduced in early 60s have substantially replaced this DDB, which is having good biodegradability (>95%)

Process Description Brief Overview: LAB manufacturing process is a technology, patented by UOP Inc (Universal oil Product). The LAB plant is divided into two parts called, a) Front End b) Back End. In Front End, Normal paraffin, which is raw material for LAB, is extracted from kerosene feed. (UOP Molex unit). UOP Molex unit Feed kerosene (Normal & Non-normal paraffin) N paraffin (C10- C13) (Raw material for LAB)

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In Back End, this Normal paraffin is dehydrogenated to linear olefins (UOP Pacol unit). The linear olefins are then alkylated with benzene to LAB.

UOP Pacol unit (Dehydrogenation) N paraffin (C10- C13)

Linear Olefins (C10-C13)

HF acid catalyst C10C13 olefins + Benzene Detail Description of Process.

Linear alkyl benzene (LAB)

1) Front End. As described earlier, Normal paraffin (C10 to C13) is extracted from kerosene feed by UOP molex process. The kerosene feed stock contains various carbon-chained compounds ranging from C7 to C17. This kerosene is processed in front end in series of processes, they are, a) Prefractionation. b) Hydrobon c) Molex a) PREFRACTIONATION The kerosene is fed to Prefractionation unit, where heart cut kerosene of carbon chain C10 to C14 is separated in two distillation columns in series 1) Stripper column In this distillation column, lighter compounds less than C10 are separated from top as distillate. The bottoms from the column is fed to second distillation column called Rerun column. 2) Rerun column In this column, Heart cut kerosene of C10 to C14 is separated from top as distillate.

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Light Kerosene

Heart cut Kerosene (C10 to C14)

S T R Feed kerosene I P P E R R E R U N

Heavy kerosene

b) HYDROBON The kerosene from petroleum refinery contains various amounts of naturally occurring contaminants, the most important ones being organic sulfur, nitrogen, and metal compounds. The purpose of UOP Hydrobon process is to remove sulfur and nitrogen from feed, which would poison the sieve in UOP Molex process unit. The catalyst used in Hydrobon reactor is S12 (Nickel molybdenumumoxide on alumina)

The heartcut kerosene from Prefractionation rerun column overhead, is fed to this Hydrobon unit to remove sulfur, nitrogen below 1 ppm This reaction is called as hydrotreating. In addition to this, metal compounds and Aromatics are also reduced in Hydrobon reactor.
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C-C-C-C-SH + H2 Organic sulfur (Mercaptan)

C-C-C-C +

H2S

H2

C-C-C-C-C + NH3

N Nitrogen compound (Pyridine) The reaction temperature is maintained at 310DegC, while pressure is maintained at 65kg/cm2g. The reactor temperature is maintained by charge heater, where heat input is given by firing fuel oil. A recycle gas compressor and makeup gas compressor maintains the reactor pressure to 65 kg/cm2g. The H2 required for reaction is compressed in makeup gas compressor upto reactor pressure. At reaction temperature cracking also takes place, where some lighter (<C10) are formed. To separate this, the reactor effluent is passed to distillation column called Product Stripper. The off gases separated in stripper are burnt in heater, as fuel. The H2S and NH3 formed in reaction form the ammonium sulfide salts. The water is injected in reactor effluent to prevent the deposition of salts that can corrode and foul the coolers. The desolved salts in water are further treated in sour water stripper to separate H2S and NH3, which are burnt in heater as off gas.

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Block Diagram of Hydrobon unit.

Feed from Prefractionation Lighters and Off gases

Charge heater

Hydrobon reactor

Product Separator

P R O D U C T

STR

To Molex unit. H2 from makeup gas compressor

c) MOLEX Molex process is effective method of separating normal paraffin from stream of hydrocarbon having normal and non-normal by physical selective adsorption process. The process uses solid adsorbent (Molecular sieve), where normal paraffin of straight chains are adsorbed in selective pores and non normal of branched chain are adsorbed in non selective pores. The adsorbed normal paraffin are then desorbed by normal pentane, while non normal are desorbed by iso-octane.

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There are two adsorption chambers, with 24 beds. The process simulates countercurrent contact between fixed bed adsorbent and feed stream. This simulation is done by flow directing device called Rotary valve. The separated streams from Molex chambers containing normal paraffin (Extract) and non normal (Raffinate) are fed to two distillation columns, a) Extract column and b) Raffinate column. In both distillation columns desorbent is separated from top and sidecut and recycled for desorption. While bottom product of Extract column is Normal paraffin send to storage.

R F D
E X T R A C T
R A F F I N A T E

ROTARY VALVE

C H A M B E R

C H A M B

E R

Normal paraffin

Non Normal

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2) Back End As described earlier, Linear alkyl benzene (LAB) is produced from linear olefins by UOP detergent alkylation process. The raw material normal paraffin of C10 to C14 from front end is processed in back end in series of processes, they are, a) Prefractionation b) Pacol c) Alkylation. a) PREFRACTIONATION The normal paraffin of C10 to C14 carbon range is separated to Normal paraffin of C10 to C13 carbon range, in two distillation columns in series. 1) Stripper column In this distillation column, lighter compound, (if any) and partly C10 paraffin is removed as light normal paraffin (LNP) from top. This LNP is sold in market as byproduct. The bottoms is send to Rerun column. 2) Rerun Column In this column heartcut paraffin (C10 to C13) is separated from top as distillate. The bottoms containing mainly C14 paraffin is sold in market as heavy normal paraffin (HNP) as byproduct.
Light NP
Heart cut Paraffin (C10 to C13)

Feed NP

S T R I P P E R

R E R U N

Heavy NP

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b) PACOL (Paraffin converted to olefin) The normal paraffin of carbon range C10 to C13 is converted to linear olefins of carbon range C10 to C13 by Dehydrogenation reaction, in UOP Pacol process. The catalyst used in reactor is alumina based platinum catalyst.

Platinum catalyst CH3-C-C-C-CH3 N paraffin CH3 - C = C C CH3 + H2 Linear Mono olefins

There are some side reactions takes places in Pacol, they are,

CH3 - C = C C CH3 Linear Mono olefins

CH3 - C = C = C CH3 + H2 Linear Di olefins.

CH3 - C = C = C CH3 Linear Di olefins.

Aromatics

+ H2

As it is dehydrogenation reaction, H2 gas is separated from reactor effluent in contact condenser, and send to Front End for Hydrobon makeup gas compressor. Cracking also takes place in reactor, where <C10 paraffin and olefins are formed, which is removed in distillation column called Pacol stripper. The gas separated in stripper is burnt in heater, as off gases. The reaction temperature is 470 to 495 Deg.C, while pressure is kept low at 1.3 kg/cm2g. The life of pacol catalyst is about 30 to 40 days. As life of the catalyst is low, there are two pacol reactors, for continuous running of the plant. The conversion of paraffin is about 12 to 13 %.

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DEFINE UNIT: The main purpose of this unit is to increase overall yield of LAB. The Diolefins formed in Pacol reaction is converted to Mono olefins and normal paraffin, thereby generating more LAB and lesser byproducts. The catalyst used in this reactor is Nickel based on alumina.

Nickel catalyst Diolefins + H2 Mono olefins

Diolefins + H2

Normal Paraffin.

The reaction temperature is 180 Deg.C and pressure is 14.0 Kg/cm2g. Block Diagram of Pacol Unit
Normal Paraffin Feed

Charge heater

Lighters and Off gases

H2 to front end Contact Condenser

Pacol reactor

P A C O L S T P R

To Alkylation. 16 of 72

C) ALKYLATION: As described earlier, linear olefins (C10 to C13) are alkylated in this unit, to form Linear alkyl Benzene (LAB), in presence of HF acid catalyst. The mono olefins are conveterd to Linear alkyl benzene (LAB), while diolefins are conveterd to Heavy alkyl Benzene (HAB). The aromatics are extracted, in counter current extraction of HF acid, and are separated in distillation column called Acid regenerators.

HF acid catalyst R- CH = CH CH2 R + Benzene M Olefins Where R and R are alkyl groups (CH3) LAB R-CH-CH2-CH2-R

R-CH=CH-CH=CH-R + 2 Benzene Di olefins

Heavy alkyl benzene HAB

The reaction is instantaneous, and carried through a two stage mixer settler system. The reactor section effluent is then processed in series of distillation columns, where excess, Benzene, Paraffin, LAB and byproduct Heavy alkyl benzene (HAB) gets separated. The separated benzene is recycled back to HF alkylation reactor, while separated Paraffin is recycled to Pacol reactor for reaction. The product Linear alkyl benzene (LAB) and byproduct Heavy alkyl benzene (HAB) are send to storage. The aromatics and non-normal, which are formed in Pacol reaction, are extracted in HF reaction unit, by counter current extraction of HF acid, as POLYMER. This polymer is separated in Acid regenerators, and then neutralized with KOH, and send to storage.

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Block Diagram of Alkylation process.

HF S T R I P P E R

I M I X E R

I Settler

2 M I X E R

II settler

From Pacol

Fresh Benzene

LAB
R E C O V E R Y R E R U N C

Recycle paraffin P A R A F F I N

B E N Z E N E C

HAB

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PROCESS INPUTS & OUTPUTS As described earlier, plant is divided into two sections, a) Front End, for Normal paraffin production from Kerosene. b) Back End for Linear alkyl Benzene (LAB) production from N paraffin. The raw material kerosene is supplied to the plant from two sources, a) From Bharat Petroleum Corp. Ltd., Chembur (BPCL) via, 55 Km pipeline. b) From Reliance Petroleum Ltd. Jamnagar via Shipping. The light kerosene, heavy kerosene and Raffinate from front end are combined and send as return kerosene via pipeline or shipping to either BPCL or to RPL Jamnagar. The manufacturing of LAB is done in two grades. a) Domestic grade (Molecular weight 235 to 239.) b) Export grade (Molecular weight 239 to 240) The byproducts of LAB plant are, a) b) c) d) Light Normal paraffin Heavy normal paraffin Heavy alkyl Benzene Tar polymer.

