1. Designer: Khaled Aldhaferi Supervised by: Prof.M.Fahim ENG: Yousif Ismail PROPYLEN OXIDE CO-PRODUCTION WITH t-BUTYL ALCOHOL BY THE TEXACO HYDROPEROXIDATION PROCESS

2. Table of content 1- Heat exchanger design ( heater, cooler ). 2- Distillation column design. 3- Separator design. 4- Pump design.

3. Heat Exchanger Design For E-101 A&B: - To decrease temperature of stream which exit from R-101. For E-101: - To increase temperature of isobutene in c-10211a stream. Objectives:

4. Assumptions: - Use shell and tube heat exchanger. - Use shell and tube heat exchanger. - Assume the water inter in tube side - Assume the water inter in tube side The value of the overall heat transfer coefficient was assumed to be: The value of the overall heat transfer coefficient was assumed to be: - For (E-101 A&B) = 30 w/m^2C. - For (E-101 A&B) = 30 w/m^2C. - For (E-101) = 100 w/m^2C. - For (E-101) = 100 w/m^2C. - For E-101 - For E-101 Steam inlet temperature (t1) = 200 oC Steam outlet temperature (t2) = 75 oC -For E101 A&B Water inlet temperature (t1) = 25 oC Water inlet temperature (t1) = 25 oC Water outlet temperature (t2) = 30 oC Water outlet temperature (t2) = 30 oC

5. Main design procedures: Main design procedure: Calculate the duty or heat load. Where, m: mass flow rate, kg/hr. Cp: specific heat, kJ/kg°C. ∆T: temperature difference, °C.

6. -Calculate Log mean Temperature. -Calculate Log mean Temperature. Where, Where,  T m = F t  T lm. ∆T lm : log mean temperature difference. T 1 : inlet shell side fluid temperature. T 2 : outlet shell side temperature fluid temperature. t 1 : inlet tube side fluid temperature. t 2 : outlet tube side fluid temperature. -Assume U : overall heat transfer coefficient, W/m 2o C. -Assume U : overall heat transfer coefficient, W/m 2o C. -Calculate heat transfer area required.

7. - Calculate area of one tube, m 2. Where -Outer diameter (d o ), (mm) -Length of tube (L), (mm) - Calculate number of tubes = provisional area / area of one tube

8. - Calculate bundle diameter. Where - do =Outside diameter (mm). - Nt= Number of tubes. - K1 & n1 are constant.

9. - Calculate shell diameter. Ds = Db + Bundle diametrical clearance - Find tube side heat transfer coefficient h i, W/m 2° C. - Find tube side heat transfer coefficient h i, W/m 2° C. - Find shell side heat transfer coefficient h s, W/m 2° C. - Find shell side heat transfer coefficient h s, W/m 2° C.

10. Calculate U overall heat transfer coefficient using: Calculate U overall heat transfer coefficient using: Where : - Uo : overall coefficient based on outside area of the tube,w/m^2.C - Uo : overall coefficient based on outside area of the tube,w/m^2.C - ho : outside fluid film coefficient, w/m^2.C, from Table (12.2) - ho : outside fluid film coefficient, w/m^2.C, from Table (12.2) - hi : inside fluid film coefficient,w/m^2, from Table (12.2) - hi : inside fluid film coefficient,w/m^2, from Table (12.2) - hod : outside dirt coefficient (fouling factor),w/m^2.C - hod : outside dirt coefficient (fouling factor),w/m^2.C - hid : inside dirt coefficient (fouling factor),w/m^2.C - hid : inside dirt coefficient (fouling factor),w/m^2.C - kw : thermal conductivity of the wall material w/m.Cs for cupronickel - kw : thermal conductivity of the wall material w/m.Cs for cupronickel - di : tube inside diameter m - di : tube inside diameter m - do : tube outside diameter m - do : tube outside diameter m

11. -Calculate tube and shell side pressure drop. - Calculate Shell thickness. Where - t: shell thickness (in). - P: internal pressure (psig). - r i : internal radius of shell (in). - E J : efficiency of joints. - S: working stress (psi). - C c : allowance for corrosion (in).

