Propylene Oxide Production Propylene Oxide Production by ARCO Processby ARCO Process

Done ByDone By

Fiasal JuhailFiasal Juhail

Out Line:

Distillation columnDistillation column ReactorReactor PumpPump SeparatorSeparator

1.Distillation ColumnT-(100): Objective : To separate TBA from TBHP to fed it to

the second reactor.

Assumptions

1-Tray spacing= 0.6 m 2-Percent of flooding at maximum flow rate=85% 3- Percent of downcomer area of total area=12% 4- The hole area =10% the active area. 5-weir height=50 mm 6-Hole diameter=5 mm 7-Plate thickness=5 mm

Design ProcedureDesign Procedure

1. Collect the system physical properties.2 .Calculate liquid - vapor flow factor.

w vLV

w L

LF

V

WV

WL

v

L

= vapor mass flow rate, Kg/s

= liquid mass flow rate, Kg/s

= vapor density, Kg/m3

= liquid density, Kg/m3

3-Select trial plate spacing from 0.15m to 1m.

4. Calculate the net area required.

2n (m )

v

VA

u

= volumetric flow rate, m3/s V

3 . (m /s)

3600

w

v

V M WtV

= flooding at maximum flow rate, m/s (m/s) %v fu flooding u

5. Calculate total column cross sectional area.

2 (m )1 %downcomer area of total area

nc

AA

6. Calculate the column diameter.

*4 (m) c

c

AD

7. Calculate number of holes.

2 (m ) %downcomer area of total area *d cA A

n c dA A A Where

Where

nA = net area, m2

= cross sectional area of downcomer , m2dA

2a c dA A A

aA

10%*h aA A

Where

= active area, m2

Where

hA =hole area, m2

Area of one hole = 2*

4 hd

Number of holes = Ah / area of one hole

(Plate spacing X actual number of trays)c cH D

Pr

0.6i

c cJ

t CSE P

ct

8. Calculate height of the column.

9. Calculate thickness of the column.

P

riS

= column thickness, in

= maximum pressure, psi

= column radius, in

= stress of metal, psi

= joint efficiencyJE

Where

10. Select the material of construction.

11. Select the material of insulation.

12. Estimate the cost of the equipment.

Equipment Name distillation

Objective Separation TBA from TBHP

Equipment Number T-100

Designer Faisal

Type Tray column

Material of Construction Carbon steel

Insulation Glass woolGlass wool

Cost ($) 410200 $

Column Flow Rates

Feed (kgmole/hr) 885.8664 Recycle (kgmole/hr) 2656.45

Distillate (kgmole/hr) 95.45 Bottoms (kgmole/hr) 790.4

Key Components

Light TBA Heavy TBHP

Dimensions

Diameter (m) 16.5300 Height (m) 40.5300

Number of Trays 40 Reflux Ratio 5

Tray Spacing 0.6 m Type of traySieve trays

Number of Holes 830497.002

Cost

Vessel 117100 Trays 60000

Condenser Unit 108100Reboiler

125000

Equipment Name distillation

Objective Separation TBA from TBHP

Equipment Number T-101

Designer Faisal

Type Tray column

Material of Construction Carbon steel

Insulation Glass woolGlass wool

Cost ($) 399700 $

Column Flow Rates

Feed (kgmole/hr) 95.45 Recycle (kgmole/hr) 633.0926

Distillate (kgmole/hr) 94.22 Bottoms (kgmole/hr) 1.229

Key Components

Light TBA Heavy TBHP

Dimensions

Diameter (m) 19.9 Height (m) 39.7

Number of Trays 33 Reflux Ratio 1

Tray Spacing 0.6 m Type of tray Sieve trays

Number of Holes 1203626.69

Cost

Vessel 117100 Trays 49500

Condenser Unit 108100Reboiler

125000

Centrifugal Pump Centrifugal pumps are essentially a type of enclosed pump in which a liquid is drawn in and delivered in a continuous stream by the rotation of a fan.

Assume: ή = 75%Assume: ή = 75% The head of the pump (H) =The head of the pump (H) =

Where:Where: H= the static head of the pump in m.H= the static head of the pump in m. ρ= the density of the fluid kg/m3ρ= the density of the fluid kg/m3

Break horse power (BHP) Break horse power (BHP) Where,Where, BHP =is the break horsepower of the pump in watt BHP =is the break horsepower of the pump in watt Q= flow rate in m3/sQ= flow rate in m3/s H= the static head of the pump in m.H= the static head of the pump in m. ρ= the density of the fluid kg/m3ρ= the density of the fluid kg/m3

Calculate the discharge diameter of the pipe (D)Calculate the discharge diameter of the pipe (D)

g

ppH inout

*

1000*)(

HgQBHB ***

horse power(HP):horse power(HP):

Calculate the discharge diameter using the following equation: Calculate the discharge diameter using the following equation:

Where,Where, ∆∆P is the pressure difference between the inlet and outlet streams in kpaP is the pressure difference between the inlet and outlet streams in kpa G: flow rate kg/sG: flow rate kg/s ρ: the density of the fluid kg/m3ρ: the density of the fluid kg/m3 μ: viscosity cpμ: viscosity cp D: pipe diameter mmD: pipe diameter mm

3960

.** gsHQHP

84.4116.084.11014.3 dGEp

Equipment Name Pump (2)

Objective To increase pressure

Equipment Number P-100

Type Centrifugal Pump

Material of Construction Carbon steel

Insulation Quartz wool or Glass wool

Cost 3900 $

Inlet Temp. (oC) 53.06Outlet Temp. (oC)

53.22

Inlet Press. (psia)

67Outlet Pres. (psia)

101.5

Efficiency (%) 75 H Power 9.4

Reactor CRV 100 :Reactor CRV 100 :It is a CSTR Reactor Which convert i-butaneIt is a CSTR Reactor Which convert i-butane

Into TBA and TBHP.Into TBA and TBHP.

