Final Design File HC

7/26/2019 Final Design File HC

1/81

Gasoline based capacity selection

Specify:

Imports Data: from jan 09- oct 10

Year Total imports (in MT) (ref: ocac.org.pk)

2008 57033

2009 507240

2010 732061

Because some more refineries will come up in oper

add more gasoline production to country's total gas

present imports data we are considering:

wt% based capacity calculation:

Total imports of gasoline in specified years (approx. avg) : 500,000

%by wt of product the gasoline is : 50

Days in industrial year : 330

sp-gr of feed: 0.864

Total product = 1,000,000 MTY

Total feed = 1,000,000 MTY

3,030 MTD

Feed Equivalent barrels = 22,063 BPD

so


2/81

7.280

22,059.85

tion by 2013 which will

oline production so analysing

vol% based capacity calculations

MTY Total imports of gasoline in specified years (approx. avg) : 500,000

% %by vol of product the gasoline is : 41.3

% by vol of feed the product is : 125.5

days Days in industrial year : 330

sp-gr of gasoline: 0.672

Imports in Equivalent barrels= 4,680,414 BPY

Total Product= 11332721 BPY

34342 BPD

Total Feed = 27363.808 BPD

Capacity = 25000 BPD


3/81

MTY

days


4/81

m= kg/hr H=kJ/kg mH = kJ/hr


5/81

Line No.

Stream Fresh Feedstock Pumped feed Mixed stream to H-Ex E-101 out stream from E-101 to F

cold hot

Component m H mH m H mH m H mH m H

Atm oil = 143124 104.07 14894863 143124 118.5 1.7E+07 143124 170 24330995 143124 813

H2 = 3462 4876 16880233 3462 8572

H2S =

NH3 =

C1,C2 =

C3 =

i-C4 =

n-C4 =

Gasoline =

Naphtha =

C=

H2O=

DEA =

NH4HS =

Total = 143124 104.07 143124 1.7E+07 146585 4.12E+07 146585

G.T =T (K) =

P (kPa) =

severity+NS 2617

Rec.mixed 845

loss

excess

quench

101.3

323

1

325

10130

345

10130

600

1006

2 3 4


6/81

(addition of 10 &25)


7/81

m H mH m H mH m H mH m H

85874 232 19922791 85874 418.3 35921136 85874 256 21983769.6 85874 256 219

236 5237 1238332 473 5526 2613337.5 473 4344 2054350 6 4344 26

297 547 162334 742 611.1 453393.35 742 526.6 390700.2787 158 526.6 832

1348 172 231889 3370 240.6 810937.56 3370 -5.144 -17337.75063 1939 -5.144 -99

3065 157 481227 7663 213.1 1632952.6 7663 -7.42 -56858.32199 5871 -7.42 -43

2095 153 320567 5238 209.3 1096319.1 5238 -15.25 -79879.91308 4299 -15.25 -65

18430 441.5 8136871 46075 639 29442018 46075 325 14974422.48 46075 325 149

33224 256 8505359 83060 488 40533350 83060 302.1 25092469.44 83060 302.1 250

100 100 100 100

144670 3.900.E+07 232596 7.549E+07 232596 6.434.E+07 227382 6.2

10

308343 390 308

9750 9750 273

11 12 13

273


8/81


9/81

Reactor R-102 effluent to E-103


85874 1038 89137316 85874 1139 97810599.9

4331 9300 40280408 4331 10030 43442203.66 7455 10500 78279279.5 7455 6104

445 1693 753652.3796 445 729

2022 1399 2829181.158 2022 400

4598 1368 6289664.514 4598 336

3143 1383 4346514.877 3143 331

27645 1200 33174105.2 27645 604

49836 1150 57311499.23 49836 383.4

90205 1.294E+08 90205 1.41.E+08 95144 1.830.E+08 95144.31

9990

650 700 730

222120 23

430

9890 982010060


10/81


11/81

m H mH m H mH m H mH m H mH m

158 492.2 77777.44

3877 -54.44 -211063.9 3877 -54.44 -211064 1939 -54.44 -105532 3877 -54.44 -211064 193