Installed Capacities: A) For Normal Paraffin 1,15,000 MT B) For LAB Plant load: A) For Normal Paraffin B) For LAB Production per day: A) For Normal Paraffin B) For LAB 117 % 120% 330 MT /day (Avrg). 324 MT/day (Avrg.) 1,00,000 MT Highest prod. 126596 MT in year 2001-2002 Highest prod. 112484 MT in year 1999-2000

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Customers: 1) The Normal paraffin produced in LAB plant is normally used for captive consumption for producing LAB. 2) The main customer of LAB is M/s Hindustan Lever and Procter & Gamble Ltd. and their subsidiary. 3) The LAB is exported to Europe, American, African and Asian countries. 4) The light and Heavy normal paraffin is used to manufacture Chlorinated Paraffin Wax. 5) Heavy alkyl Benzene is used as lubricants in oil industry.

Utility system in LAB plant Hot oil system: There are two Hot oil Heaters available in LAB plant, one for Front End and other is for Back End. The Heaters are fired with furnace oil / LSHS and off gases from process. The Hot oil (Dow Therm), which is thermic fluid is heated in these Hot oil heaters. The all heat inputs to the column, preheater, are given by circulating Hot oil at supply temperature of 330 Deg.C. Effluent System: The effluent generated in LAB plant mainly constitute, a) Fluoride. b) Oil. Maximum limit < 10 ppm. Maximum limit < 10 ppm.

For reduction of fluoride in effluent water, LAB plant have two neutralisation basins, where effluent from HF area is collected, and then reacted with Lime (CaCO3) to reduce fluoride content below 10ppm. For reduction of oil in effluent water, LAB plant have CPI separator installed, to separate oil from effluent water. The oil separated is send to Slope oil storage. In addition to this, there is hydrocarbon pit installed in front end, to collect pump and filter drains, which is being blended in return kerosene, to reduce oil load in effluent system. There all oil collection pits installed in storm water channels to avoid oil going into the river via gates.

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Cooling water system. For cooling the final products/ Byproducts to normal ambient temperatures, the products/ byproducts are cooled in coolers. The cooling media used is water. There are three cooling towers installed in LAB plant. a) HF cooling tower, it is separate cooling tower, to avoid HF ingrace in coolers, in non-HF area. b) Front End Cooling tower. c) Back End cooling tower. Fin Fan coolers.  The distillation columns overheads are condensed in air-cooled fin fan coolers.  The advantage of these coolers over water-cooled coolers is low operating cost. Safety measures taken in LAB Plant. 1) Safety Interlocks, for tripping the operation of equipments, in case process variables touches maximum allowable value. 2) Flare system for burning, excess gases from process. 3) Infra red detection system for Pacol Reactor and, Hot pumps. 4) Hydrocarbon detection system, for detecting hydrocarbon leakages. 5) H2S detection system and siren, for detecting H2S gas leakages. 6) HF Detection system, for detecting HF leakages. 7) Schedule HF leak testing of HF flanges. 8) Application of HF detection paints to all HF flanges, to detect HF leak, by decolouration. 9) Schedule Thickness survey of pipelines in HF area. 10) Fire water sprinkler system for HF vessels, Columns and pumps 11) Fire water sprinkler system for Hot oil pumps. 12) Yellow boundary marking of HF area, where personal protective equipments (PPEs) are mandatory . 13) Personal protective equipments (PPEs) for HF area. Different types of PVC suits are defined for different types of jobs. ( A, B, C and D type.) 14) Separate breathing air reciprocating compressor, for breathing air for C and D type PVC suits, in case of eemergency. 15) KOH scrubbing, for venting from all HF equipments, so that HF will not release into the flare. 16) Daily Benzene monitoring, with dragger tubes, to detect any Benzene leaks, from process. 17) Close draining system of HF and Benzene.

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PROJECT I: The project is about developing a BENZENE-WATER WASH system to remove the impurities coming with fresh benzene that enters into benzene stripper and effects thefin-fan cooler. The project is about developing such a scheme which will remove these impurities before entering the benzene stripper to eliminate the failure of fin-fan cooler. The scheme should also be such that it should not reduce the efficiency of the equipment and should be cost-effective. What is Benzene stripper? The high volatility of water dissolved in hydrocarbons is used in this column to obtain water-free benzene in the column bottoms which also removes any dissolved oxygen or non-condensibles in the benzene or off spec feeds. Makeup benzene is fed to the overhead receiver on level control reset by the overhead receiver level controller. It is refluxed via the overhead pump on flow control reset by the column bottom level controller and sent to the reaction section by the bottoms pump via the benzene stripper feed/bottoms exchanger on flow control which is reset by the benzene column receiver level controller. The benzene stripper receiver floats on the flare and is sized big enough to allow enough settling time for the water. There is a small nitrogen flow via a conservation vent into the receiver vapor flare to maintain a slight nitrogen purge. Water is collected in the boot and drained periodically whenever there is a boot high alarm. Maintain a visible benzene water interface in the boot sight glass. The benzene at the column bottom normally has a water content of less than 20ppm; actually much lower if the column is operated well. A moisture analyzer alarm high is provided. The heat input to the column is provided by a hot oil reboiler with the hot oil flow controlled. Off-spec material from the offspec tank is normally rerun via the benzene stripper coming into the column receiver. What is the Issue? The benzene stripper column overheads are condensed in air-cooler (fin-fan coolers: EC301).The advantage of using this fin-fan cooler is the low operating cost, no space constraint as are not on ground level etc. This tube-bundle was failing at a frequency of once in a span of two years. Failure analysis study was carried out and found that there are some impurities coming along with fresh benzene which are forming acidic solution after condensing in fin-fan. This acidic solution formed was causing the repeated failure of tube-bundle. Water dosing was started upstream of the fin-fan bundle to dissolve out the impurities or to neutralize the acidic solution so that tubes can be saved. This practice was started in 2008. Even after this modification, the failures and continue and its difficult to analyze that what type of impurities are coming with benzene.

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So, to eliminate this problem, a scheme has been plotted to design a benzene scrubbing system. This will be basically washing of benzene with DM water to remove the impurities before it enters the benzene stripper. The schematic diagram of this system is shown below. The scheme consists of a static mixture: for mixing benzene and water for a particular residence time and at a particular velocity as required. A gravity settler is for separating benzene and water on the basis of density difference.

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STATIC MIXER

This mixing device has no moving parts; is simple and its cost can be quite reasonable when compared to mechanical driven mixers. Static or motionless mixers are relatively new development and have proven to be effective for many specific and valuable process application. It is useful for a wide range of viscosity fluids; particularly useful in liquid-liquid mixing; and also for some gas-liquid dispersion. The concept of motionless mixers is to achieve a uniform composition and temperature distribution in fluids flowing through the device. The concept is build around a stationary, rigid, element placed in a pipe or cylinder that uses the energy of fluid flowing past to produce the mixing. The unit becomes more efficient by adding additional static elements causing the flowing fluid elements to split; rearrange; recombine and split again to repeat the process x times for a uniform or homogeneous flowing stream is produced at discharge Principle of operation: The static mixer unit is a series of fixed, helical elements enclosed within a tubular housing.

LIQUID LIQUID SEPARATION(Decanters)

Separation of two liquid phases, immiscible or partially miscible liquids is a common requirement in the process industries. It is also frequently necessary to separate small quantities of entrained water from process streams. The simplest form of equipment used to separate liquid phases is the gravity settling tank, the decanter. Various proprietary equipment is also used to promote coalescence and improve separation in difficult systems , or where emulsions are likely to form. Centrifugal separators are also used.

Decanters (settlers) Decanters are used to separate liquids where there is a sufficient difference in density between the liquids for the droplets to settle readily. Decanters are essentially tanks which give sufficient residence time for the droplets of the dispersed phase to rise (or settle ) to the interface between the phases and coalesce. In an operating decanter there will be three distinct zones or bands: clear heavy liquid; separating dispersed liquid (the dispersion zone); and clear light liquid. The position of the interface can be controlled, with or without the use of instruments, by use of a siphon take-off for the heavy liquid.

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Vertical decanter The height of the take-off can be determined by making a pressure balance. Neglecting friction loss in the pipes, the pressure exerted by the combined height of the heavy and light liquid in the vessel must be balanced by the height of the heavy liquid in the take-off leg,

Z1

(z1-z3) 1g + z3 2g= z2 2g z2 = (z1-z3) 1 + z3 2 WhereZ1= height from datum to light liquid overflow, m Z2=height from datum to heavy liquid overflow, m Z3=height from datum to interface, m 1=density of the light liquid, kg/m 2=density of the heavy liquid, kg/ m The height of the liquid interface should be measured accurately when the liquid densities are close, when one component is present only in small quantities, or when the throughput is very small. A typical scheme for the automatic control of the interface, using a level instrument that can detect the position of the interface is shown in the diagram below. Where one phase is present only in small amounts it is often recycled to the decanter feed to give more stable operation. (1)

Z3

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CALCULATIONS  STATIC MIXER DESIGN

Required data: 1. Physical properties of materials:  Density: kg/m  Viscosity: Pas = 0.001Cp. 2. Pressure drop Pressure drop in static mixer is best described by comparison with pipe flow. 3. Geometrical parameters :  Diameter: m  Type of static mixer constant (k)

 Length (l): m 4. Process variables:  Flow rate: m /s  Temperature:C  Pressure: bar

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Pressure drop calculation a) Velocity (v): V= /4 D b) Reynoldss number(Re): Re= d*v* c) Pressure drop ( p): For Re <50 p =k1x d d k1= laminar flow constant For Re >10 d 2 p =k2 x x l x v Q

x l xQ

= k2 x Q x l x 8 x Q d d k2= turbulent flow constant. Pipe diameter, Flow seems to be turbulent as both the materials (B2+ H2O) are not viscous. D =3.9Q

