1. Equipment design Ethylbenzene production by liquid phase
KUWAIT UNIVERSITYCOLLEGE OF ENGINEERING & PETROLEUMCHEMICAL ENGINEERING DEPARTMENT
Equipment design Ethylbenzene production by liquid phase
Done by: Mohammed Almohsen
Supervised By:
Prof. M. A. Fahim
Eng. Yusuf Ismail

2. Distillation column: Distillation T-101
Separate and recycle Ethylbenzene

3. LIQUID VAPOR FLOW FACTOR
COLUMN DIAMETER:
LIQUID VAPOR FLOW FACTOR
FOR TOP
FOR BOTTOMS
TAKE PLATE SPACING AS 0.6 M
FROM FIGURE
BASE K1 = 0.08TOP K1 = 0.12
CORRECTION FOR
SURFACE TENSIONS
BASE K1 = 0.066TOP K1 =

4. DESIGN FOR 85% FLOODING AT MAXIMUM FLOW RATE
FLOODING VELOCITY:
DESIGN FOR 85% FLOODING AT MAXIMUM FLOW RATE
BASE
TOP

5. BOTTOM TOP MAXIMUM VOLUMETRIC FLOW RATE NET AREA REQUIRED:
TAKING DOWNCOMER AREA AS 12 per cent OF TOTAL AREA
COLUMN CROSS-SECTIONAL AREA
COLUMN DIAMETER:
USE SAME DIAMETER ABOVE AND BELOW FEED =6.328M=20.76FT

6. COLUMN HEIGHT:
Column height = (Number of stage * Plate spacing) + Column Diameter
H = 27.9m =91.6 FT

7. MAXIMUM VOLUMETRIC LIQUID RATE
LIQUID FLOW PATTERN:
MAXIMUM VOLUMETRIC LIQUID RATE
FROM FIGURE
DOUBLE PASS PLATE IS USED

8. PROVISIONAL PLATE DESIGN:
Column diameter =
Column area =
Downcomer area =
Net area =
Active area =
Hole area =

9. ASSUME WEIR LENGTH Take weir height = Hole diameter =
FROM FIGURE
WEIR LENGTH
Take weir height =
Hole diameter =
Plate thickness =
ASSUME

10. CHECK WEEPING: MAXIMUM LIQUID RATE MINIMUM LIQUID RATE
TURNDOWN PERCENTAGE = 0.80
MINIMUM LIQUID RATE
MAXIMUM WEIR CREST:
MINIMUM WEIR CREST:

11. MINIMUM VAPOR VELOCITY THROUGH HOLE:
AT MINIMUM RATE
FROM FIGURE
MINIMUM VAPOR VELOCITY THROUGH HOLE:
ACTUAL MINIMUM VAPOR VELOCITY
SO MINIMUM OPERATING RATE WILL BE ABOVE WEEP POINT.

12. MAXIMUM VAPOR VELOCITY THROUGH HOLES
PLATE PRESSURE DROP:
MAXIMUM VAPOR VELOCITY THROUGH HOLES
Plate thickness / hole dia. = 1.25
FROM FIGURE
DRY PLATE DROP
RESIDUAL DROP
TOTAL PLATE PRESSURE DROP

13. DOWN COMER LIQUID BACK-UP: DOWNCOMER PRESSURE LOSS
TAKE
AREA UNDER APRON
HEAD LOSS IN THE DOWNCOMER
BACK-UP IN DOWNCOMER
CHECK RESIDENCE TIME
SATISFACTORY

14. CHECK ENTRAINMENT
FROM FIGURE
ψ =0.013 , well below 0.1

15. PERFORATED AREA: FROM FIGURE
Angle subtended by the edge of the plate = 85
Mean length, unperforated edge strips =
Area of unperforated edge strips= m
Mean length of calming zone,approx =4.7738
Area of calming zones = m
Total area for perforations, Ap =