11741 -51.63 -606187.8 11741 -51.63 -606188 5871 -51.63 -303094 11741 -51.63 -606188 587

8599 -60.36 -519023.6 8599 -60.36 -519024 4299 -60.36 -259512 8599 -60.36 -519024 429

1500 71.47 107205

25875 -1.15E+06 24217 -1336275 12108 -668138 24217 -1336275 1210

31 32 33 34

290 290290 290

130130 130 130


12/81


13/81


8446 5453 46054883.59 7601 5453 41448253 845 5453 4606630.595 3462 5381

8446 4.6055E+07 7601 4.145E+07 845 4,606,631 3462

10130

42 43 44 45

358 358 358 35

10130 10110130


14/81


15/81


16/81


17/81


18/81

assumptions

T = 298 K T = 298 K

P = 101.3 kPa P = 10130 kPa

F = 25000 BPD (sheet1) F = 143124 kg / hr

315250 lb / hr (sheet1)

143124 kg / hr

46.60% 50% H2 to

T = 298 K T = 298 K

P = 101.3 kPa P = 10130 kPa

makeup

H2 = scf/bbl (sheet1)

lb / hr (sheet1)

7432 kg / hr 53.40% 50% H2 to

T = 298 K from pump

P = 10130 kPa

F = 143124 kg / hr

T = 298 K from compressor division check T = 298

P = 10130 kPa stg-1 later P = 10130

pump1

2

com

3

637

2

38 45


19/81

makeup

H2= 3462 kg / hr Rich H2

stream = 3462

recycle H2

linked to some later calc

T = K

P = kPa

Rec. H2 = kg / hr


20/81


21/81

assumptions

1st-stg reac

stream 3 T

Difference

In(linked to 1) H-EX-1 Tem

100 times inc furnace Te

T : 298

tg-1 = 3462 kg / hr

(linked to 3)

100 times inc

tg-2 = 3970 kg / hr

(dictated by 45)

T = 298 K

P = 10130 kPa

to H-ex

m = 146586 kg / hr

K

kPa (wiil change after loop)

38

39

3

3


22/81

kg / hr


23/81


24/81

tor T = 673 K (assume)

298 K

375

perature rise = 75 K (assume)

mperature rise = 300 K (assume)

K 373 K 673 K

H2 in Hydrocarbon

(S&N2 free)

H2 as severity =

(required for hydro

(include loss also)

Excess (of severity)

H2 req.for S & N2

total in

total severity=

h2 in

Uncon feed =

H2 =

F-1E-

01

5

E-01


25/81

total in =

H2 in Hydrocarbon

(S&N2 free)

H2 as severity =

(required for hydro

Excess =

H2 req.for S & N2

total in =

(from R-101)

(from R-102)