Q =5.2 + 5.72 = 10.92m /hr = 3.03 x 10 m /s = 385.64 ft /hr = 926.328 kg/m =57.828 lb/ft D =3.9 x Q x x (57.828)

D =3.9 x (385.64) 3600

D= 2.4 inch = 2.5 inch = 0.0635m

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Velocity(v) : V =4 Q d = 3.03 x 10 m /s x 4 3.14 x (0.0635) = 0.957 m/s (approx 1m/s) Reynoldsnumber(Re): Re = d*v* = 0.0635 x 1 x 926.328 0.572 Re =1.03 x 10 Thus , the flow is highly turbulent. Flow regime Reynolds no(Re) No of element No of elements to add if viscosity ratio between fluids exceeds 1000:1 6 6 6 6 6 4 4 2 2 No of elements to add if volumetric ratio between fluids exceeds 100:1 6 6 6 6 6 4 4 2 2

Laminar

Transitional Turbulent

<1 1-10 11-50 51-100 101-500 501-1000 1001-2000 2001-5000 5001+

24 18 14 12 10 8 6 4 2

Thus from the above table, the mixer will have 2 elements. The mixer length will be based on the number of elements required. An approximate length can be determined by multiplying the number of elements by 1.5. Mixer length = 1.5 x 2 =3

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For turbulent flow applications, it is generally recommended that a minimum velocity of 1.0 ft/sec be maintained. V= 0.408 x Q/D = 0.408 x 48.1/3 = 2.18 ft/sec =0.66 m/s

DECANTER DESIGN Benzene Water

Flow rate (m /h) Flow rate (kg/h) Density (kg/m ) Viscosity (Pas)

5.2 4543.812 873.81 0.000604

5.72 5703.11 997.04 0.00089

Take Dd = 150 m d = (150 10 ) 9.81 (873.81-997.04) 18 0.00089

d = -1.69787 10 m/s = -1.7 mm/s (rising) As the flow rate is small, we will use a vertical cylindrical vessel. The decanter vessel is sized on the basis that the velocity of the continuous phase must be less than settling velocity of the droplets of the dispersed phase. Plug flow is assumed, and the velocity of the continuous phase calculated using the area of the interface: c =Lc< d Ai Where d = settling velocity of the dispersed phase droplets, m/s, c = velocity of the continuous phase, m/s, Lc = continuous phase volumetric flow rate , m /s, Ai = area of the interface, m.

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Lc = 5703.11

X 1 997.04

3600

= 0.0015889 m/s Ai=Lc = 0.0015889 c 0.0017 = 0.935817588 m For a vertical cylindrical decanter: Ai = r

r=

0.935817588 r = 0.545835318 m Diameter= 1.091670637 m Taking the height as twice the diameter, a reasonable value for a cylinder: Height = 2.183341274 m The position of the interface should be such that the band of droplets that collect at the interface waiting to coalesce and cross the interface does not extend to the bottom (or top) of the vessel. The depth of the dispersion band is a function of the liquid flow rate and the interfacial area. A value of to per cent of the decanter height is usually taken for the design purposes. Take the dispersion band as 10 per cent of the height = 0.21833m. The residence time of the droplets in the dispersion band = 0.21833 = 0.21833 d 0.0017 =128.5926 s (approx 2 min) This is satisfactory time, a time of 2 to 5 min is normally recommended. Thus the size of the water (continuous , heavy phase) droplets that could be entrained with benzene (light phase) will be, Velocity of benzene phase = 4543.812 X 1 X 1 873.811 36000.93581 =0.001543511 m/s =1.543511mm/s

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So from equation ( ) So the entrained droplet size will be =0.0015435 X 18 X 0.000604 9.81 X (997.04-873.812) =0.0001178 m =117.8 m which is satisfactory; below 150 m

Piping arrangement: To minimize entrainment by the jet of liquid entering the vessel, the inlet velocity for a decanter should keep below 1 m/s The velocity from static mixer= 0.66 m/s Flow rate= 4543.812 + 5703.11 X 1 873.81 997.04 3600 = 0.003033345m/s. Area of pipe= flow rate/velocity = 0.003033345/0.66 = 0.004554572m Pipe diameter =0.004554572 x 4 = 0.076158749 m =2.9983 inch (approx 3 in)

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PROJECT II:
CALULATING THE DEW POINT

This project is about the study and evaluation of the performance of the compressors in the Hydrobon section of the LAB plant which is installed to optimize the purity of hydrogen coming from the product separators. The compressors in this section include recycle gas compressor and make-up gas compressor.The purity of hydrogen can be increased upto 90%. This project will give the company an overall view of this loop. The plant is running well about its installed capacity(131-140%). The company wants to retain the purity level of nearly 90% for hydrogen even after operating above installed capacity. Hence the current project will give the company an idea of the current hydrogen quality(purity) which is obtained and give an idea about changes if any to be made to existing process set-up HYDROBON REACTOR Hydrobon reactor is designed to remove contaminants present in the raw kerosene without changing the boiling range. The hydrocarbon is passed through a 2 bed reactor feed with S 12 catalyst through a feed effluent exchanger and charge heater which maintain the required reaction temperature(310 c). The reaction required hydrogen gas which is supplied from pacol net gas generated from back end and tattoray hydrogen from PX plant. The reaction charge is heated to the reaction temperature in the charge heater, enters the reactor from the top and is distributed over the catalyst bed. Catalytic hydrogenation takes place in the reactor. The impurities react with hydrogen and form salts which are subsequently separated and finally removed in sour water stripper. The reactor effluents after separation is fed to the product stripper to remove lighters and hydrotreated kerosene is fed to molex unit. The sulfur and nitrogen levels are reduced to 1 ppm or less. PARAMETERS Plant load(%) Hydrobon feed rate(mt/hr) Temperature Pressure (kg/cm2 g) H2/HC ratio Recycle hydrogen purity(mole%) Hydrobon feed specification a. Bromine index(mg/100gm) DESIGN 100 58 416 82.2 385 75 min ACTUAL 115 60 310 62 460 95

800

800

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b. Nitrogen(ppm) c. Sulphur(ppm) d. Aromatics(%) Hydrobon outlet specification e. Bromine index(mg/100gm) f. Nitrogen(ppm) g. Sulphur(ppm) h. Aromatics(%) Catalyst yield(mt of hydrocarbon feed/kg catalyst)

2 1500 24 150 max 0.5 max 1 max 20 52.68

2 1038 24 90 0.1 .2 20

PROCESS VARIABLES H2/HC ratio: =total gas at stp per unit time * h2 purity/charge rate A decrease in this ratio will led to rapid catalyst deactivation An increase in this ratio will mean higher utility cost. Recycle hydrogen gas purity A decrease in minimum hydrogen purity will affect h2/HC ratio and partial pressure of hydrogen. The purity of recycle gas should be higher than a min value of 70-80% mole to achieve the desired product quality of normal operating temp. Brief Overview The Linear Alkyl Benzene, produced from Kerosene is a useful detergent intermediates and can be readily sulfonated to give linear alkyl benzene sulfonates. The kerosene from petroleum refinery contains various amounts of naturally occurring contaminants, the most important ones being organic sulfur, nitrogen, and metal compounds. The purpose of UOP Hydrobon process is to remove sulfur and nitrogen from feed, which would poison the sieve in UOP Molex process unit thus reducing the adsorbent life. The catalyst used in Hydrobon reactor is S12 (Cobalt-Molybdenum Oxide on alumina) The UOP Hydrobon process is a catalytic hydrogenation method for upgrading the feed quality by removing sulfur and nitrogen without greatly changing its boiling range. In addition to this, metal compounds and Aromatics are also reduced in Hydrobon reactor. This upgrading, oftencalled Hydrotreating is done by passing the feedstock over a fixed bed of UOP Hydrobon catalyst.

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HD Hydrobon Process unit in LAB Front End consist of a high-pressure reactor section and a lower pressure product stripper section. The following reactions represent in general what is taking place inside the reactor. 1) Sulfur Removal

2) Nitrogen Removal

3) Metals Removal While mechanism of organo-metallic compound removal is not well understood, it is known that metals are retained on the catalyst. The limiting amount of metals the catalyst can remove is related to the amount of catalyst in the plant . Once the limit is exceeded metals can be found in reactor product stream

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4) Oxygen Removal

5) Olefin Saturation

6) Halides Removal

7) Other Reactions

Near the end of the run to compensate for the lower catalyst activity the reactor temperatures will be relatively high. With the higher temperature there will be increased tendency to hydrocrack the feed which will be evident from more H2 consumption and more net stripper overhead liquid production.