- Oxidization of i-butane by O2Oxidization of i-butane by O2

Procedure Design:Procedure Design:

To calculate volume of reactor:To calculate volume of reactor:

V=(Fao-Fa)/-ra = (Fao-Fa)/kCao(1-X)V=(Fao-Fa)/-ra = (Fao-Fa)/kCao(1-X)

Assume H/D = 4Assume H/D = 4 V = 3.14/4 * D^2V = 3.14/4 * D^2

FA0=Molar flow rateFA0=Molar flow rate .-rA =Reaction rate..-rA =Reaction rate. FA=Molar flow rate of outletFA=Molar flow rate of outlet X=Conversion.X=Conversion. K= Constant of rate of reaction K= Constant of rate of reaction CA0= Entering concentration.CA0= Entering concentration. H = Height of reactorH = Height of reactor D = Diameter of reactorD = Diameter of reactor V = Volume of the reactor.V = Volume of the reactor.

Equipment Name Reactor

Objective Oxidization of i-butane to get TBHP

Equipment Number CRV-100

Designer Faisal

Type CSTR

Material of Construction Carbon steel

Operating Condition

Operating Temperature (oC) 136.7 Volume of Reactor (m3) 404.665

Operating Pressure (psia) 450 Reactor Height (m) 20.20453

Feed Flow Rate (mole/s) 1145 Reactor Diameter (m) 5.051131

Conversion (%) 36.9  

Cost ($) 287400  

Separator DesignSeparator Design

Objectives:Objectives:

-To separate vapor gases from the liquid-To separate vapor gases from the liquid

Design ProcedureDesign Procedure

1) Calculate the settling velocity.1) Calculate the settling velocity. 2) Calculate vapor volumetric flow rate.2) Calculate vapor volumetric flow rate. 3) Calculate liquid volumetric flow rate.3) Calculate liquid volumetric flow rate. 4) Determine the volume held in vessel using the above information's.4) Determine the volume held in vessel using the above information's. 5) Then calculate the minimum vessel diameter.5) Then calculate the minimum vessel diameter. 6) Calculate the liquid depth.6) Calculate the liquid depth. 7) Determine the thickness of the wall.7) Determine the thickness of the wall. 8) Calculate the length of the vessel.8) Calculate the length of the vessel. 9) Then calculate the volume of metal using the difference between 9) Then calculate the volume of metal using the difference between

volumes using inside and outlet diameters.volumes using inside and outlet diameters. 10) Calculate the weight of the metal.10) Calculate the weight of the metal.

11) Calculate the cost11) Calculate the cost..

Correlations Used in DesignCorrelations Used in Design Settling velocity:Settling velocity:

Where:Where: Ut=Settling velocity (m/s)Ut=Settling velocity (m/s) ρL= density of liquidρL= density of liquid ρV; density of vaporρV; density of vapor

5.0)(07.0v

vlUt

15.0*UtUs

- Calculate vapor volumetric flowrate.- Calculate vapor volumetric flowrate.

- Calculate liquid volumetric flowrate.- Calculate liquid volumetric flowrate.

- Determine the volume held in vessel using the above information's.- Determine the volume held in vessel using the above information's.

- Then calculate the minimum vessel diameter.- Then calculate the minimum vessel diameter.

LV

MlL

*3600

vV

MvV

*3600

60**TLVVHV

5.0)*14.3

*4(

S

VV U

VD

Liquid Depth (HV):Liquid Depth (HV):

Length (h) :Length (h) :

- Surface area of the vessel: (2*pi*(Dv/2)*h) - Surface area of the vessel: (2*pi*(Dv/2)*h)

)

4*14.3(

2VD

VHVHV

37021.39*2VDRi

224.0

2VV

VV DD

HVDD

H

- Determine the thickness of the wall.

Where: TH: thickness (in) P: internal pressure (psig) RI: internal radius of shell (in) Ej: efficiency S: working stress (psi) =13700 for Carbon Steel Cc: allowance for corrosion (in)

CcPEJS

RIpTH

*6.0*

*

Volume of metal:Volume of metal:

Weight of metal:Weight of metal:

SATHVm *

*VmWm

Equipment Name separator

Objective Separate liquid from vapor

Equipment Number V-103

Designer faisal

Type Vapor liquid separator

Material of Construction Carbon steel

Cost($) 125000

Operating Condition

Operating Temperature (oC) 108.1Operating Pressure (psig)

435.1

Design Considerations

Liquid Density (kg/m3) 570.381Gas Density (kg/m3)

42.95451

Viscosity (cp) 0.15611 Z factor 1.00

Gas Flow rate (kg/hr) 35473.66Liquid Flow rate (kg/hr)

45137.64

Dimensions

Diameter (m) 2.81825 Height (m) 9.561032

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