26/81

Recycle unconv =


27/81

Quench H2 = 760

(kg/hr) from overall balnc along r

atm oil = 143124 kg/hr

H2 = 3462 H2S = 2083

total in = 146586 NH3 = 54

C= 100

S = 1961 C3 = 1348

N2 = 44 i-C4 = 3065

C = 100 n-C4 = 2095

Gasoline = 18430

147346 Naphtha = 33224

C1,C2 = 297

(kg/hr) Total 60697Feed= 16793 85874

146571

H2 leaving= 1081

2485 H2 going out in

crkng) unconverted hydrocarbons =

19278 H2 going out

in converted

= 845 34% hydrocarbons =

17770

132 H2 loss in solution =

20255

H2 going out

in NH3 &H2S =

send in makeup 2617

H2 for recycle =

236791 total out 234260 H2 consumed for Hydrocracking =

6094 H2 for S & N2 =

7793 H2 dissolved in porducts =

7432-total excess-for S & N2 = severity for hC & loss

quench = 649.684

kg/hr from overall balnc along r

85874 kg/hr

4331 H2S = 0

Unconv Feed =

HYDROCRACKIN

G

REACTOR

R-101

T= 700K

P =9990kPa

40 %

conversion per

pass


28/81

90205 NH3 = 0

C= 0

C3 = 2022

i-C4 = 4598

n-C4 = 3143

(kg/hr) Gasoline = 27645

Feed= 10076 Naphtha = 49836

C1,C2 = 445

Total 87689

3609 Unconv Feed = 0

crkng) 87689

13685 H2 leaving= 958

H2 going out in

722 unconverted hydrocarbons =

H2 going out

0 in converted

14407 hydrocarbons =

H2 loss in solution =

H2 going out

in NH3 &H2S =

H2 for recycle =

10798

kg/hr

(linkled to up R-1

144434

87689

232123

Debutanozed

HYDROCRACKING

REACTOR

R-102

T= 720K

P =9990kPa

60 %

conversion per

pass

FRACTIONATOR

FR-102

P =203 kPa


29/81

kg/hr

85874 (link to R-1)

C =

Naphth


30/81

(from overall sheet)

H2 req (kg/hr)

123

10

245

528

361

2949

4817 total H2 in-(severity+H2 for S & N2) =loss +excess = H2 leaving

65

9098 total in (feed+ H2+quench) -total out(products+unconv+h

148413

10076 kg/hr

8966 kg/hr

236 kg/hr

19278

132 kg/hr

19410 kg/hr

845

20255

6094

132

473

(from overall sheet)

H2 req (kg/hr)

0


31/81

0

0

368

793

542

4423

7226

97

13449

88647

0 kg/hr

13449 kg/hr

236 kg/hr13685

0 kg/hr

13685 kg/hr

722

14407

Off gases = 742 kg/hr

C3,C4 = 16271 kg/hr 4400 BPD

46075 kg/hr 10325 BPD 101487.1 LB/HR

2416.36 FT3/HR

10328.21 bpd

gasoline =


32/81

83060 kg/hr 16650 BPD

100

Total out = 232123

a =


33/81

2 leave)


34/81

HS1 144670

HS2 87926

R 8449 R 7219

quench 7604 quench 0 6497R-1 in 146586 R-2 in 89844 90205

R-1 out 154190 R-2 out 89844 96702

total of components = 155257 (more) total of components = 95144

diff= 1067 diff= 1558

MW

4644

58

58

82.47

124.63

2


35/81

(more)


36/81

Stream 6 T= 688

9890

kg/hr MW kmol/hr wt.fr

H2S (v)= 2083 34.1 61.1 0.013416246

NH3 (v) = 54 17 3.2 0.000346948

C1(v) = 104 16 6.5 0.000669736C2 (v)= 193 30 6.4 0.001242876

C3 (v) = 1348 44.0965 30.6 0.008682051

i-C4 (v)= 3065 58.1234 52.7 0.019738797

n-C4 (v)= 2095 58.1234 36.0 0.013492682

Gasoline (l) = 18430 82.77 222.7 0.118685394

Naphtha = 33224 123.63 268.7 0.213955391

unconv. Feed= 85874 262.58 327.0 0.553009717

H2 leaving = 8814 2.02 4363.4 0.05676016

155285 5378.363726 1

Stream 7 T= 538

9820

kg/hr MW kmol/hr wt.fr

H2S (v)= 2083 34.1 61.1 0.013416246

NH3 (v) = 54 17 3.2 0.000346948

C1(v) = 104 16 6.5 0.000669736

C2 (v)= 193 30 6.4 0.001242876

C3 (v) = 1348 44.0965 30.6 0.008682051

i-C4 (v)= 3065 58.1234 52.7 0.019738797

n-C4 (v)= 2095 58.1234 36.0 0.013492682

Gasoline (l) = 18430 82.77 222.7 0.118685394

Naphtha = 33224 123.63 268.7 0.213955391

unconv. Feed= 85874 262.58 327.0 0.553009717

H2 leaving = 8814 2.02 4363.4 0.05676016

155285 5378.4 1

cst cm2/s density (g/cm3) gm cm-1 s-1

AGO 0.328 0.00328 0.864 0.00283392

Gasoline 0.167 0.00167 0.672 0.00112224

Naphtha 0.217 0.00217 0.751 0.00162967


37/81

avg.viscosity (cp) avg.density(kg/m3) avg.Cp (kJ/kg K)