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FLOW DIAGRAM OF HYDROBON SECTION

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Process Description The UOP Hydrobon process is a catalytic hydrogenation method for upgrading the feed quality by removing sulfur and nitrogen without greatly changing its boiling range. In addition to this, metal compounds and Aromatics are also reduced in Hydrobon reactor. This upgrading, oftencalled Hydrotreating is done by passing the feedstock over a fixed bed of UOP Hydrobon catalyst. HD Unibon Process unit in LAB Front End consist of a high-pressure reactor section and a lower pressure product stripper section. (A) Reactor Section: Heart Cut Kerosene from Prefractionation Section is sent to Hydrobon feed surge drum (FA601). This stream consists of C10-C14 range of hydrocarbons, which include normal paraffins, nonnormal paraffins and various contaminants like organic sulfur, nitrogen etc. The reactor charge pumps (GA601 A/B/C) pumps Kerosene to combine feed exchanger (EA602). The charge pumps used in Hydrobon are Sundyne pumps capable of pumping feed to high pressure of around 95-100kg/cm2g. New reactor charge pump is being installed in the unit, as a part of energy conservation drive. However, this PHA study excludes this pump operation. Before entering the combined feed exchanger, Kerosene is mixed with recycle Hydrogen from Recycle Gas Compressor (GB601). A single stage double acting reciprocating compressor (GB601) is used to raise the pressure of gas. The recycle gas also acts a medium for quenching the heat of reaction from the reactor, in case of loss of liquid charge to the reactor. The reactor charge and recycle hydrogen gas are preheated by the reactor effluent in combine feed exchanger, which is a series of shell and tube heat exchangers. In CFE, combined feed is preheated to 294C and then enters the reactor charge heater (BA601). The reactor charge is heated to reaction temperature in Charge Heater. The heater is convection, radiation type natural draft heater. The temperature is raised upto 302-305C in this heater. The heated feed enters at the top of Hydrobon Reactor (DC601) and is evenly distributed over the top of catalyst bed by vapor liquid distributor. The reactor is divided into two catalyst beds; separated by catalyst support grids and redistributors. Due to the exothermic nature of reactions taking place in the reactor (due to aromatic saturation and partly due to thermal hydrocracking of long molecules), the temperature of outlet stream leaving is higher than the reactor inlet stream temperature. The heat of reaction as well as a large portion of the heat contained in the reactor feed is recovered in combine feed exchangers (EA602). Final cooling of the reactor effluent is obtained by passing it through air-cooled fin-fan exchanger (EC601). DM water is injected into the reactor effluent before it enters EC601 in order to prevent the deposition of salts that can corrode and foul the coolers. The sulfur and
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nitrogen contained in the feed is converted to hydrogen sulfide (H2S) and ammonia (NH3) in the reactor, these two reaction products combine to form ammonium salts that can solidify and precipitate as the reactor effluent is cooled. Hence DM water is added to reactor effluent to dissolve these salts before they precipitate. To maintain the reaction loop pressure and to makeup for the hydrogen consumed in the reaction, make up Hydrogen is added to reactor loop before it enters the cooler EC601. This make up gas is supplied by four stage double acting reciprocating make up compressor (GB602). The addition of this Hydrogen before cooler also serves the purpose of removal of after-cooler in the 4th stage of compressor (GB602). The make up hydrogen is obtained from LAB PACOL process at 2.3kg/cm2g, which enters the 1st stage of make up gas compressor. The balance hydrogen is obtained from Tatoray Unit from PG-PX at 13.5kg/cm2g and LPFD gas that enter the 3rd stage suction of compressor. The reactor effluent is cooled to about 60C using air-cooled fin-fan heat exchangers (EC601). Cooled effluent enters the high-pressure separator (FA602) where the hydrocarbon, water and gas phases disengage and are removed individually. A circumferential mesh blanket is placed in the separator to help separate water from hydrocarbon. The water collected in a boot attached to separator is removed on level control and sent to a sour water-degassing drum (FA606). This water contains high concentration of toxic gases H2S and NH3. The hydrogen rich gas leaving the top of separator is sent to recycle gas compressor section through recycle compressor suction drum. The H2S content in the recycle gas is controlled by a slip stream/vent provided above the Product Separator (connected to FA605 Off Gas line). This venting is to be done when the H2S in recycle gas crosses 10% by volume. (B) Fractionation Section: The hydrocarbon liquid collected in separator FA602 is sent to the low-pressure flash drum (FA603) where additional hydrogen and other dissolved gases are removed from top. A part of this gas is burnt in the heater and the remaining part is used as makeup gas. LPFD bottom is sent to the product stripper (DA601) on level control. The product stripper strips out the water, light ends and H2S in the separator liquid. The overhead vapors are condensed in an air-cooled fin fan condenser (EC602) enters the overhead receiver (FA605). The water collected in the receiver boot is sent to the sour water stripper unit. Condensed hydrocarbon is refluxed back to the column and a net overhead liquid draw is removed for further processing in light end stripper column (DA603). The non-condensable gases leave the overhead receiver on pressure control and are normally routed to fuel gas system through FA 802. The contaminant free material from column bottom is first exchanged with PACOL Stripper feed and then with product stripper feed and sent to Molex unit on level control. A slipstream is bypassed around the stripper feed/bottom exchanger on TRC control to ensure a constant feed temperature to

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Molex Unit. Molex feed temperature is to be constantly monitored to prevent ingress of unsaturates into Molex Unit. The Light End Stripper bottom liquid is routed to either return Kerosene or to PX as a fuel. Purpose of Light End Stripper is to stabilize the lights stream of dissolved gases. Light End Stripper bottom temperature is a significant parameter. It is to be maintained above 160C to prevent H2S carryover to storage tank. (C) Sour Water Stripping Section: The water collected in Product Separator (FA602) and other sections contains large concentration of toxic gases like H2S and NH3. Hence the water from boot is diverted to sour water degassing drum (FA606), which removes dissolved gases at lower pressure of 1.0kscg. Bottom liquid is fed to sour water stripping column (DA602). The H2S and NH3 stripped water from sour water stripping column is then drained to sewer system. The off gases, which contain H2S and NH3, are burnt in heater as off gas. Sour Water Stripper bottoms are analyzed for pH and H2S once in a week. Reciprocating compressor A reciprocating compressor or a piston compressor is a positive-displacement compressor that consists of a piston driven by a crankshaft to deliver gases at high pressure. The intake gas enters a suction manifold, then flows into the compression cylinder where it gets compressed by a piston driven in a reciprocating motion via a crankshaft, and the gas is then discharged. The reciprocating air compressor is said to be double acting when the compression is accomplished using only both sides of the piston.

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DEMISTER PAD: A demister, is a device often fitted to vapor liquid separator vessels to enhance the removal of liquid droplets entrained in a vapor stream. Demisters may be a mesh type or vane pack or other structure intended to aggregate the mist into droplets that are heavy enough to separate from the vapor stream. Demisters can reduce the residence time required to separate a given liquid droplet size thereby reducing the volume and associated cost of separator equipment. Demisters are often used where vapor quality is important in regard to entrained liquids particularly where separator equipment costs are high or where space or weight savings are advantageous.

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DEW POINT: When a liquid mixture is heated from a sub-cooled state at constant pressure,the vaporization occurs over a range of temperatures unlike vaporization of a pure substance which occurs at a constant temperature at a given pressure. For any mixtures the two limiting temperatures of the above range are known as bubble point and dew point. Figure shows T vs x, y of n-pentane for the n-pentane/n-hexane system at 101.325kPa(760 torr) considering the mixture to be an ideal one. As the heating process continues beyond M, the temperature rises, the amount of vapour increases and the amount of liquid decreases. During this process, the vapor and liquid phase composition change along the paths MN and MN, respectively. Finally as the point N is approached, the liquid phase is reduced to minute drops( called dew) and at point N, the liquid phase is completely vaporized to a saturated vapour phase. Hence the point N is called the dew point. For an ideal mixture, the dew point can be calculated using the Raoults law. For a given pressure and composition, the dew point and the composition at respective points are calculated by the iterative calculations as shown below. Dew point i. ii. iii. iv. v. For a vapor mixture of known composition, assume a temperature and find the vapor pressure of all the components, pis at this temperature. Calculate xi=yi*p/pis xi should be 1. If xi 1, then a new temperature should be assumed and the above calculations be repeated. The temperature for which xi=1 is the dew point and the liquid composition at dew point is given by xi Initial guess value of temperature can be taken as Ti= Xi. Tis.

Performance evaluation of compressor GB-601 A/B GB-601 A/B is a one stage double acting reciprocating compressor. 1. First Stage Calculation The following are the 1st stage condition for the calculation: Suction temperature = 58C =331 K Suction pressure = 60 kg/cma =58.83 bar Discharge temperature = 83C = 356 K Discharge pressure = 74 kg/cma=72.56 bar

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Thus, MW mix =Average molecular weight = 3.713kg/kmol Pc of mixture = 14.47 bar Tc of mixture = 47.346K Cp of mixture = 30.892

componentsmol wt mol % mole fraction Tc K h2 2.016 95.1 0.951 33 C1 16.042 0.7 0.007 190.4 C2 30.069 2.2 0.022 305.4 C3 44.096 1.3 0.013 369.8 C4 58.123 0.5 0.005 425.2 C5 72.15 0.1 0.001 469.7 C6 86.178 0.1 0.001 508.3 00 1 SUM

Pc bar 12.9 46 48.8 42.5 38 33.7 30.3

Cp vap ACp vap B Cp vap C Cp vap D Cp @ 58 C wt MW wt Pc KJ/KmolK kg/kmol bar a 27.14 0.00927 -1.381E-05 7.645E-09 28.9739 1.91722 12.2679 19.25 0.05213 1.197E-05 -1.132E-08 37.405959 0.11229 0.322 5.409 0.1781 -6.938E-05 8.713E-09 57.074732 0.66152 1.0736 -4.224 0.3063 -0.00016 3.22E-08 80.799263 0.57325 0.5525 9.487 0.3313 -0.00011 -2.8E-09 106.99405 0.29062 0.19 -3.62 0.3313 -0.00026 5.31E-08 79.480095 0.07215 0.0337 -4.413 0.582 -0.0003119 6.494E-08 156.41195 0.08618 0.0303 3.71322 14.47

wt Tc K 31.383 1.3328 6.7188 4.8074 2.126 0.4697 0.5083 47.346

wt Cp KJ/kmolK 27.554179 0.2618417 1.2556441 1.0503904 0.5349702 0.0794801 0.156412 30.892918

component mol wt mol% mol fraction Tc K h2 2.016 95.1 0.951 33 C1 16.042 0.7 0.007 190.4 C2 30.069 2.2 0.022 305.4 C3 44.096 1.3 0.013 369.8 C4 58.123 0.5 0.005 425.2 C5 72.15 0.1 0.001 469.7 C6 86.178 0.1 0.001 508.3 SUM 100 1

