Process Flow diagram

Fig : Process Flow sheet Made with help of ASPEN PLUS

Equipment Designed
1. Compressor 2. Pump 3. Reactor 4. Gas Absorber 5. Crude Fractionating Column 6. Refining Column 7. Effluent Column 8. End stripping Column

Compressor Design
Positive Displacement Reciprocating compressor Multi Stage.

Assumptions: - Zero clearance Volume Swept in compressor

n = No. of cylinder

Fig:- Interior of reciprocating Compressor

N = rotational speed
D = dia/bore of the cylinder L = Stroke length

[1]
PB= power consumed by compressor
Fig: Gas Compression Cycle
[1]References: mccabe smith unit operation of chemical engineering 7th edition 7th chapter page 221

Calculated Data
Pressure
Inlet condition Outlet Condition 1 atm 42 atm

Temperature
373 k 453 k

Flow Rate
0.024 m3/sec

AIM : To compress the CO coming from Sub group 1 Inter Stage Cooling Assuming Temperature rise in water (T) = 20oc Coolant Used :water Power = 165.56 kw = 221 hp No. of stage = 3 Compression ratio R(total) = 41.95 Heat load in each cooler = 49,570.834 kJ/hr Total heat load = 3*49,570.834 = 148712.50 KJ/hr Amount of water required = 1770.38 Kg/hr

Fig: water cooling system

[1] References: COMPRESSOR

HANDBOOK Paul C. Hanlon 2001 Chapter 2 compressorperformance - positive displacemnt by

The McGraw-Hill Companies

Design Data
RPM calculation bore/stroke ratio < 1.7. [1] No. of Cylinders Stroke length and bore diameter Maximum Volume occupied in each cylinders.

RPM No. of cylinder (each stage) Bore/ Stroke Stroke Bore volume of each cylinder per revolution

720 2 1.35 5.00 6.75 24.48 cu inch

Table : Calculation of RPM, bore length, piston speed, volume of each cylinder[2]

References : [1] Stroke-to-Bore Ratio: A Key to Engine Efficiency by Dr. Randy Herold Engineer General Atomics Systems [2] ''Large reciprocating Compressor Design Guide Lines''(1972) M.W Garland Frick Company, International Compressor Engineering Conference

Fig: Schematic Diagram for Pump design

Requirements for adiabatic Pump

Pressure inlet Temperature Mass flow rate 1 atm 55 c
1.034 kg/sec

Pressure Inlet Temprature

42 atm 57.54 c

Specific volume = 1262 cm3/ kg Thermal Expansion Coefficient() = 425 x 10-6K-1 Specific Heat capacity = 2.74 KJ/kg k Assuming Pump Efficiency = 75 % equations used for pump : Ws(isentropic)=V (P2-P1)=Hs ----------- (i) Hs=Ws ------------ (ii) Hs = CpdT+ V(1-T)P[1] ----------- (ii) Using equation (i) (ii) and (iii) we get Ws= 5.24kJ/kg Hs = 6.98 kJ/kg, and temperature rise to be 2.5 0 c , So final temperature is 57.540 c and pressure is 42 atm out of adiabatic pump of 9.67 hp

Centrifugal Pump

Density of methanol
Flow rate

791.8 kg/m3

RPM
Suction head loss

1900
0.469 m of methanol 13.62 m = 44.7 feet of methanol

Length of pipe

50 m

Friction factor 0.0193

30 gpm , 1.8 kg/ sec 1 atm

Total dynamic head

Presuure

WHP
BHP(with eff. 0.75)

0.6 hp
0.8 hp

Total frictional head loss Diameter of pipe(standar d stainless steel)

0.78 m of methanol 1.0 in

Temperature 55 0C

Reactor Design
FAo (molar flow rate of methanol) X (conversion of methanol) 132948 mol/hr 0.98

(-rmethanol )exit
W (weight of catalyst in reactor) Bulk density of catalyst Volume of catalyst in reactor