0.333 843.6 3.04


2.75 843.6 2.42


38/81

K 415C

kpa 9789 kpaa

mol.fr viscosity(cp) density (kg/m3) Cp (kj/kg K) avg. MW avg.viscosity

0.0113594 0 60.25 1.2 0.387355998 0

0.0005892 0.025 30 0.68 0.010017131 8.67369E-06

0.0012085 0.02152 26.76 3.578 0.019336736 1.44127E-050.0011962 0.02079 51.53 3.285 0.03588452 2.58394E-05

0.0056846 0.02044 78.54 3.22 0.250669569 0.000177461

0.009805 0.02036 108 3.214 0.569901704 0.000401882

0.0067023 0.02074 110.3 3.19 0.389562875 0.000279838

0.0414003 0.08803 672 3.53 3.426703619 0.010447875

0.0499665 0.122 751 3.3941 6.177354158 0.026102558

0.0608066 0.2445 864 2.998 15.9665847 0.135210876

0.8112814 0.0158 0.085 14.6 1.638788384 0.000896811

1 28.8721594 0.173566226

K 265C

kpa 9719 kpaa

mol.fr viscosity(cp) density (kg/m3) Cp (kj/kg K) avg. MW avg.viscosity

0.0113594 0 82.69 1.11 0.387355998 0

0.0005892 0.02012 41.4 0.606 0.010017131 6.98059E-06

0.0012085 0.0189 34.37 3.021 0.019336736 1.2658E-05

0.0011962 0.01804 69.81 2.73 0.03588452 2.24215E-05

0.0056846 0.01894 116.6 2.68 0.250669569 0.000164438

0.009805 0.02196 180.2 2.69 0.569901704 0.000433464

0.0067023 0.02321 194.7 2.687 0.389562875 0.000313165

0.0414003 0.1122 672 3.2857 3.426703619 0.013316501

0.0499665 0.163 751 2.7988 6.177354158 0.034874729

0.0608066 0.4355 864 2.998 15.9665847 0.240835732

0.8112814 0.01335 0.085 14.53 1.638788384 0.000757748

1 28.8721594 0.290737837

cp

0.283392

0.112224

0.162967


39/81

shell side tube side


0.174 723.44 0.13123

shell side


0.291 726.7 0.125

E-101


40/81

stream 15 T

avg.density avg.Cp (kJ/kg K) P

0.80832883 0.016099495 kg/hr wt.fr

0.01040843 0.000235924 DEA 12218 0.36799

0.01792215 0.002396317 H2O 20985 0.632010.06404541 0.004082848 33203 1

0.68188831 0.027956205

2.13179012 0.063440495

1.48824286 0.043041657 stream 16 T

79.7565849 0.418959441 P

160.680499 0.726185993 kg/hr wt.fr

477.800396 1.657923132 DEA 12218 0.347519

0.00482461 0.828698335 H2O 20985 0.596852

723.44493 0.131234377 H2S= 1956 0.055628

35159 1

avg.density avg.Cp (kJ/kg K)

1.1093894 0.014892033

0.01436364 0.00021025

0.02301884 0.002023274

0.08676519 0.003393052

1.01232718 0.023267897

3.55693129 0.053097365

2.62702525 0.036254837

79.7565849 0.3899646

160.680499 0.598818349

477.800396 1.657923132

0.00482461 0.824725123

726.672125 0.124845872


41/81


42/81

30

8000kpa

viscosity density avg.viscosity avg.density

553 203.49847

0.8194 997.44 0.517868994204.016339

40C

8000kpa

viscosity density avg.viscosity avg.density

195.5

0.671 997.44

0.1059 741


43/81

T 105 C

P 304 kpa

components kmol/h Xfi MW

C1,C2 = 3.4268 0.001927459C3 = 43.9604 0.024725927

i-C4 = 101.0006 0.056808718

n-C4 = 73.9702 0.041605213

Gasoline = 556.6648 0.313101157

Naphtha = 671.8446 0.377885055

unconv. Feed= 327.0398 0.183946471

1777.91 1

F (kmol/h) B( kmol/h) Top (kmol/h)