Pc Cp vap A Cp vap B Cp vap C bar a 12.9 27.14 0.00927 -1E-05 46 19.25 0.05213 1.2E-05 48.8 5.409 0.1781 -7E-05 42.5 -4.224 0.3063 -0.0002 38 9.487 0.3313 -0.0001 33.7 -3.62 0.3313 -0.0003 30.3 -4.413 0.582 -0.0003

Cp vap D Cp @ wt MW KJ/KmolK kg/kmol 7.65E-09 29.03625 1.91722 -1.1E-08 38.81457 0.11229 8.71E-09 60.41277 0.66152 3.22E-08 85.99384 0.57325 -2.8E-09 113.3625 0.29062 5.31E-08 83.76721 0.07215 6.49E-08 166.18 0.08618 3.71322

wt Pc bar a 12.268 0.322 1.0736 0.5525 0.19 0.0337 0.0303 14.47

wt Tc K 31.383 1.3328 6.7188 4.8074 2.126 0.4697 0.5083 47.346

wt Cp KJ/kmolK 27.61347 0.271702 1.329081 1.11792 0.566813 0.083767 0.16618 31.14893

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At suction conditions: Pr = P suction /Pc = 58.83/14.47 =4.O66 Tr = T suction/ Tc=331/47.34 =6.99 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 4.066&Tr =6.99 Suction Compressibility =Z1 =0.99 At discharge conditions: Pr = P discharge/Pc = 72.56/14.47 =5.0151 Tr = T discharge/ Tc= 356/47.34 =7.52 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 5.0151&Tr =7.52 Suction Compressibility =1.01 Thus, K-value of mixture =Cp mix/ C v mix = Cp mix/ (Cp mix R) = 30.892/ (30.892 8.314) =1.368 Average compressibility = Z avg =(Z1 +Z2)/2 = (0.99+1.01)/2 =1 Pressure ratio: PR = Pressure ratio = P discharge/P suction =72.569/58.83 =1.233 Volumetric Efficiency: It is defined as the actual gas delivered to the piston displacement of the compressor. When the discharge pressure is high, the quantity that is left back in space between piston and the cylinder end walls is also high. Thus volumetric efficiency of the compressor can be theoretically estimated as: ad = 0.97 C x [ PR ^(1/k) -1] L Where, C= Clearance in % for 1st stage = 14% (from design data) PR= Pressure Ratio = 1.233 k= Ratio of specific heats = 1.368 L= Leakage losses normally 0.03 to 0.05 for Lubricated compressor and 0.075 to 0.1 for nonlubricated compressor.
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Since GB-601 is LUBRICATED COMPRESSOR , we will take L=0.03. Thus, Volumetric efficiency =0.97 0.14 [1.233^(1/1.368)-1] 0.03 =0.97 0.14[1.165 -1]-0.03 =0.97- 0.0231 -0.03 =0.9168 =91.68 % Piston Displacement: Piston displacement is defined as the net volume actually displaced by the piston at rated machine speed, as the piston travels its length from top dead center to bottom dead center. Piston displacement = Vd(m /hr) = (/4) x (D+(D- d))x S x N x 60 Where, d= diameter of the rod =65mm=0.065m S= Cylindrical Stroke = 200mm=.2m D= Cylindrical Bore Diameter=220mm =.22m N= Speed of Compressor =416 rpm Therefore; Piston displacement = (3.14/ 4) x (.22 +(.22 - 0.065))x .2 x 416 x 60 = 0.785 x (0.0484 + 0.044175) x 4992 = 362.7755m/hr Capacity of the compressor: Inlet capacity of the compressor = Q (m /hr) =Vd x ad =362.7755 x 0.9168 =332.592m/hr

Specific Volume : It is the inverse of gas density .i.e. it is the volume of the gas per kilogram at specified conditions. It is given as follows; Vsp = Z x Ts x R Ps MW

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Where, Vsp = Specific volume of Gas in m /hr Z = Compressibility factor at first stage suction condition = 1 Ts = Suction temperature at 1st stage = 331K Ps = Suction pressure at 1st stage =58.83 bar a= 58.83/1.01325 =58.06atm a R = Universal gas constant = 0.08206m -atm/k-molK MW = Molecular weight of gas at 1st stage =3.713 kg/k-mol Therefore, V sp= (1 x 331 ) x 0.08206 58.06 3.713 = 0.1259m/kg Capacity in kg/hr M =Q x Vsp =332.592x0.1259 =41.87 kg/hr Adiabatic Discharge Temperature: When the compression takes place by adiabatic process, the discharge temperature can be predicted by, Tad = Ts x (PR)^(k-1/k) = 331 x 1.233^(1.368-1/1.368) = 331 x 1.0666 =350.185K Adiabatic Efficiency It indicates the actual process compressor deviation from the adiabatic compression. It is given by, ad = Tad- Ts Td actual Ts

=350.185-331/(356-331) =0.764 =76.4 Adiabatic Head : It is defined as the work done by the compressor to raise the pressure of the gas. It is given by, Had (kN-m/kg) = Z avg x R x Ts x k x [PR^(k-1/k) 1] MW mix k-1
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=1 x(8.314/3.713)x 331 x (1.368/1.368-1)x (1.233^(1.368-1/1.368)-1) =741.16 x 3.717 x0.057 =159.6 Kn-m/kg Adiabatic Power: It is the power required by the compressor to raise the pressure of gas. It is brake power; in mechanical terms. Pad (kW) = m x Had ad x 3600 Where, Had = Adiabatic Head =159.6kN-m/kg m = Total Inlet Feed to the compressor in kg/hr=5864 kg/hr ad = Adiabatic efficiency=0.764 Pad(kW) = 5864 x 159.6/(.764 x 3600) =338.797 kw Adiabatic efficiency can be enhanced by maintaining Td-actual as close to Tad as possible. Now,if the adiabatic efficiency is increased to 100% i.e Td-actual =Tad then, Adiabatic power required = 5864 x 159.6/(1 x 3600) =259.9 kw Power saved= 338.797 -259.9 =78.897 kw If the cost of the power is rs 6/kw hour Savings per day= 6 x24 x78.897 =rs. 11361.168/day If we consider that the plant operates for around 8040 hours/day Savings per year =6 x 8040 x 78.897 =rs 3805991.28 =rs 38.05 lakhs/ year Isothermal work: W iso = R gas x Ts x Z1 x ln(P2/P1) =8.314 x 331 x 1 x ln(72.56/58.83) =2751.934 x.209 =577.13 Kj/Kmol =577.13 Kj/Kmol x 111.607 kmol/hr =64.411 x 10^3 Kj/hr =17.89 kw

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Polytropic Work Wpoly=R gas x T1x Z1 x n/(n-1)x ((P2/P1)/n-1) =8.314 x 331 x 1 x 1.2/(1.2-1) x [(72.56/58.83)/1.2 -1] =2751.934 x 6 x .03557 =587.459Kj/kmol =587.459 Kj/kmolx 111.607 kmol/hr =65.551 x 10^3 kmol/hr =18.208 Kw PERFORMANCE EVALUATION OF GB-602 1.First Stage Calculations: The following are the 1st stage conditions for our calculations Suction Temperature = 35C =308K Suction Pressure =1.58kg/cma =1.54 bar Discharge temperature =121C = 394K Discharge Pressure =4.7kg/cma =4.6 bar Thus, MW mix = Average Molecular Weight = 3.1842 Pc of Mixture=14.34 Tc of Mixture=43.367 Cp of Mixture=29.92

components mol wt mol% molfrac Tc

Pc bar

Cp vap A Cp vapB Cp vap C Cp vap D Cp @38 C wt MW wt Pc wt T c KJ/KmolK kg/kmol bar a

wt Cp KJ/kmolK 0.7256

K
h2 C1 C2 C3 C4 C5 NC-6 h2s SUM

K
3.808

2.016 16.042 30.069 44.096 58.123 72.15 86.178 34.076

95.9 2 0.8 0.6 0.3 0.3 0 0.1

100

0.959 0.02 0.008 0.006 0.003 0.003 0 0.001

1

33.2 190 305 370 425 470 508 373

13 46.4 48.8 42.5 38 33.7 30.3 89.4

27.14 19.25 5.409 -4.224 9.487 -3.62 -4.413 31.94

0.00927 0.05213 0.1781 0.3063 0.3313 0.3313 0.582 0.00144

-1E-05 1.2E-05 -7E-05 -0.0002 -0.0001 -0.0003 -0.0003 2.4E-05

7.6E-09 -1.1E-08 8.7E-09 3.2E-08 -2.8E-09 5.3E-08 6.5E-08 -1.2E-08

28.91846 1.9333 12.47 31.839 27.733 36.27967 0.3208 0.928 54.34969 0.2406 0.39 2.4432 0.4348

76.52852 0.2646 0.255 2.2188 0.4592 101.7978 0.1744 0.114 1.2756 0.3054 75.8641 0.2165 0.101 1.4091 0.2276 148.3751 0 0 0 0 29.92 34.38511 0.0341 0.089 0.3732 0.0344 3.1842 14.34 43.367

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At suction conditions: Pr = P suction /Pc = 4.936 Tr = T suction/ Tc= 6.9252 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 4.936 &Tr =6.9252 Suction Compressibility =1.05 At discharge conditions: Pr = P discharge/Pc = 6.05 Tr = T discharge/ Tc= 7.37 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 6.05 &Tr =7.37 Suction Compressibility =1.03 Thus, K-value of mixture =Cp mix/ C v mix = Cp mix/ (Cp mix R) = 30.12491/ (30.12491 8.314) =1.38 Average compressibility = Z avg=(Z1 +Z2)/2 = (1.05+1.03)/2 = 1.04 Pressure ratio: PR = Pressure ratio = P discharge/P suction = 94.08/76.711 =1.2264 Volumetric Efficiency: It is defined as the actual gas delivered to the piston displacement of the compressor. When the discharge pressure is high, the quantity that is left back in space between piston and the cylinder end walls is also high. Thus volumetric efficiency of the compressor can be theoretically estimated as: ad = 0.97 C x [ PR ^(1/k) -1] L Where, C= Clearance in % for 1st stage = 14% (from design data) PR= Pressure Ratio = 1.2264 k= Ratio of specific heats = 1.38 L= Leakage losses normally 0.03 to 0.05 for Lubricated compressor and 0.075 to 0.1 for nonlubricated compressor.
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Since GB-601 is LUBRICATED COMPRESSOR , we will take L=0.03. Thus, Volumetric efficiency =0.97 0.14 [1.2264 ^(1/1.38)-1] 0.03 =0.97 0.14[1.1591 -1]-0.03 =0.97- 0.022285 -0.03 =0.917715 =91.771 %