30.3 mol/ gcat-hr

1.225 kg 12410 kg /m3 9.87 x 10-5 m3

Volume of slurry in the reactor with s=0.3

Diameter of tank with (L/D=5)
Height of the reactor

3.29 x 10-4 m3
2.57 m
13 m

Bubble specifications

Gas Absorber
Gases Volume (g mol) % volume

CO

3545

23.66

CO2

360

2.40

CH4

75

0.50

HI

60

0.40

CH3I

10940

73.03

Assumptions
gas and liquid streams flow through the absorber not change appreciably 90% reduction of CH3I from Inlet concentration 75% Flooding Velocity Stream Flow rate = 1.77m3/min Temp = 328K and pressure = 1atm

Calculation for Tower Diameter

Calculation for Tower height

Z = Height HTU = height of transfer unit NTU no of transer unit

Final Data for absorber

Diameter Height Area Number of Transfer units Gas flow rate 1.6m 5.1m 2.24m2 2.43 68.35 g-mol /min

Liquid Flow rate

2187.5 gmol/min

Packing Data
Packing used here is Intalox saddles (plastic) Size - 2in Weight - 38(lb/ft2) Surface area/packing volume - 36 ft2/ft3 VOid Fraction - 79% Packing factor - 40ft2/ft3

Crude Fractionating Column

Extractive Distillation:
No azeotropic High Boiling

Low relative volatility

Fig#1 C 301 Crude Fractionating Column

Designing:
Column Diar

References:

Coulson and Richardson: Volume 6, Tamkang Journal of Science and Engineering, Vol. 4, No. 2, pp. 105-110 (2001)

Hydraulics
Column Diameter
Fair Correlation

Total Column Area:

Ac = An + Ad

Liquid Flow Arrangement

Cross Flow

Check Weeping Plate Designing

Active area Aa=Ac-2Ad Minimum Vapor Velocity

Weir length

Ad / Ac

Crest Depth

how=750[(Lm/lw*)2/3]

References:

Coulson and Richardson: Volume 6, Tamkang Journal of Science and Engineering, Vol. 4, No. 2, pp. 105-110 (2001)

Pressure Drop

Dry Plate Drop

Total Pressure Drop

Downcomer Liquid Backup

Residence Time: Downcomer Back-up Head Loss
hb = (hw+ how) + ht + hdc

tr =Ad hbc L/L(max)

Entrainment: Number of Holes:

Fractional entrainment ()

Area of 1 Hole = (/4) Dhole2

Design Data
Active holes No. of trays Pressure 68 101.325 kpa Weir Height Weir Length Reflux Ratio Tray Spacing Active Area 5900 50mm 1m 6.23 0.5m 1.16 m2

Height of column
Diameter of column Hole size Pressure drop per tray Tray thickness Vapour Flow Rate lbmol/hr Downcomer liquid backup

35m
1.45m 5mm 1.2kpa

Percentage Flooding
5mm 331 lb mol/hr 0.20mm Entrainment Liquid Flow rate Residence time

85%
0.075 880 lbmol/hr 10 sec

Actual minimum Vapor Velocity

12.81 m/sec

MIn. Designing Vapor Velocity

9m/sec

Refining Column
Refining column mass balance
Total Distillate Rate =2Kg/sec Compound Acetic acid Propionic Acid Mass Flow Rate (Kg/sec) 1.97 0.03 Mole Flow Rate (KMol/sec) 3.28 x 10-2 4.21 x 10-4 Feed Flow Rate =2.29 Kg/sec Acetic Acid Propionic Acid 2.22 0.07 3.28 x 10-2 9.49 x 10-4 Bottom Flow Rate =0.29 Kg/sec Acetic Acid Propionic Acid 0.25 0.04 3.28 x 10-2 4.42 x 10-4 86.45 13.54 97.75 2.25 Mole Fraction (Percentage) 98.73 1.27

Design and optimization of a dividing wall column for debottlenecking of the acetic acid purification process By:-Nguyen Van Duc Long, Seunghyun Lee, Moonyong Lee Chemical Engineering and Processing 49 (2010)

