Professional Documents
Culture Documents
PRESSURE
DROPAND PUMPING
POWER.
CHAPTER 4
HEAT EXCHANGER PRESSURE DROP
AND PUMPING POWER.
HEAT EXCHANGERS: SELECTION, RATING, AND THERMAL
DESIGN, FOURTH EDITION
ADHIKARI AMIT
KARKI KAMAL
JOHNSON JULIAN
SUBMITTED TO:
ENGINEERING DEPARTMENT
MCNEESE STATE UNIVERSITY
PANKAJ R. CHANDRA, PH.D. P.E.
12/02/2014
Contents
I.
Executive Summary............................................................................................. 3
II.
Body of Report..................................................................................................... 4
A.
Introduction....................................................................................................... 4
B.
Reaction Process............................................................................................... 5
C. Previous Work................................................................................................... 5
D. Project Importance............................................................................................ 5
E.
Project Background........................................................................................... 6
F.
Equipment......................................................................................................... 7
a.
Reactor.......................................................................................................... 7
b.
Neutralizer:.................................................................................................... 8
c.
Evaporator:.................................................................................................... 8
d.
Crystallizer:.................................................................................................... 9
e.
Dryer:............................................................................................................. 9
III.
Recovery Process.............................................................................................. 9
IV.
Economic Analysis.......................................................................................... 10
V.
PFD..................................................................................................................... 13
VI.
Assumptions.................................................................................................... 14
VII.
Error................................................................................................................ 14
VIII.
Conclusion....................................................................................................... 15
IX.
Appendix......................................................................................................... 15
A.
B.
References:..................................................................................................... 15
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
I.
Executive Summary
This project involves the design of a new plant that produces the
Pentaerythritol. The desired plant capacity is 60 tons of technical-grade
Pentaerythritol per month. For economic purposes all equipment are
assumed to be purchased new. The facility is an expansion to an existing
anhydrous ammonia plant in Louisiana, Missouri. The base design for this
plant is based on the Industrial Engineering Project by Siddharth Maity and
the US Patent 3410915. All of the data required for the Material and Energy
Balance were collected from Bhageria Dye-Chem Ltd (Manufacturers of Dye
Intermediates and Dyes) by Siddharth Maity in December 2009. The total
equipment cost for this Plant without installation is $600,000. The total
installation cost is $300,000. The total capital investment for this plant is
around 3 Million Dollars, and has a break even period of 2 years. The plant
operates 12 hours a day and 23 days in a moth.
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
II.
Body of Report
A. Introduction
The Pentaerythritol Production plant was designed to produce 60 tons of
Pentaerythritol per month. The plant operated 23 days per month for 12
hours a day. To achieve the desired production rate, 4745 kg of
Pentaerythritol in a day must be produced. The product Pentaerythritol was
made from formaldehyde and acetaldehyde in the presence of sodium
hydroxide/calcium hydroxide and water.
over calcium hydroxide because sodium ions directly combined with formate
ions from formic acid to give sodium formate which was easily removed
through the process of centrifuge. The yield in this process was 85 to 90%,
and 89% yield was assumed for this design. Sodium formate was the main
byproduct along with dipentaerythritol and tripentaerythritol. The byproducts
were formed due to the side reactions of formaldehyde and acetaldehyde
reacting with each other.
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
B. Reaction Process
4HCHO + CH3CHO
C5H9O + CHO2Na
C. Previous Work
This case was designed on the basis of Industrial Engineering Project by
Siddharth Maity, and the US Patent 3410915, Process for continuous
manufacture of Pentaerythritol. The data was collected from two different US
patents: US 2532253 A, Separation of Pentaerythritol and formic acid, and US
5741956 A, Process for the preparation of Pentaerythritol.
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
D. Project Importance
Pentaerythritol has a wide area of application. Some of the areas of
application are:
1) Raw materials for paint industry. Pentaerythritol is used to make the
alkyd resin which is the raw material for the paint.
2) Lubricating Oil: It is used in lubricating oil. An ester of Pentaerythritol is
useful for high temperature lubrication (US 2961406 A).
3) Explosives: PETN (Pentaerythritol tetranitrate) is best known as
explosive. PETN is the nitrate ester of Pentaerythritol.
4) Sodium Formate: Sodium formate is the main byproduct in the
production of Pentaerythritol. Sodium formate is used in the production
of hydro, nickel format and in leather industry
E. Project Background
Pentaerythritol was produced from formaldehyde and acetaldehyde in the
presence of sodium hydroxide. This design consisted of nine different stages,
and Pentaerythritol is recovered in fifth and ninth stage. Nine different stages
were:
1) Reactor
2) Neutralizer
3) Evaporator
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
4)
5)
6)
7)
8)
9)
Crystallizer
Dryer
Recovery Unit
Centrifuge
Chiller
Filter
88% (4940 out of 5551 kg/day) of pentaerythritol formed in the reactor was
recovered from the dryer. 12% of the pentaerythritol along with the sodium
formate and water was fed to the recovery unit which helped to recover the
rest 12% of pentaerythritol. The pentaerythritol produced will be of technical
grade.