Piston Displacement: Piston displacement is defined as the net volume actually displaced by the piston at rated machine speed, as the piston travels its length from top dead center to bottom dead center. Piston displacement = Vd(m /hr) = (/4) x (D+(D- d))x S x N x 60 Where, d= diameter of the rod =65mm=0.065m S= Cylindrical Stroke = 200mm=.2m D= Cylindrical Bore Diameter=220mm =.22m N= Speed of Compressor =416 rpm Therefore; Piston displacement = (3.14/ 4) x (.22 + (.22 - 0.065))x .2 x 416 x 60 = 0.785 x (0.0484 + 0.044175) x 4992 = 362.7755m/hr Capacity of the compressor: Inlet capacity of the compressor = Q (m /hr) =Vd x ad =362.7755 x 0.917715 =332.9244m/hr

Specific Volume : It is the inverse of gas density .i.e. it is the volume of the gas per kilogram at specified conditions. It is given as follows; V sp = Z x Ts x R Ps MW
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Where, V sp = Specific volume of Gas in m /hr Z = Compressibility factor at first stage suction condition = 1.04 Ts = Suction temperature at 1st stage = 328K Ps = Suction pressure at 1st stage = 76.71 bar a= 76.71/1.01325 =75.7068atm a R = Universal gas constant = 0.08206m -atm/k-molK MW = Molecular weight of gas at 1st stage =3.3809 kg/k-mol Therefore, V sp = (1.04 x 328 ) 75.708 = 0.10936m/kg Capacity in kg/hr: M= Q*V sp = 2165.68 kg/hr Adiabatic Discharge Temperature: When the compression takes place by adiabatic process, the discharge temperature can be predicted by, Tad = Ts x (PR)^(k-1/k) = 328 x 1.2264 ^(1.38-1/1.38) = 328 x 1.0666 =346.96K Adiabatic Efficiency It indicates the actual process compressor deviation from the adiabatic compression. It is given by, ad = Tad- Ts = 95.23% Td actual Ts x 0.08206 3.3809

Adiabatic Head : It is defined as the work done by the compressor to raise the pressure of the gas. It is given by, Had (kN-m/kg) = Z avg x R x Ts x k x [PR^(k-1/k) 1] MW mix k-1.4 =1024.077 k-N/m

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Adiabatic Power: It is the power required by the compressor to raise the pressure of gas. It is brake power; in mechanical terms. Pad (kW) = m x Had ad x 3600 Where, Had = Adiabatic Head m = Total Inlet Feed to the compressor in kg/hr ad = Adiabatic efficiency = 80.352 kw Isothermal work: W iso = R gas x Ts x Z1 x ln(P2/P1) = 86.54 kw Polytropic Work: W poly =Rgas *T1*Z1*n/(n-1)*((P2/P1)^(1-(1/n)))-1) =3061.206803 =341652.1077 =94.90351752 GB-602 2ND STAGE
componentsmol wt h2 C1 C2 C3 C4 C5 NC-6 NC-7 NC-8 h2s 2.016 16.042 30.069 44.096 58.123 72.15 86.178 100.203 114.23 34.076 mol% 88.18 1.87 4.62 1.52 1.33 1.14 0.7 0.44 0.19 0.01 100 molfrac 0.8818 0.0187 0.0462 0.0152 0.0133 0.0114 0.007 0.0044 0.0019 0.0001 1 Tc Pc Cp vap A bar 13 46.4 48.8 42.5 38 33.7 30.3 27.4 24.9 89.4 27.14 19.25 5.409 -4.224 9.487 -3.62 -4.413 -5.619 -7.477 31.94 0.009274 0.05213 0.1781 0.3063 0.3313 0.3313 0.582 0.67692 -1.4E-05 1.2E-05 -6.9E-05 -0.00016 -0.00011 -0.00026 -0.00031 -0.00036 -1.1E-08 Cp vapB Cp vap C Cp vap D Cp @38 C wt MW KJ/KmolK kg/kmol wt Pc bar a wt T c wt Cp KJ/kmolK

kj/kmol kj/hr kw

K
33.2 190.4 305.4 369.8 425.2 469.7 508.3 540.1 569.1 373.2

7.65E-09 28.91846 1.77771 11.4634 29.2758 25.500298 36.27967 0.29999 0.86768 3.56048 0.6784299 0.646 0.5054 0.2121 5.62096 1.1632336 5.65516 1.3539103 3.5581 1.0386259 8.71E-09 54.34969 1.38919 2.25456 14.1095 2.5109555 3.22E-08 76.52852 0.67026 -2.8E-09 5.31E-08 101.7978 0.77304 75.8641

0.82251 0.38418 5.35458 0.8648507

6.49E-08 148.3751 0.60325

7.41E-08 171.9298 0.44089 0.12056 2.37644 0.7564909 9.18E-08 195.6374 0.21704 0.04731 1.08129 0.3717111 -1.2E-08 34.38511 0.00341 0.00894 0.03732 0.0034385 6.99727 16.5101 70.6296 34.241945

0.777471 -0.00043 0.001436 2.43E-05

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At suction conditions: Pr = P suction /Pc = 4.936 Tr = T suction/ Tc= 6.9252 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 4.936 &Tr =6.9252 Suction Compressibility =1.05 At discharge conditions: Pr = P discharge/Pc = 6.05 Tr = T discharge/ Tc= 7.37 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 6.05 &Tr =7.37 Suction Compressibility =1.03 Thus, K-value of mixture =Cp mix/ C v mix = Cp mix/ (Cp mix R) = 30.12491/ (30.12491 8.314) =1.38 Average compressibility = Z avg=(Z1 +Z2)/2 = (1.05+1.03)/2 = 1.04 Pressure ratio: PR = Pressure ratio = P discharge/P suction = 94.08/76.711 =1.2264 Volumetric Efficiency: It is defined as the actual gas delivered to the piston displacement of the compressor. When the discharge pressure is high, the quantity that is left back in space between piston and the cylinder end walls is also high. Thus volumetric efficiency of the compressor can be theoretically estimated as: ad = 0.97 C x [ PR ^(1/k) -1] L Where, C= Clearance in % for 1st stage = 14% (from design data) PR= Pressure Ratio = 1.2264 k= Ratio of specific heats = 1.38 L= Leakage losses normally 0.03 to 0.05 for Lubricated compressor and 0.075 to 0.1 for nonlubricated compressor.
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Since GB-601 is LUBRICATED COMPRESSOR , we will take L=0.03. Thus, Volumetric efficiency =0.97 0.14 [1.2264 ^(1/1.38)-1] 0.03 =0.97 0.14[1.1591 -1]-0.03 =0.97- 0.022285 -0.03 =0.917715 =91.771 %

Piston Displacement: Piston displacement is defined as the net volume actually displaced by the piston at rated machine speed, as the piston travels its length from top dead center to bottom dead center. Piston displacement = Vd(m /hr) = (/4) x (D+(D- d))x S x N x 60 Where, d= diameter of the rod =65mm=0.065m S= Cylindrical Stroke = 200mm=.2m D= Cylindrical Bore Diameter=220mm =.22m N= Speed of Compressor =416 rpm Therefore; Piston displacement = (3.14/ 4) x (.22 + (.22 - 0.065))x .2 x 416 x 60 = 0.785 x (0.0484 + 0.044175) x 4992 = 362.7755m/hr Capacity of the compressor: Inlet capacity of the compressor = Q (m /hr) =Vd x ad =362.7755 x 0.917715 =332.9244m/hr

Specific Volume : It is the inverse of gas density .i.e. it is the volume of the gas per kilogram at specified conditions. It is given as follows; V sp = Z x Ts x R Ps MW
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Where, V sp = Specific volume of Gas in m /hr Z = Compressibility factor at first stage suction condition = 1.04 Ts = Suction temperature at 1st stage = 328K Ps = Suction pressure at 1st stage = 76.71 bar a= 76.71/1.01325 =75.7068atm a R = Universal gas constant = 0.08206m -atm/k-molK MW = Molecular weight of gas at 1st stage =3.3809 kg/k-mol Therefore, V sp = (1.04 x 328 ) 75.708 = 0.10936m/kg Capacity in kg/hr Adiabatic Discharge Temperature: When the compression takes place by adiabatic process, the discharge temperature can be predicted by, Tad = Ts x (PR)^(k-1/k) = 328 x 1.2264 ^(1.38-1/1.38) = 328 x 1.0666 =346.96K Adiabatic Efficiency It indicates the actual process compressor deviation from the adiabatic compression. It is given by, ad = Tad- Ts =94.67% Td actual Ts x 0.08206 3.3809

Adiabatic Head : It is defined as the work done by the compressor to raise the pressure of the gas. It is given by, Had (kN-m/kg) = Z avg x R x Ts x k x [PR^(k-1/k) 1] MW mix k-1.4 =12.4037kN-m/kg