Column Height
Ideal No. of tray Actual no. of tray Tray spacing Column height 4 6 0.5 m 3m

Temperature inside the column=400 K Pressure=100 Kpa

Mass transfer operation By:-Robert E. Treybal Third Edition

Column Diameter
Gas density

1.81 Kg/m3 1.01 m3/sec 725.175 Kg/m3

Vapor rate Q Liquid density L Liquid flow rate Hole diameter plate thickness(0.65 *Hole area) Pitch ( P'=hole diameter/0.33) Downspout area Hole area/Active area=0.907x(d0/l)2

4.21 10-4 m3/sec

3 mm 1.95 mm 9.09 mm

98.79 10-3

Mass transfer operation By:-Robert E. Treybal Third Edition http://profmaster.blogspot.in/2007/06/surface-tension.html (surface tension) Fluid Phase Equilibria 54 (1990) Masahiro kato, Hiroshi yoshikawa and Yamaguchi Dustrial chemistry department of faculty of engineering Nihon University Koriyama Fukushima Japan

Net tower cross section area of gas flow Anf=Q/V Tower cross-sectional area At=An/(1downspout) Tower Diameter T=[(4At)/]0.5 Weir length W =0.55T Liquid rate /weir length (q/W) Active area

0.68 m2

0.711 m2

95.15 x 10-2 m
52.33 10-2 m 8.04 10-4 m2/m-s 53.59 10-2 m2 for perforated sheet

Weir Crest h1 and weir height hw q/Weff=1.8939 h13/2

When taking W= Weff

Weff = 0.9656 W again

h1=5.78 10-3 m

=5.89 10-3 m Repeat with new value of h1 Weff = 0.9649 W so h1=58.94 10-4 m Set weir height hw= 0.012 m

Mass transfer operation By:-Robert E. Treybal Third Edition

Dry Pressure Drop

Hydraulic Head HL Residual Pressure Drop Total gas pressure drop Tray pressure drop Pressure loss at liquid entrance Ada Backup in downspout Checking on flooding Weeping Velocity Weir set = 0.418 T Z=2 Times weir set Entrainment

4.62 10-2 m 8.25 10-3 m 8.85 10-4 m 5.938 10-2 m 0.00256 psi or 17.650547 Pa 0.56 10-2 m

0.31 10-2 m 6.4 10-2 m =81.89 10-2 m 0.068 m/sec 0.3978 79.56 10-2 m 0.0035

Because h1 + hw+ h3 < t/2 so my assuming tray spacing (0.50) its perfectly satisfied Weeping will not occur till velocity through orifice reduce to weeping velocity

Mass transfer operation By:-Robert E. Treybal Third Edition

Tray Performance Constraints 1.Foaming:-It's depend on material property. 2. Entrainment:-The entrainment is too small to influence the tray hydraulics appreciably. 3.Flooding:-flooding will not occur until velocity V is increase above flooding velocity.

4.Weeping:-The tray will not weeping excessively until the gas velocity through the hole Vo is reduced to close this value. 5. Downcomer flooding:it's happened when liquid rate is high and vapor flow rate is less.

End Stripping Column

Plate or Packed Column:
Packed column was selected for the reasons given below:

Good liquid distribution can be maintained throughout

Economic to replace packings than trays in case of fouling

Since the liquid is corrosive hence packed column is relatively cheaper

Liquid holdup is comparatively lower in packed columns. Important in case of flammable inventory

More suitable for handling foaming systems

Relatively lower pressure drop

Choice of Packing:
Random packing of 0.038m ceramic intalox saddle has been chosen for the following reasons: One of the most efficient packings

Material Balance:

Little tendency to nest and block areas of bed

Gives a fairly uniform bed Higher floodingDetails point Packing Lower pressure drop
52 50 624 kg/m3

Packing Factor

Dry Bed Packing Factor Mass

Surface Area
Voidage Min. Wetting Rate

195 m2/m3
76% 3.4x10-6 m2/s

Design Calculations:
Parameter and Equations
1 Height Equivalent of Theroretical Plate (HETP)