F. Equipment
a. Reactor
Reactor had to produce 4743 kg of pentaerythritol in a day to produce 60
tons of pentaerythritol in a month. According to the US patent 3410915, a
six-stage CSTR would be the best option for the reaction of formaldehyde
and acetaldehyde to produce pentaerythritol. Residence time goes on
decreasing as the number of the stages go on increasing in the CSTR.
Example 1 of the US patent 3410915 used five-stage reactor, which had a
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
residence time of 1.5 hours, and example 2 of the US patent 3410915 used
six stage reactor, which had a residence time of 1 hour. The reactor operated
at the temperature of 250C. It was an exothermic reaction, and it generated
888,064.34 kcal of heat per day. The cooling jacket was used outside the
reactor to maintain the temperature at 250C.
b. Neutralizer:
The products of the reactor were the inputs for the neutralizer. Formic acid
was added to neutralize the excess alkali. PH of the solution was reduced to
6-8 from 10-11. The temperature of the product from the reactor was 25 oC,
and it was stored in the holding tank to heat the product approximately to
90oC before sent to the neutralizer. Sodium formate was formed in the
neutralizer. The total energy needed to heat the reactor products to the
desired temperature was 937,503 kcal/day. Residence time in the neutralizer
was 0.77 m3/hr., and the diameter of the neutralization tank was 0.84m.
c. Evaporator:
The products from the neutralizer consisted of formaldehyde which was
removed from the evaporator along with some amount of water. The product
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
coming out from the evaporator was known as slurry which consists of
pentaerythritol, sodium formate and water. Specific gravity of slurry was
around 1.3. Total cost to run the evaporator was around 600 dollars per day.
d. Crystallizer:
e. Dryer:
The pentaerythritol from crystallizer was sent to the dryer to remove the
water from pentaerythritol crystals absorbed in the crystallizer. The final
pentaerythritol
crystal
contains
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
0.25%
of
water
in
it.
4940
kg
CREATED BY:
AMIT
of
10
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
11
The equipment cost for each of the equipment was calculated, and the table
6-9 from Plant Design and Economics for Chemical Engineers was used to
calculate the direct plant cost, indirect plant cost along with the working
capital. The total capital investment was around 3 million dollars. The
following table shows the direct and indirect plant cost along with the
working capital.
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
12
$
$
$
$
$
$
$
$
$
587,926.76
229,291.44
152,860.96
182,257.30
58,792.68
170,498.76
70,551.21
323,359.72
1,775,538.81
Percentage
1.00
0.39
0.26
0.31
0.10
0.29
0.12
0.55
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
13
$
$
$
$
$
$
188,136.56
199,895.10
23,517.07
111,706.08
217,532.90
740,787.72
Cost Factor
0.32
0.34
0.04
0.19
0.37
Working Capital
Total Capital Investment
Total Capital Investment in MM
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
$
$
440,945.07
2,957,271.60
$
2.96
Cost
Factor
0.75
CREATED BY:
AMIT
14
V.
PFD
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
15
VI.
Assumptions
VII. Error
The yield of the crystallizer was assumed to be 89% for this design, and it
was used to calculate the required feed flow rate for the production of the
desired product. If the required yield was plus/minus 5% then total capital
investment would be plus/minus 25%. If evaporator did not evaporate the
89% of water, more energy would required in the recovery unit that would
make the total capital investment go high. The equipment cost were
calculated from the graph which might be different than the actual market
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
16
price. The total capital investment cost calculated in this design is plus/minus
50% because there are many assumptions
VIII. Conclusion
A new plant that produces 60 tons of pentaerythritol was designed. A plant
operates 12 hours a day for 23 days in a month. The cost of the plant can be
reduced by operating the plant 24 hours a day. The raw materials price are
relatively low compared to the selling price of pentaerythritol. The demand of
pentaerythritol is high and it supposed to go up by 10% in future.
IX.
Appendix
Case 4.xlsx
B. References:
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT
17
1. Process for Continuous Manufacture of Pentaerythritol. Montedison Spa,
assignee. Patent US 3410915A. 12 Nov. 1968.
2. Separation of Pentaerythritol and Formic Acid. Trojan Powder Co, assignee.
Patent US 2532253A. 28 Nov. 1950.
3. Process for the Preparation of Pentaerythritol. Patentes Y Novedades,
assignee. Patent US 5741956A. 21 Apr. 1998.
4. Peters, Max S., Klaus D. Timmerhaus, and Ronald E. West. Plant Design and
Economics for Chemical Engineers Fifth Edition.
SUBMITTED TO:
ENGINEERING DEPARTMENT
ADHIKARI
MCNEESE STATE UNIVERSITY
DR. J.R.BORDEN
12/02/2014
CREATED BY:
AMIT