C1,C2 = 3.426843973 0 3.426843973

C3 = 43.96040502 0 43.96040502

i-C4 = 101.0006297 0 101.0006297

n-C4 = 73.97020821 0 73.97020821

Gasoline = 556.6648073 0 556.6648073

LK (97% RECOV AT TOP ) Naphtha = 671.8445669 20.15533701 651.6892299

HK (99.5% RECOV AT BOTTOM unconv. Feed= 327.0397593 325.4045605 1.635198797

1777.90722 345.5598975 1432.347323

ESTIMATION OF TOP TEMPERATURE

by dew point calculations

T 100

P 13

components Xdi VP Ki

C1,C2 = 0.0023925 147.5

C3 = 0.0306912 32

i-C4 = 0.0705141 18

n-C4 = 0.0516426 17

Gasoline = 0.3886381 288.5 22.1923

LK Naphtha = 0.4549799 28.7 2.2077

Hk unconv. Feed= 0.0011416 0.018 0.0014

1.0000000

ESTIMATION OF BOTTOM TEMPERATURE

bybubble point calculations

T 200

P 30


44/81

components Xbi VP Ki

C1,C2 = 0

C3 = 0

i-C4 = 0

n-C4 = 0

Gasoline = 0LK Naphtha = 0.058326609 390.75 13.025

HK unconv. Feed= 0.941673391 2.846 0.094866667

1

GILLILAND RELATIONSHIP

Rmin = 0.3

Nmin = 7

R (R-Rmin)/(R+1)^.566 (N-Nmin)/(N+1)

0.5 0.320 0.510

xf viscosity (cp)

Ago 0.18395 0.0022

Gasoline 0.31310 0.0088Naphtha 0.37789 0.0068

Eo=51-32.5(logavgaavg)

Eo= 54.41756439

Feed Location


45/81

selected T 105

y VP Ki ai KiXfi

60 4560000 0.11564813 988000 0.321437

6 456000 0.340852

5 380000 0.208026

326.505 1.074029605 81626.25 0.33628

34.007 0.111865132 8560 0.042272

0.004 1.31579E-05 1 2.42E-06

1.364517

Xfi Xbi Xdi

0.001927459 0 0.002392467

0.024725927 0 0.030691163

0.056808718 0 0.070514063

0.041605213 0 0.051642648

0.313101157 0 0.388638146

0.377885055 0.0583266 0.454979892

0.183946471 0.9416734 0.001141622

1 1 1

C selected T 90

kpa

ai Yi/Ki

106527.7778 1.62E-05

23111.11111 9.59E-04

13000 3.92E-03

12277.77778 3.04E-03

16027.77778 1.75E-02

1594.444444 2.06E-01

1 8.25E-01

1.06E+00

C selected T 200

kpa


46/81

ai KiXbi

137.2979621 0.7597041

1 0.0893334

0.8490375

N (theoretical) N (actual)

15.335 28.179383

avg viscosit at 293F

0.000404682

0.002755290.002569618

0.005729591


47/81

1.225

(ai*Xfi)/(ai-) underwood eqn 1

0.001927460.024725958

0.05680887

0.041605347

0.313105856

0.37793914

-0.817539872

-0.00142724

(ai*Xdi)/(ai-)

0.002392495 Rmin= 0.3

0.03069279 Ract= 0.45

0.070520708

0.051647801 Ropt = 0.5

0.388667851

0.455329718

-0.005073874

0.994177489

aavg 1232.866


48/81

137


49/81

Feedstock : Atm gas oil

Basis = 25000 BPD 1,133,5381041.66667 bbl / hr

Severity = 2431 scf / bbl

Feed Analysis : type 1 type 2

atm gas oil

vol % 100

API = 32.2

sp-gr = 0.86 (not fill)

S % = 1.37

N2 % = 0.031

C residue % = 0.07

ramsbottom : 0.07

conradson :Aromatics (vol) % =

Aniline point (oF) 174 79 C

Pour point (oF)

Viscosity, SUS @130

ASTM distillation :

(recoverd vol %) (oF) (oR)

0% 0 0

10% 554 1014

30% 0 0

50% 627 1087

70% 0 0

90% 707 1167

100% 0 0

total non-zero values = 3

Product Analysis:

No. Yields: vol. % API sp-gr

1 H2S (wt %) -

2 NH3 (wt %) -

3 C (wt%) -

4 -

5 -

6 -

7 -

f 328671 8 C3 4 147.2 0.508

p 326841 9 i-C4 8.2 119.8 0.563-1830 10 n-C4 5.4 110.6 0.584

2431 11 Gasoline 41.3 79 0.672

12 Naphtha 66.6 56.8 0.751

for wt % given Methane & ethane(wt%) 0.5

(add more u want)

(change formula each time) Total vol % 125.5

Gasoilne ASTM distillation :

(recoverd vol %) (oF) (oR)

0% (initial ) 96 556

10% 119 579

30% 0 0

50% 146 606

70% 0 0

90% 184 644

100% (EP) 200 660


50/81

Compressor set point= 10130 kPa

Pump set point = 10130 kPa

sheet 3 link Severity in reator 1 3462

sheet 3 link severity in reactor 2 4331

atm 143124

T= 673 K H2 3462

P= 9990 kPa quench 7601

m= 146585 kg/hr 154187

(sheet3)


51/81

843.599265 0.277075203

(70 kPa drop)

(73 T rise)

3.056 liq Cp

2.76 vap Cp

avg Density viscosity Cp kJ/kmol K avg viscosity avg Cp (kJ/kg K) T=

atm oil = 0.3404 2.76 0.3323617 2.694833987 P=

H2 0.0144 14.6 0.00034009 0.344818365 m=

843.599265 0.33270179 3.04

1.8737 Kj/kg K vap Cp of ago

2.1275 Kj/kg K liq Cp of ago

MW kmol/hr mol.fr viscosity(cp) density (kg/m3) Cp (kj/kg K)

atm oil = 262.58 545 0.241294255 2.815 864 2.1275

H2 2.02 1714 0.758705745 0.009847 0.085 14.4

2259

m

atm oil = 143124

H2 3461.9

146585

changes wich can be made

si units from overall diagram

english from top intital calc.

m=mass flowrate (2 rise for T)

F=liquid flowrate set point= 10130 kPa

323 K T=

101.3 kPa P=

25000 BPD m=

315250 lb/hr

143124 kg/hr

(wt%) (kg/hr)

S = 1.37 1961

N2 = 0.031 44

C = 0.07 100

P =

Atm.oil =

T =

1

2

P-101

F-101


52/81

C-101


53/81

lb/day 7579707.24

kg/day 3441187.09

VABP :

MTY (oF) (oR) KBPD 25000 feed 629.3 1089.3 1960

1042 BBL/hr Product:

SG 0.864 gasoline 149 609 1096

density 54 lb/ft3 Naphtha 303.6 763.6 1374

303.18829 lb/bbl

lb/hr 315821.135

kg/hr 143382.795

factor 12.63 Component vol % BPD API (lb/hr)

(fact

(from ap

Feed: (linked)

atm gas oil 100 25000 32.2

0 0 0 0

25000

H2 (scf/bbl) 2431

Products: (linked to data input)

1 H2S (wt %) - -

2 NH3 (wt %) - -

3 C (wt%) - -

4 - - -

5 - - -

6 -

7 - - - (calcula8 C3 4 1000 147.2

9 i-C4 8.2 2050 119.8

10 n-C4 5.4 1350 110.6

11 Gasoline 41.3 10325 79

12 Naphtha 66.6 16650 56.8

for wt % given Methane & ethane(wt%) 0.5 -

(wt%.avoid to * by vol 31375

(linked to up)

wt % H2 lb / hr

out:

1 H2S (wt %) 5.9 4589

2 NH3 (wt %) 17.65 119 these are th

3 C (wt%) 221 associated a

4 - - hydrogens g

5 - - alongwith

6 - - individual c

7 - - (element

(not specify isome 8 C3 18.2 7424 formula app

9 i-C4 17.2 16879 i.e req.H2

10 n-C4 17.2 11538

from fig.9.7 11 Gasoline 16.0 101487

(approx) 12 Naphtha 14.5 182952

Methane & ethane(wt%) 21.7 1634

Assume H2 in soln (1 lb/bbl feed)