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Adiabatic Power: It is the power required by the compressor to raise the pressure of gas. It is brake power; in mechanical terms. Pad (kW) = m x Had ad x 3600 Where, Had = Adiabatic Head m = Total Inlet Feed to the compressor in kg/hr ad = Adiabatic efficiency Isothermal work: W iso = R gas x Ts x Z1 x ln(P2/P1) =71.32 kw Polytropic Work: W poly= Rgas *T1*Z1*n/(n-1)*((P2/P1)^(1-(1/n)))-1) =77.0088kw GB-602 3RD STAGE At suction conditions:
components wt mol% mol h2 C1 C2 C3 C4 C5 NC-6 NC-7 NC-8 h2s SUM 2.016 16.042 30.069 44.096 58.123 72.15 86.178 100.203 114.23 34.076 84.36 4.75 6.3 2.24 0.86 0.64 0.4 0.25 0.11 0.04 99.95 molfrac Tc 0.8436 0.0475 0.063 0.0224 0.0086 0.0064 0.004 0.0025 0.0011 0.0004 0.9995 K 33.2 190.4 305.4 369.8 425.2 469.7 508.3 540.1 569.1 373.2 Pc bar 13 46.4 48.8 42.5 38 33.7 30.3 27.4 24.9 89.4 Cp vap A Cp vapB Cp vap C Cp vap D Cp @38 C wt MW wt Pc wt T c wt Cp KJ/KmolK kg/kmol bar a K KJ/kmolK 27.14 0.009274 -1.4E-05 7.65E-09 28.91846 1.700698 10.9668 28.00752 24.39561 19.25 0.05213 1.2E-05 -1.1E-08 36.27967 0.761995 2.204 9.044 1.723284 5.409 0.1781 -6.9E-05 8.71E-09 54.34969 1.894347 3.0744 19.2402 3.42403 -4.224 0.3063 -0.00016 3.22E-08 76.52852 0.98775 0.952 8.28352 1.714239 9.487 0.3313 -0.00011 -2.8E-09 101.7978 0.499858 0.3268 3.65672 0.875461 -3.62 0.3313 -0.00026 5.31E-08 75.8641 0.46176 0.21568 3.00608 0.48553 -4.413 0.582 -0.00031 6.49E-08 148.3751 0.344712 0.1212 2.0332 0.593501 -5.619 0.67692 -0.00036 7.41E-08 171.9298 0.250508 0.0685 1.35025 0.429824 -7.477 0.777471 -0.00043 9.18E-08 195.6374 0.125653 0.02739 0.62601 0.215201 31.94 0.001436 2.43E-05 -1.2E-08 34.38511 0.01363 0.03576 0.14928 0.013754 7.040911 17.99253 75.39678 33.87044

Pr = P suction /Pc = 4.936 Tr = T suction/ Tc= 6.9252

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Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 4.936 &Tr =6.9252 Suction Compressibility =1.05 At discharge conditions: Pr = P discharge/Pc = 6.05 Tr = T discharge/ Tc= 7.37 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 6.05 &Tr =7.37 Suction Compressibility =1.03 Thus, K-value of mixture =Cp mix/ C v mix = Cp mix/ (Cp mix R) = 30.12491/ (30.12491 8.314) =1.38 Average compressibility = Z avg=(Z1 +Z2)/2 = (1.05+1.03)/2 = 1.04 Pressure ratio: PR = Pressure ratio = P discharge/P suction = 94.08/76.711 =1.2264 Volumetric Efficiency: It is defined as the actual gas delivered to the piston displacement of the compressor. When the discharge pressure is high, the quantity that is left back in space between piston and the cylinder end walls is also high. Thus volumetric efficiency of the compressor can be theoretically estimated as: ad = 0.97 C x [ PR ^(1/k) -1] L Where, C= Clearance in % for 1st stage = 14% (from design data) PR= Pressure Ratio = 1.2264 k= Ratio of specific heats = 1.38 L= Leakage losses normally 0.03 to 0.05 for Lubricated compressor and 0.075 to 0.1 for nonlubricated compressor. Since GB-601 is LUBRICATED COMPRESSOR , we will take L=0.03.

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Thus, Volumetric efficiency =0.97 0.14 [1.2264 ^(1/1.38)-1] 0.03 =0.97 0.14[1.1591 -1]-0.03 =0.97- 0.022285 -0.03 =0.917715 =91.771 %

Piston Displacement: Piston displacement is defined as the net volume actually displaced by the piston at rated machine speed, as the piston travels its length from top dead center to bottom dead center. Piston displacement = Vd(m /hr) = (/4) x (D+(D- d))x S x N x 60 Where, d= diameter of the rod =65mm=0.065m S= Cylindrical Stroke = 200mm=.2m D= Cylindrical Bore Diameter=220mm =.22m N= Speed of Compressor =416 rpm Therefore; Piston displacement = (3.14/ 4) x (.22 + (.22 - 0.065))x .2 x 416 x 60 = 0.785 x (0.0484 + 0.044175) x 4992 = 362.7755m/hr Capacity of the compressor: Inlet capacity of the compressor = Q (m /hr) =Vd x ad =362.7755 x 0.917715 =332.9244m/hr

Specific Volume : It is the inverse of gas density .i.e. it is the volume of the gas per kilogram at specified conditions. It is given as follows; V sp = Z x Ts x R Ps MW

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Where, V sp = Specific volume of Gas in m /hr Z = Compressibility factor at first stage suction condition = 1.04 Ts = Suction temperature at 1st stage = 328K Ps = Suction pressure at 1st stage = 76.71 bar a= 76.71/1.01325 =75.7068atm a R = Universal gas constant = 0.08206m -atm/k-molK MW = Molecular weight of gas at 1st stage =3.3809 kg/k-mol

Therefore, V sp = (1.04 x 328 ) 75.708 = 0.10936m/kg Capacity in kg/hr

x 0.08206 3.3809

Adiabatic Discharge Temperature: When the compression takes place by adiabatic process, the discharge temperature can be predicted by, Tad = Ts x (PR)^(k-1/k) = 328 x 1.2264 ^(1.38-1/1.38) = 328 x 1.0666 =346.96K Adiabatic Efficiency It indicates the actual process compressor deviation from the adiabatic compression. It is given by, ad = Tad- Ts Td actual Ts

Adiabatic Head : It is defined as the work done by the compressor to raise the pressure of the gas. It is given by, Had (kN-m/kg) = Z avg x R x Ts x k x [PR^(k-1/k) 1] MW mix k-1.4 Adiabatic Power: It is the power required by the compressor to raise the pressure of gas. It is brake power; in mechanical terms.

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Pad (kW) = m x Had ad x 3600 Where, Had = Adiabatic Head = m = Total Inlet Feed to the compressor in kg/hr= ad = Adiabatic efficiency= Isothermal work: W iso = R gas x Ts x Z1 x ln(P2/P1) Polytropic Work: GB-602 4TH STAGE
components wt mol% molfrac Tc mol h2 C1 C2 C3 C4 C5 NC-6 NC-7 NC-8 h2s SUM 2.016 16.042 30.069 44.096 58.123 72.15 86.178 100.203 114.23 34.076 84.73 4.76 6.31 2.23 0.84 0.18 0.31 0.14 0.03 0.04 99.53 0.8473 0.0476 0.0631 0.0223 0.0084 0.0018 0.0031 0.0014 0.0003 0.0004 0.9957 K 33.2 190.4 305.4 369.8 425.2 469.7 508.3 540.1 569.1 373.2 Pc Cp vap A bar 13 27.14 46.4 19.25 48.8 5.409 42.5 -4.224 38 9.487 33.7 -3.62 30.3 -4.413 27.4 -5.619 24.9 -7.477 89.4 31.94 Cp vapB Cp vap C Cp vap D Cp @38 C wt MW KJ/KmolK kg/kmol 0.00927 -1.38E-05 7.645E-09 28.91846 1.708157 0.05213 1.197E-05 -1.132E-08 36.279672 0.763599 0.1781 -6.94E-05 8.713E-09 54.349686 1.897354 0.3063 -0.00016 3.22E-08 76.528523 0.983341 0.3313 -0.00011 -2.8E-09 101.79777 0.488233 0.3313 -0.00026 5.31E-08 75.8641 0.12987 0.582 -0.000312 6.494E-08 148.37513 0.267152 0.67692 -0.000364 7.40735E-08 171.92976 0.140284 0.77747 -0.000428 9.17635E-08 195.63741 0.034269 0.00144 2.432E-05 -1.176E-08 34.385107 0.01363 6.425889 wt Pc wt T c bar a K 11.0149 28.1304 2.20864 9.06304 3.07928 19.2707 0.94775 8.24654 0.3192 3.57168 0.06066 0.84546 0.09393 1.57573 0.03836 0.75614 0.00747 0.17073 0.03576 0.14928 17.806 71.7797 wt Cp KJ/kmolK 24.50261 1.726912 3.429465 1.706586 0.855101 0.136555 0.459963 0.240702 0.058691 0.013754 33.13034