16. FROM FIGURE
NUMBER OF HOLES:
AREA OF ONE HOLE:
NUMBER OF HOLES:

17. AREA OF CONDENSER AREA OF REBOILER Inlet temperature T1 159.8721 Co
Outlet temperature T2
Mean overall heat transfer coefficient U
W/m2.Co
Heat flow Q KW
AREA OF REBOILER
Inlet temperature T1 Co
Outlet temperature T2
Mean overall heat transfer coefficient U
W/m2.Co
Heat flow Q KW

18. THICKNESS CALCULATIONS:
Internal raduis of shell before allowance corrosion is added ri in
Maximum allowable internal pressure P
psi
Working stress for carbon steel S
Efficincy of joients EJ
0.850
Allowance for corrosin Cc
0.125

19. SPECIFICATION SHEET OF BENZENE COLUMN T-101
Equipment Name
Benzene Column
Objective
Separate and recycle Benzene to the reactor
Equipment Number
T-101
Designer
Mohammed Al-Mohsen
Type
Continuous Distillation Column
Location
After Mixer (MIX-108)
Material of Construction
Carbon steel
Insulation
Mineral wool
Cost ($)
$711,828
Operating Condition
Operating Temperature (oC)
171
Operating Pressure (psi)
100
Feed Flow Rate (kg/h)
451181
Diameter (m)
6.328
Height (m)
27.9
Thickness (mm)
30.47

20. FROM: WWW.MATCHE.COM COST CALCULATIONS: Column cost:
Cost of tray = 1,100 $/trays
Cost of trays = 52,800$
Cost of Vessel:
Diameter outside=6m
Volume outside=895
Volume inside=878
Volume of metal=17
Weight of metal=296,080lb
Cost of vessel 2007 =547,200$
Vessel type: Large ,No Internals , Medium
Cost of reboiler:
Cost 2007 = 39,300$
Cost of condenser:
Cost 2007 =19,800$
Total cost of without insulation=659,100$
Insulation cost = 52,728$
Total cost of T-101=711,828$
FROM:

21. Heat exchanger: 3 heat exchanger has been designE-102 ,E103 and e-105.
The type of the 3 heat exchanger are shell and tube.

22. Cooler E-102 detailed calculation:
Heat load:
BECAUSE THERE IS PHASE CHANGE
COOLING FLOW:
TRY AND ERROR
ASSUME

23. USING ONE SHELL PASS AND TWO TUBE PASSES
TEMPERATURE CORRECTION FACTOR: CALCULATION:
USING ONE SHELL PASS AND TWO TUBE PASSES
FROM FIGURE

24. ASSUME PROVISIONAL AREA:
CHOOSE TUBE MATERIAL TO BE carbon steel WITH THE FOLLOWING PROPERTY
OUTER DIAMETER Do = 25 MMINNER DIAMETER Di = 20 MMTUBE LENGTH = 4.88 M

25. AREA OF ONE TUBE NUMBER OF TUBES USING 1.25 TRIANGULAR PITCH
Nt = provisinal area / area of one tube = = 793
USING 1.25 TRIANGULAR PITCH

26. USING SPLIT RING FLOATING
TUBE BUNDLE DIAMETER:
CONSTANT
USING SPLIT RING FLOATING
HEAD TYPE
FROM FIGURE
Bundle diametrical clearance = 71 mm
Shell diameter =Bundle diameter+Bundle diametrical clearance
= mm=1.037

27. TUBE-SIDE COEFFICIENT:
METHOD 1
Mean water temperature =
Tube cross sectional area =
Total flow area=Tubes per pass x Cross sectional area=

28. Water mass velocity=mass flow rate/total flow area=
Water linear velocity Ut = mass velocity / density =
Inside coefficient for water hi:

29. TUBE-SIDE COEFFICIENT:
REYNALDO NUMBER
PRANDTL NUMBER
TUBE-SIDE COEFFICIENT:
METHOD 1I
FROM FIGURE
HEAT TRANSFER
FACTOR

30. INSIDE COEFFICIENT FOR WATER Hs:

31. SHELL-SIDE COEFFICIENT:
Choose baffle spacing =
Tube pitch =
Cross flow area=
Mass velocity Gs= mass flow rate/cross flow area =