54/81

atm oil = 143124 kg/hr

H2 = 6093 kg/hr

total in = 149217 kg/hr

S = 1961 kg/hr

N2 = 44 kg/hr

C = 100 kg/hr

H2 Elemental Balance IN

H2 in Hydrocarbon Feed= 16793 kg/hr

(S&N2 free)

H2 as severity = 6093 kg/hr

(required for hydrocrkng) 22886

H2 req.for S & N2 = 132 kg/hr

23018

172235

H2 going out

in converted H2 loss in solution =

hydrocarbons +

set point =

T= 358

802.0136351 P= 10130

Rec.H2 = 8446

density wt.fr avg den

864 0.928249463 802.0075363

0.085 0.022453255 0.0019085270.085 0.049297282 0.004190269

T= 358 K

R t T(K) 673 P 10130 kP

42


55/81

600 K T= 688 K

10060 kPa P= 9890 kPa

146586 kg/hr m= 154186 kg/hr

(70 kPa drop)

(255 T rise 150 T drop)

avg. MW avg.viscosity avg.density avg.Cp (kJ/kg K) T= 538 K

63.35904556 2.748525787 843.597258 2.077260608 P= 9820 kPa

1.532585604 0.000232563 0.0020075 0.340094826 m= 154186 kg/hr

64.89163117 2.748758351 843.599265 2.42

H kJ/kg kJ/hr

170 24330995

4876 16880233.03 T= 345 K (avg.of 2 mixing streams)

P= 10130 kPa

m= 146585 kg/hr

325 K T= 355 K (avg.of 2 mixing streams

10130 kPa P= 10130 kPa

143124 kg/hr H2 = 3462 kg/hr

3

4

7

45

44

E-101


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Kw

11.90

12.61

12.16

cracked com

8965.83113


58/81


59/81

kg/hr

2083

54

297

1348

3065

2095

18430

33224

100

85874

8814

7156

162541

343

9750

161343


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61/81

*

H2S:

H2 S H2S

lb 2 32 34

h2 req

for 32 lb S, H2 req 2

for 4319 lb/hr S ,H2 req 270 lb/hr ****

H2S prod2 lb H2 produces 34 lb H2S

270 lb/hr H2 will prod 4589 lb/hr H2S

* * NH3:

3H2 N2 2NH3

lb 6 28 34

h2 req

for 28 lb N2, H2 req 6

for 98 lb/hr N2 ,H2 req 21 lb/hr

NH3 prod

6 lb H2 produces 34 lb NH3

21 lb/hr H2 will prod 119 lb/hr NH3

punds


62/81

T= 338

P= 7000

flare = 152.0 kg/hr

H2= 132 kg/hr

H2S= 20 kg/hr

T= 338 K

P= 7000 kPa


63/81

H2= 8578 4224.5 0.98643219 7891.458

4283

(sheet 3)

H (kJ/kg) mH (KJ)

(loss+excess+quench)

(more)

NH3 H2S NH4HS

kg 17 34 51

K

kPa NH4HS prod

kg/hr 17 kg NH3 produces 51 kg NH4HS

54 kg/hr NH3 will prod 162 kg/hr NH4

H2S req

T= 343 for 17 kg NH3, H2S req 34P= 9750 for 54 kg/hr NH3, H2S req 108

m= 7318

kg/hr kg/hr H (kJ/kg) mH (KJ)