At suction conditions: Pr = P suction /Pc = 4.936 Tr = T suction/ Tc= 6.9252 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 4.936 &Tr =6.9252 Suction Compressibility =1.05 At discharge conditions: Pr = P discharge/Pc = 6.05 Tr = T discharge/ Tc= 7.37 Thus from Nelson-Obert generalized Compressibility Charts (Annexure 1.1) Pr= 6.05 &Tr =7.37
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Suction Compressibility =1.03 Thus, K-value of mixture =Cp mix/ C v mix = Cp mix/ (Cp mix R) = 30.12491/ (30.12491 8.314) =1.38 Average compressibility = Z avg=(Z1 +Z2)/2 = (1.05+1.03)/2 = 1.04 Pressure ratio: PR = Pressure ratio = P discharge/P suction = 94.08/76.711 =1.2264 Volumetric Efficiency: It is defined as the actual gas delivered to the piston displacement of the compressor. When the discharge pressure is high, the quantity that is left back in space between piston and the cylinder end walls is also high. Thus volumetric efficiency of the compressor can be theoretically estimated as: ad = 0.97 C x [ PR ^(1/k) -1] L Where, C= Clearance in % for 1st stage = 14% (from design data) PR= Pressure Ratio = 1.2264 k= Ratio of specific heats = 1.38 L= Leakage losses normally 0.03 to 0.05 for Lubricated compressor and 0.075 to 0.1 for nonlubricated compressor. Since GB-601 is LUBRICATED COMPRESSOR , we will take L=0.03. Thus, Volumetric efficiency =0.97 0.14 [1.2264 ^(1/1.38)-1] 0.03 =0.97 0.14[1.1591 -1]-0.03 =0.97- 0.022285 -0.03 =0.917715 =91.771 % Piston Displacement: Piston displacement is defined as the net volume actually displaced by the piston at rated machine speed, as the piston travels its length from top dead center to bottom dead center.
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Piston displacement = Vd(m /hr) = (/4) x (D+(D- d))x S x N x 60 Where, d= diameter of the rod =65mm=0.065m S= Cylindrical Stroke = 200mm=.2m D= Cylindrical Bore Diameter=220mm =.22m N= Speed of Compressor =416 rpm Therefore; Piston displacement = (3.14/ 4) x (.22 + (.22 - 0.065))x .2 x 416 x 60 = 0.785 x (0.0484 + 0.044175) x 4992 = 362.7755m/hr Capacity of the compressor: Inlet capacity of the compressor = Q (m /hr) =Vd x ad =362.7755 x 0.917715 =332.9244m/hr

Specific Volume : It is the inverse of gas density .i.e. it is the volume of the gas per kilogram at specified conditions. It is given as follows; V sp = Z x Ts x R Ps MW Where, V sp = Specific volume of Gas in m /hr Z = Compressibility factor at first stage suction condition = 1.04 Ts = Suction temperature at 1st stage = 328K Ps = Suction pressure at 1st stage = 76.71 bar a= 76.71/1.01325 =75.7068atm a R = Universal gas constant = 0.08206m -atm/k-molK MW = Molecular weight of gas at 1st stage =3.3809 kg/k-mol Therefore, V sp = (1.04 x 328 ) 75.708 = 0.10936m/kg x 0.08206 3.3809

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Capacity in kg/hr Adiabatic Discharge Temperature: When the compression takes place by adiabatic process, the discharge temperature can be predicted by, Tad = Ts x (PR)^(k-1/k) = 328 x 1.2264 ^(1.38-1/1.38) = 328 x 1.0666 =346.96K Adiabatic Efficiency It indicates the actual process compressor deviation from the adiabatic compression. It is given by, ad = Tad- Ts Td actual Ts Adiabatic Head : It is defined as the work done by the compressor to raise the pressure of the gas. It is given by, Had (kN-m/kg) = Z avg x R x Ts x k x [PR^(k-1/k) 1] MW mix k-1.4 Adiabatic Power: It is the power required by the compressor to raise the pressure of gas. It is brake power; in mechanical terms. Pad (kW) = m x Had ad x 3600 Where, Had = Adiabatic Head = m = Total Inlet Feed to the compressor in kg/hr= ad = Adiabatic efficiency= Isothermal work: W iso = R gas x Ts x Z1 x ln(P2/P1)

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FLASH CALCULATION FOR GB-601 A/B: Dew point calculations at 1st stage discharge pressure of 7256.92kPa
comp h2 c1 c2 c3 c4 c5 c6 sum mol frac yiantioine constant a b 0.951 12.7844 232.32 0.007 13.584 968.13 0.022 13.8797 1582.18 0.013 13.709 1872.8 0.005 13.9836 2292.44 0.001 13.9778 2554.6 0.001 5.9951 1168.7 1 temp k c 8.08 -3.72 -13.7622 -25.1 -27.8623 -36.2529 -48.95 351.5 351.5 351.5 351.5 351.5 351.5 351.5 12.13831 10.80026 9.19506 7.971255 6.900247 5.874315 2.132267 186897 49033.42 9848.358 2896.49 992.5201 355.781 8.433968 25.75438 6.7568 1.357103 0.399136 0.136769 0.049027 0.001162 0.036926 0.001036 0.016211 0.03257 0.036558 0.020397 0.860437 1.004135 lnPi pi ki=pi/pt xi=yi/ki

Dew point of the mixture at 7256.92kPa is 351.5k(78.5 c) FLASH CALCULATION FOR GB-602 A/B: Dew point calculations at 1st stage discharge pressure of 460.9 kPa

Dew point of the mixture at 460.9 kPa is 225.9k(-47.1 c)

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h2 c1 c2 c3 c4 c5 c6 h2s

12 7844 13 584 13 8797 13 709 13 9836 13 9778 5 9951 34 0819

232 32 968 13 1582 18 1872 8 2292 44 2554 6 1168 7 14 5513

8 08 3 72 13 7622 25 1 27 8623 36 2529 48 95 1964 37

225 9 225 9 225 9 225 9 225 9 225 9 225 9 225 9

11 79149 9 226587 6 421435 4 382307 2 407824 0 507518 0 60959 34 07526

                            

co

ol f ac yia a 0 959 0 02 0 008 0 006 0 003 0 003 0 0 001 1

tioi

co sta t

132123 8 10163 79 614 8846 80 02241 11 10976 1 661162 0 543573 6 29E+14

i= i t 286 6648 22 05206 1 334096 0 173622 0 024104 0 003604 0 001179 1 36E+12

i=yi i

0 003345 0 000907 0 005997 0 034558 0 124458 0 832369 0 7 33E 16 1 001634

Dew point calculations at 2nd stage discharge pressure of 1119.7 kPa

Dew point of the mixture at 1119.7 kPa is 240k(-33 c) Dew point calculations at 3rd stage discharge pressure of 2823.6 kPa

c 8.08 3.72 13.7622 25.1 27.8623 36.2529 48.95 1964.37

Dew point of the mixture at 2823.6 kPa is 300.6k(27.6 c)

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0 0

2 c1 c2 c3 c4 c5 c6 2s

12.7844 13.584 13.8797 13.709 13.9836 13.9778 5.9951 34.0819

232.32 968.13 1582.18 1872.8 2292.44 2554.6 1168.7 14.5513

300.6 300.6 300.6 300.6 300.6 300.6 300.6 300.6

12.03178 10.32299 8.36376 6.911178 5.578308 4.313991 1.350951 34.07548

"

"!%

( $ $ %$ $

# ! "!

co

ol f ac yia a 0.917 0.016 0.035 0.021 0.009 0.002 0.001 0.001 1.002

tioi

co sta t

l Pi

ki= i

168009.5 30423.95 4288.792 1003.428 264.6235 74.73814 3.861097 6.29E+14

59.50188 10.77488 1.518909 0.355372 0.093718 0.026469 0.001367 2.23E+11

& ' "& "

i=yi ki

0.015411 0.001485 0.023043 0.059093 0.096032 0.07556 0.731295 4.49E 15 1.001919

 

     

   

 

  

    

   

 

 

   

     

     

h2 c1 c2 c3 c4 c5 c6 h2s

0 959 0 02 0 008 0 006 0 003 0 003 0 0 001 1

12 7844 13 584 13 8797 13 709 13 9836 13 9778 5 9951 34 0819

232 32 968 13 1582 18 1872 8 2292 44 2554 6 1168 7 14 5513

8 08 3 72 13 7622 25 1 27 8623 36 2529 48 95 1964 37

 
240 240 240 240 240 240 240 240

 

comp

mol f ac yia tioi a

constant

t mp

lnPi

pi

i =pi pt

11 84793 9 486616 6 886262 4 994249 3 177223 1 439707 0 12215 34 0753

139794 4 13182 11 978 7362 147 5621 23 98006 4 219461 0 885018 6 29E+14

124 8499 11 77289 0 874106 0 131787 0 021417 0 003768 0 00079 5 62E+11

 

 

i=yi i

0 007681 0 001699 0 009152 0 045528 0 140079 0 796097 0 1 78E 15 1 000236

) )

Dew point calculations at 4th stage discharge pressure of 6426.2 kPa

Dew point of the mixture at 6426.2 kPa is 348.5k

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5 6 5 5 5 5 5 5 5 5

5 5 5 5 5 5 5

5 5

5 5 5

5 5 5 5 5

5 5 5 5 5 5 5 5

5 5 5 6 5 5 6 5 5 6 5 5 6 5 5 6 5 56 5 5 5

5 5

5 5 5 5 5 5

5 5 5 5 5 5 5 5 5

h2 c1 c2 c3 c4 c5 c6 h2s

comp

mol f ac yiantioine constant temp k a c 0 917 12 7844 232 32 8 08 348 5 13 584 968 13 3 72 348 5 0 016 0 035 13 8797 1582 18 13 7622 348 5 0 021 13 709 1872 8 25 1 348 5 0 009 13 9836 2292 44 27 8623 348 5 0 002 13 9778 2554 6 36 2529 348 5 0 001 5 9951 1168 7 48 95 348 5 0 001 34 0819 14 5513 1964 37 348 5 1 002

lnPi 12 13288 10 77604 9 153075 7 918029 6 833973 5 796459 2 093581 34 07561

pi 185883 8 47860 01 9443 436 2746 353 928 8738 329 132 8 11392 6 29E+14

ki=pi pt 28 92593 7 447637 1 469521 0 427368 0 144545 0 051217 0 001263 9 79E+10

2 3

i=yi ki

0 031702 0 002148 0 023817 0 049138 0 062264 0 039049 0 791997 1 02E 14 1 000116

Recommendations:

1. As per the standard calculations, a vertical vessel can be used as a decantor but it will be more efficient to use horizontal vessel as it will give more residence time for settling. 2. Static mixer metallurgy should be selected as per benzene and taking in care the acidic solution formation after extraction of impurities from benzene. 3. All instruments like pH meter, Control valves should be reliable. Their importance in this scheme should ne taken care of while purchasing.

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