Calculated Value
0.035 m

Number of Transfer Units

Height of overall Gas Transfer Units

1.45

4 5

Column Height: HTotal = HOG x NTotal Diameter of Column:

7.78 m 0.83 m

Harriott, P. Chemical Reactor Design. New York: Marcel Dekker, 2003; Chapter 8 Carl R. Branan. Rule of Thumbs for Chemical Engineers, 4th ed. Butterworth-Heinemann, 2005; p. 109-113; p.143152 Perry, R.H., and D.W. Green. Perrys Chemical Engineers Handbook, 7th ed. New York: McGraw-Hill, 1997; p. 15-86

Mechanical Design:
Parameter and Equations
1 Thickness of Shell (ts):

Calculated Value
30.8 mm

2 3

Shell Weight (W): W= Vol. of Shell x Density of Material Head Selection and Thickness (th):

9670 kg 32 mm

Head Weight (Wh):

58 kg

Gavin Towler, R.K. Sinnott. Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, 2nd ed. Butterworth-Heinemann, 2013; p. 279-302; p. 807-923

Heat Exchanger
Preliminary calculations
Procedure for estimating area Shell side Q = W*C*dT Q=4254.34*0.64*(180-57)

Q=334901644.8 cal = 1402166.206449 KJ = 1.402 * 106 KJ

LMTD = (T1-t2)-(T2-t1)/(ln(T1-t2)/(T2-t1)) =((198-180) (108-57.546))/ln((198-108)/(108-57.546)) =48.88 deg C Assumed data : Di = 1.049 inches = 0.0874 ft

DO = 1.315 inches = 0.1096 ft

XW = 0.133 inches = 0.0111 ft Methanol coefficient = 1020 Water = 1700 Inside Fouling Factor = 5680

Outside Fouling Factor = 2840

DL = (DO DI)/(ln(Do/DI)) = (0.1096 0.0874) / (ln(0.1096/0.0874)) = 0.0983 ft Overall coefficient, UO = 459 W/m2 deg C Total outside heat transfer area , Ao = Q/Uo*LMTD = 1402166.20/(459 * 48.88)

=62.49 sq m

Pinch Design Method

Stream no 1
2 3 Stream type Het capacity Flow rate 6 3 3.5 Source temperature 200 90 57.5(temp from the absorber) 25 Target temperature 65 30 180(final temp as reqd in the reactor) 130

Hot Hot Cold

Cold

Reference : B. LINNHOFF and E. HINDMARSH THE PINCH DESIGN METHOD FOR HEAT EXCHANGER NETWORKS

Department of Chemical Engineering, University of Manchester Institute of Science and Technology

Chemical Engineering Science Vol. 38, No 5 pp 745-763, 1983

Hot End Design

Design 1 Design 2

Cold End Design

Design 1 Design 2

Liquid effluent column

absorbent - CaO 75%-MgO 25%
Mass of absorbent
L/D porosity Diameter of spehrical particle Diameter Height of tower total No. of particle total no. of particle in 1 layer height of absorbent bed

1.31 kg
1.75 0.4 1um 5.5 9.625 771*10 18 96.35 *10 12 8m

Storage of acetic acid

L/D ratio ? Design and construction of tank
Stainless steel grade 304 ,316,314 High density polyethene .propylene and rubber lined carbon steel hydrostatic gauge fabricated with stainless steel of suitable grade gauge glass covered from all sides (especially for 80% acetic acid). self- priming centrifugal pumps mechanically sealed with PTFE wedges pvc or polypropylene ball valves earthing should be provided The fitting of low and high temperature alarms ACETIC ACID CORROSIVE TO SKIN Emergency instructions, in case of splashing eye baths or wash bottles containing water Buckets of sodium bicarbonate

Storage of raw material (methanol)

volume of raw material L/D 113597m 3 0.5

diameter
height no. of tanks

13.65m
6.825m 14

Design and construction of tank

carbon steel with interior surface coated with epoxy resin. side ways agitator according to API-650