H2O = 7156 C1,C2 = 297

NH4HS = 162 C3 = 1348

H2S= 108 i-C4 = 3065

NH3 = 54 n-C4 = 2095

Gasoline = 18430

Naphtha = 33224

Sour water C= 100

unconv. Feed= 85874

loss H2 = 236

144670

sheet 3

T= 343 K

P= 9750 kPa

m= 144670 kg/hr

L= 1176.52

10

40

52

HS-101


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Start o

set point = 10130 kPa

T= 410 T= 420

P= 9750 P= 10130

m= 7219 m= 7219

46

47

C-103


67/81

7219

C1,C2 = 445

C3 = 2022

i-C4 = 4598

n-C4 = 3143

Gasoline = 27645

Naphtha = 49836

H2 = 7455 (AW179)95144

T=

P=

m=

kg/hr MW

C1,C2 = 445 46

C3 = 2022 44

i-C4 = 4598 58 T=

n-C4 = 3143 58 P=

Gasoline = 27645 82.47 m=

Naphtha = 49836 124.63

loss H2 = 236 2

87926

T=

P=m=

HS-102

46

49

5

24

25


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T= 700

P= 9990

m= 90205

K C

Reactor T(K)= 700 427 kg/hr H (kJ/kg) mH (KJ) wt fr dens


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(50T rise)

T= 650

P= 10060

m= 90205

(70 kPa drop)

(210 T rise

T= 440 (avg of 2 mixing)

P= 10130

m= 90205

T= 505

P= 10130

m= 85874

E-103

F-102


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74/81

T= 303 (13 T drop)

P= 200 (70 P drop)

m= 25875

kg/hr

158

3877

11741 Vn

8599

0

1500

25875

kg/hr

T= 290 C3 = 1939

30

31


75/81

Steam

T= 550

P= 300

m= 1500

T= 500

P= 200

m= 85874

T= 308

P= 273

m= 227382

T= 500

T= 505 (5 T drop) P= 200

P= 10130 m= 85874

m= 85874

set point = 10130

17

55

P-102


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water

290

130

1500


79/81

Reactor 1

Feed Rate (kg/hr)= 154187 Dp (m) =

Avg Density (kg/m3) = 802 liquid visco

LHSV (hr-1) = 2

Bed Porousity = 0.2

L/D = 6%age of reactor volume = 70

the catalyst volume is

Catalyst density (kg/m3) = 881

Vol. Feed Rate (m3/hr) = 192.25

Catalyst volume (m3) = 96.13

Actual Catalyst volume (m3) = 115

(accounting porousity)

Volume of Reactor (m3) = 165

Dr (m) = 3.3

Lr (m) = 19.6 Lc (m) =

Remaining volume (m3) = 49.4

Catalyst weight (kg) = 101625

Define No. of beds = 3

A (% by wt of catalyst ) 30

B (% by wt of catalyst ) 40

C (% by wt of catalyst ) 30

D (% by wt of catalyst ) 0

wt (kg) V (m3) Lci (m)

A 30487 34.61 4

B 40650 46.14 5

C 30487 34.61 4

D 0 0 0

Pressure Drop

Reactor cross sectional area S (m2)= 8

Mass velocity G (kg/s m2) 5.100

pressure drop per length (pa/m)= 4294

CALCULATIONS


80/81

Reactor 1

0.003 Feed Rate (kg/hr)= 96702

sity (Pa-s) = 0.000283 Avg Density (kg/m3) = 785

LHSV (hr-1) = 0.9

Bed Porousity = 0.2

L/D = 7.0%age of reactor volume = 70

the catalyst volume is

Catalyst density (kg/m3) = 881

Vol. Feed Rate (m3/hr) = 123.19

Catalyst volume (m3) = 136.87

Actual Catalyst volume (m3) = 164

(accounting porousity)

Volume of Reactor (m3) = 235

Dr (m) = 3.5

14 Lr (m) = 24.5

Remaining volume (m3) = 70

Catalyst weight (kg) = 144704

Define No. of beds = 4

A (% by wt of catalyst ) 20

B (% by wt of catalyst ) 30

C (% by wt of catalyst ) 30

D (% by wt of catalyst ) 20

delta P (Pa) wt (kg)

17693 A 28941

23591 B 43411

17693 C 43411

0 D 28940.79

58978

Reactor cross sectional area S (m2)= 10

Mass velocity G (kg/s m2) = 2.800

pressure drop per length (pa/m)= 1931

CALCULATIONS


81/81

17

V (m3) Lci delta P (Pa)

32.85 3 6612.61167

49.27 5 9918.91751

49.27 5 9918.91751

32.84994 3 6612.61167

33063.0584

Date post:	13-Apr-2018
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Final Design File HC

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