32. Equivalent diameter for triangular arrangement
Mean shell side diameter temperature:
Reynaldo number
Prandtl number

33. CHOOSE 25% BAFFLE CUT
HEAT TRANSFER
FACTOR
FROM FIGURE

34. OVERALL HEAT TRANSFER COEFFICIENT:
Thermal conductivity of steel =
Outside coefficient (fouling factor) =
Inside coefficient (fouling factor) =
OVERALL HEAT TRANSFER COEFFICIENT:
CLOSE TO INITIAL VALUE ASSUMED

35. PRESSURE DROP: TUBE SIDE:
FROM FIGURE
HEAT TRANSFER
FACTOR

36. SHELL SIDE:
Linear velocity =
FROM FIGURE

37. SHELL THICKNESS CALCULATIONS:
Internal raduis of shell before allowance corrosion is added ri
20.416 in
Maximum allowable internal pressure P 85
psi
Working stress for carbon steel S
Efficincy of joients EJ
0.85
Allowance for corrosin Cc
0.125

38. Cost Calculations:
From
Heat transfer area = 3,269 ft2
Exchanger Type: Carbon steel
Internal Pressure: 450 psi
Cost with out insulation: 110,900$
Insulation cost: 8,872$
Final cost 2007:119,772$

39. Shell and Tube Heat Exchanger Location After E-103 Heat Exchanger
Equipment Name
Heat exchanger
Objective
Heat the Benzene recycled stream before feed to the distillation
Equipment Number
E-102
Designer
Mohammed Al-Mohsen
Type
Shell and Tube Heat Exchanger
Location
After E-103 Heat Exchanger
Utility
Cooling Water
Material of Construction
Cupro Nickel for shell side
Carbon Steel for tube side
Insulation
Glass wool
Cost ($)
$110,900
Operating Condition
Shell Side
Inlet temperature (C)
159.38
Outlet temperature (C)
158.58
Tube Side 27 78
Number of Tube Rows 2
Number of Tubes
793
Tube bundle Diameter (m)
0.966
Shell Diameter (m)
1.037
Q total (kW)
22617
LMTD (oC)
104.48
U (W/m2C)
738
Heat Exchanger Area (m2)
303.69

40. Shell and Tube Heat Exchanger Location After P-101 pump Utility
Equipment Name
Heat exchanger
Objective
Heat the polyethylbenzen recycled stream before feed to Trans-reactor
Equipment Number
E-105
Designer
Mohammed Al-Mohsen
Type
Shell and Tube Heat Exchanger
Location
After P-101 pump
Utility
Cooling Water
Material of Construction
Cupro Nickel for shell side
Carbon Steel for tube side
Insulation
Glass wool
Cost ($)
$110,880
Operating Condition
Shell Side
Inlet temperature (C)
247.8
Outlet temperature (C)
127.5
Tube Side 27 45
Number of Tube Rows 4
Number of Tubes 12
Tube bundle Diameter (m)
0.157
Shell Diameter (m)
0.205
Q total (kW)
256.5
LMTD (oC)
145.69
U (W/m2oC)
608.4
Heat Exchanger Area (m2)
2.736

41. Shell and Tube Heat Exchanger Location
Equipment Name
Heat exchanger
Objective
Heat the Benzene recycled stream using the hot product stream from the reactor
Equipment Number
E-103
Designer
Mohammed Al-Mohsen
Type
Shell and Tube Heat Exchanger
Location
Between Mix-106 and Flash drums V-100
Utility
Cooling Water
Material of Construction
Cupro Nickel for shell side
Carbon Steel for tube side
Insulation
Glass wool
Cost ($)
$354,996
Operating Condition
Shell Side
Inlet temperature (oC)
158.6
Outlet temperature (oC)
159.4
Tube Side
267.9
190
Number of Tube Rows 2
Number of Tubes
3026
Tube bundle Diameter (m)
1.844
Shell Diameter (m)
1.942
Q total (kW)
22294
LMTD (oC)
62.2
U (W/m2oC)
Heat Exchanger Area (m2)
12987