Methanol Recovery System Design

a. Methanol Evaporator
From Energy Balance:
Q = 196.0336 kW
Heat Transfer Area:
Q = UATm
Where: A =heat transfer area
Q = heat transferred
U = over-all heat transfer coefficient
Tm = mean temperature difference
Tm

=
=

;
ln [ /]
(70;60) (65;60)
[ (70;60)/(65;60]

= 7.2135 oC
From Table 6, p.600, Plant Design and Economics
For methanol:

U = 1575.7

196.0336

2;C

A = (1575.7)(7.2135)
A = 17.2469 2
1

For tube side coefficient: Use 1 outside diameter BWG 16

4
Do = 1.25 in
L = 0.6 m

1
4

pitch = 1

Di = 1.12 in

Area per tube = LDo = () (0.6 m)(0.03175 m) = 0.0598 m2

Number of tubes =

17.2469 m2
0.0598 m2

Tube cross-sectional area =

= 289 tubes

Di2
4

(0.0284)2m2
4

= 0.02234 m2

Area per pass = (number of tubes)(tube cross-sectional area)

= (289) (0.02234 m2)
= 6.4563 m2
Plate Design
From p.85, Eqn 4-3 PED by Hesse and Rushton
ts =

2;

+C

where:
ts = thickness of the plate e= efficiency of the joint
p = internal pressure
C= corrosion allowance
D = internal diameter
P = pressure
Sw = working stress

Material of Construction: SS 316 Stainless Steel

Su = 82 000 psi from ChE Handbook Table 28-18

From Eqn 4-1 PED by Hesse and Rushton
Sw = Su x Fm x Fa x Fr XFs

Su = ultimate tensile strength

Fm = material factor = 1.0
Fr = stress relieving factor = 1.06
Fa = radiograoh factor = 1.12
Fs = allowable fraction = 0.25
Sw = (82 000) (1.0) (1.12) (1.06) (0.25)
= 24 337.6 psia (

101325
)
14.7

= 167 755 Pa
Shell Thickness
Type of joint:
Double welded V-butt joint
1

16
(168.6451)(23.62)

e = 0.8 C =
ts =

2(8609.28)(0.8); 168.6451

1
16

= 0.3977 in 0.5 in
Head Design
Using standard ellipsoidal
Consider seamless head concave to pressure
From Eqn 4-5

tH =
+C
2
where: e= seamless head = 1.0
D = diameter of head flange
tH =

(168.6451)(23.62)

2(8609.28)(1.0)
3
0.2938 in
8

1
16

(b) Methanol Condenser

= 664

KJ
s
Btu
184.7450
hr

From Energy Balance: Q = 194.7946

Shellside: Methanol
Mass flowrate:
Temperature entering:
Temperature leaving:

Tubeside: Cooling Water

Mass flowrate:
Temperature entering:
Temperature leaving:

28.93604

65 oC
60oC

4000

25 oC
32oC

Heat transfer area, A

A=

Where: A =heat transfer area

Q = heat transferred
U = over-all heat transfer coefficient
Tm = mean temperature difference
Tm = FtTL
- from p.590, Plant Design and Economics

TL

;
ln [/]

TL

(65;60) (32;25)
[ (65;60)/(32;25)]

= 5.9440 oC

For Ft: from Fig.15-2, p.590, Plant Design and Economics

For 1 shell-2 tube pass:
R=

1 2
65;60
=
2;1
32;25
2 1
32;25
=
1;1
65;25

= 0.7143

P=
= 0.1750
Ft = 0.99
Tm = FtTL = 5.8846 oC 42.5922 oF
From Figure 14-14, p.648, Plant Design and Economics
For methanol-water:

U = 250-500
;2;

W
Use: 500
= 1575.7 2
;2;
m C

A=

Btu
hr

(500
)(42.5922 F)
2

664 184.7450

= 31.1881 ft2

For tubeside heat transfer coefficient:

From Table 12, p.886, Plant Design and Economics
3

Use in OD BWG 16
4
Do = 0.75 in 0.0625 ft

L = 4 ft

Di = 0.62 in 0.0517 ft
pitch = 1
4
pitch = 1.25(0.0625 ft) = 0.0781 ft
Properties of cooling water (range from 25 to 32 oC )
From App.14, p.1102, Fig.d-3, p.880, Plant Design and Economics / Unit Operations by McCabe
mean

;2
BTU
0.354
lb F

= 1.362 cP = 1.39 x 10-4

Kf

C mean

= 1 BTU

mean

= 1024.39

kg
m3

Number of Tubes
Area per tube = LDo = () (4 ft) (0.0625 ft) = 0.7854 ft 2
Number of tubes =

31.1881 ft2
0.7854ft2

= 39.7098 40 tubes

Tube cross-sectional area =

Di2
4
(0.0517 ft)2
4

=
= 0.0021 ft2

Area per pass = (number of tubes) (tube cross-sectional area)

= (40) (0.0021 ft2)
= 0.0840 ft2 0.0078 m2
Q, Volumetric flowrate

=
=

Mass
Density
kg
hr
kg
1024.39 3
m
m3

4000

= 3.9048
V, Tubeside velocity
=

m3
hr
0.0078m2

3.9048

= 0.1391

m
s

hr
Q
Area per pass

1 hr
3600 s

Hi =

1057 (1.3052:0.02 T)(V0.8 )

Di0.2

Where: H1 = inside coefficient of water

V =water velocity
T = water temperature
Hi = tubeside diameter
Hi =

1057 ((1.3052:(0.02)(25) )(0.1391

w
=4354.1210
C;m2

Hi

0.0158 m0.2

m 0.8
)
s

For Shellside Heat Transfer Coefficient

For bundle diameter: Eq. 12.3 p591 Chem . engg by R&C
n 1
K1

Db = Do( 1 )
From table 12.4 for 2 passes
1 = 0.158
1 = 2.263
1

40 2.263
)
0.158

Db = (0.0625 ft)(
Db = 0.7210 ft

Estimate tube wall temp

w
Hi =297.9424
2
C;m

U = 500
Mean Temperature:
Shell side =

;2;

65:60
2

= 62.5 oC
Tube side

32:25

=
2
= 28.5 oC

= 1575.7

W
m2 C

Hi (Ts-Tw) = U (Ts-Tt)

-equation 12.16 R&C

4354.1210
(62.5 oC Tw) = 1575.7 2 (62.5 oC -28.5 oC)
C;m2
m C
Tw =50.1958 OC
Mean temperature of the condensate

50.1958 :62.5

=
2
= 56.3479 oC

Tube loading:
From equation 12.5 R&C
Rh =

Wc
LNt

Where :
Rh = tube loading
Wc = total condensate flow
L = tube length
Nt = total number of tubes
Rh =

4000

kg
hr

(4 ft)(40)

= 25

kg
hr;ft

Number of tubes in the center

Nc =
0.6442 ft

Db
Do

Nc =
0.0625 ft
= 10.3072 tubes 11 tubes
2
3

Nt = 11 tubes ( )
= 7.3333 tubes 8 tubes