12. ResultsHeater Equipment Name To increase temperature of isobutene in c-10211a stream Objective E-101 Equipment Number Khaled Aldhaferi Designer Shell And Tube Type Before R-101 Location Carbon Steel Material of Construction Glass wool Insulation 78,600 Cost ($)

13. Operating Condition Shell Side 134 Outlet temperature ( o C) 45.46 Inlet temperature ( o C) Tube Side 75 Outlet temperature ( o C) 200 Inlet temperature ( o C) 382 Number of Tubes 2 Number of Tube Rows 0.7752328 Shell Diameter (m) 0.723 Tube bundle Diameter (m) 45.3534 LMTD ( o C) 10.7 Q total (KW) 183.085 Heat Exchanger Area (m 2 ) 100 U (Btu/hr. o F. ft 2 )

14. Cooler Equipment Name To decrease temperature of stream which exit from R-101 Objective E- 100 A&B Equipment Number Khaled Aldhaferi Designer Shell And Tube Type After R-101 Location Carbon Steel Material of Construction Glass wool Insulation 68,400 Cost ($)

15. Operating Condition Shell Side 711 Outlet temperature ( o C) 134 Inlet temperature ( o C) Tube Side 30 Outlet temperature ( o C) 25 Inlet temperature ( o C) 930 Number of Tubes 2 Number of Tube Rows 0.7461946 Shell Diameter (m) 0.6831946 Tube bundle Diameter (m) 97.87743 LMTD ( o C) 1494 Q total (KW) 210.39735 13 Heat Exchanger Area (m 2 ) 30 U (Btu/hr. o F. ft 2 )

16. Distillation ColumnT-(102) design Objective : - To separate isobutene from tert-butanol.

17. Assumptions 1. Tray column. 2. Sieve plate. 3. Material of the distillation is carbon steel. 4. Plate spacing= 0.6 m 5. Efficiency = 50% 6. Flooding % = 85% 7. Weir height = 50 mm 8. Hole diameter = 5 mm 9. Plate thickness =5 mm

18. 1) Actual number of stages = (hysys number stages/η) 2) FLV= ( LW/VW)*( ρv / ρL)^.5 Where:- Lw: liquid flow rate ρL: liquid density Vw: vapor flow rate, ρv :vapor density FLv: liquid-vapor flow factor 3) Find K1 (Top) & K1 (Bottom) from fig. K1correction = (σ/0.02)^.2*K1 Where:- σ: Surface tension Main design procedures:

19. 4) Uf (bottom)= K1 ((ρL- ρv)/ ρv) 0.5 Uf (Top) = K2 ((ρL- ρv)/ ρv) 0.5 Where: Uf : flooding vapor velocity K1: constant obtained from figure 5) uv = uf * x Where:- Uv : maximum velocity X : percentage of flooding at max flow

20. 6) Max liquid flow-rate = (Lw*Mwt / ρL*3600) Where:- Max.: Maximum Volumetric Flow rate. Lw: liquid flow rate ρL: liquid density M.wt: molecular weight 7) Anet = Mmax/uv Where:- Anet: Net area required 8) Ad = An/(1-y*10^-2) Where: Ad: down comer area

21. 9) D =(Ad*4/(3.14))^.5 Where:- D: diameter 10) H= (Tray spacing * actual NO. stage ) + D Where:- H: Column height 11) MVL =(Lbottom*Mwt)/(3600* ρL) Where:- MVL: maximum volumetric liquid rate

22. 12) Ac = (3.14/4)*D^2 Ad = 0.12Ac An = Ac-Ad Aa = Ac-2Ad Ah take %Z Aa as first trial = %Z*Aa Where: - Ac: column area Aa: active area Ah: hole area Ad= Downcomer area

23. 13) max Lw = Lw*Mwt/3600 min Lw @ % turn down = %*max Lw max how =750 (max Lw/ρL*wierlength)^(2/3) min how =750 (min Lw/ ρL*wierlength)^(2/3) actual minimum vapor = vapor rate min/Ah Where:- max Lw: maximum liquid rate. min Lw : minimum liquid rate.

24. 14) The actual min vapor velocity = vapor rate min/An 15) uh = Vw max/Ah hr = 12.5E+03/ ρL Where:- uh: maximum vapor velocity through holes max.Vw: maximum volumetric flow rate hd: dry plate drop hr: Residual head

25. Aap= wier length*hap hdc= 166*(max liquid flowrate/ ρL*Aap)^2 hb= Minimum rate (hw + how) + ht + hdc Where:- Aap: Area under aporn hdc: head losses in the down comer Hb: Back up in downcomer 17)tr = Where : tr : residence time, should be > 3 s

26. 18) Percent flooding = Where :- uv: vapor velocity, uf: flooding vapor velocity 19) Number of holes Area of one hole = (π/4)*(hole diameter^2) Total number of holes = Ah / area of one hole Holes on one plate = total Number of holes/number of stages

27. 20) Area of condenser& reboiler = Q/(U*∆T) 21) Thickness = [(ri P)/(Ej S-0.6P)]+Cc Where:- ri = Inside radius of the shell P =Maximum allowable internal pressure S = Maximum allowable working stress EJ = Efficiency of joints Cc = Allowance for corrosion

28. Distillation column Equipment Name To separate isobutene from tert- butanol Objective T-102 Equipment Number Khaled Aldhaferi Designer Plate column Type After P-100 Location Carbon steel Material of Construction Glass wool Insulation 324,700 Cost ($)

29. Column Flow Rates - Recycle (kgmole/hr) 527.9 Feed (kgmole/hr) 335.7 Bottoms (kgmole/hr) 192.1 Distillate (kgmole/hr) Dimensions 35.13045 Height (m) 1.53045 Diameter (m) 2 Reflux Ratio 56 Number of Trays Sieve single pass Type of tray 0.6 Tray Spacing - Number of Caps/Holes 7120 Number of Holes Cost 33600Trays114300Vessel 44600Reboiler132200 Condenser Unit

30. Pump Design Objective: - To increase the pressure.

31. - Centrifugal pump. Assumption:

32. Main design procedures: 1.Calculate the flow rate, m. - m= ρ * Q 2.Calculate the work shift, Ws. - Ws = -ha * g 3.Assume efficiency, ζ. - ζ = 0.75

33. 4.Calculate the brake horse power. - Brake HP = (-Ws * m) / (ζ * 1000) 5.Calculate the diameter, d. 6.Calculate the cost - From www.matche.comwww.matche.com

34. Pump Equipment Name To increase the pressure Objective P-100 Equipment Number Khaled Aldhaferi Designer Centrifugal Pump Type After C-101 Location Cast Iron Material of Construction Glass Wool Insulation 9700 Cost ($) Operating Condition 12.3 Outlet Temp eratur e ( o C) 12.03 Inlet Temperature ( o C) 105 Outlet Press ure (Psia) 43 Inlet Pressure (Psia) 861.066 Powe r (Hp) 70 Efficiency (%)

35. Pump Equipment Name To increase the pressure Objective P-103 Equipment Number Khaled Aldhaferi Designer Centrifugal Pump Type After C-301 Location Cast Iron Material of Construction Glass Wool Insulation 9500 Cost ($) Operating Condition -210.1 Outlet Temp eratur e ( o C) -210.6 Inlet Temperature ( o C) 125 Outlet Press ure (Psia) 60 Inlet Pressure (Psia) 454.14 Powe r (Hp) 63 Efficiency (%)

36. Separator Design Objectives: -To separate vapor gases from the liquid.

37. Assumption: - Vertical separator.

38. Main design procedures: - Calculate settling velocity by knowing density of vapour and liquid. U t = 0.07*((ρl-ρv)/ρv)^.5 Where: Where: - U t: settling velocity,m/s - U t: settling velocity,m/s - ρl:liquid density,Kg/m 3 - ρl:liquid density,Kg/m 3 - ρv: vapour density,Kg/m 3 - ρv: vapour density,Kg/m 3

39. - Calculate vapor volumetric flowrate. - Calculate liquid volumetric flowrate. - Determine the volume held in vessel using the above information's. - Then calculate the minimum vessel diameter.

40. - 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) VDv = (3.14/4)*(Dv^2)*h Where: - Dv: min vessel diameter. - Dv: min vessel diameter. - h: total length. - h: total length. - Calculate volume of cylinder using Dv:

41. - Weghit of metal: Wm=Vm* ρ Where: - ρ: density of steel. - ρ: density of steel. - Vm: volume of metal - Vm: volume of metal

42. separator Equipment Name To separate oxygen from the isobutane Objective V-100 Equipment Number Khaled Aldhaferi Designer Vertical separator Type After C-101 Location Carbon Steel Material of Construction Class wool Insulation 5,100 Cost ($)

43. Operating Condition 43 Operating Pressure (psig) -3.2 Operating Temperature (oC) Design Considerations 24.055 Gas Density (kg/m3) 595.27 Liquid Density (kg/m3) 11.81 Liquid Flow rate (Kg/h) 79.037 Gas Flow rate (Kg/h) Dimensions 1.026 Height (m).221 Length (m)

44. separator Equipment Name To separate isobutane from the gases Objective V-102 Equipment Number Khaled Aldhaferi Designer Vertical separator Type After V-100 Location Carbon Steel Material of Construction Class wool Insulation 68,300 Cost ($)

45. Operating Condition 42.7 Operating Pressure (psig) 1.39 Operating Temperature (oC) Design Considerations 24.055 Gas Density (kg/m3) 595.27 Liquid Density (kg/m3) 40588 Liquid Flow rate (Kg/h) 14448 Gas Flow rate (Kg/h) Dimensions 9.276 Height (m) 2.877 Length (m)

46. Thank you for listening