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EXECUTIVE SUMMARY: The main objective of this project was to carry out a design on the Propane distillation column for a process that produces 1,3 Butadiene. The raw materials used are Butane, Oxygen and Water and the process capacity is 100 000 tonnes per annum nominal. In the previous work it was stated that the plant is located in China. The main location of the plant is in the capital city of the Gansu Provence, Lanzhou. This was decided as the location over other provinces due to the excellent transport links and the availability of raw materials and cheap labour. The close proximity to suppliers, customers and skilled labour all make Lanzhou the ideal location for the plant to be located. The design of the distillation column consists of the packed type. The distillation is a multicomponent distillation involving separation of Propane from the other components at very high pressure. The number of theoretical stages chosen was 16 stages based on a reflux ratio of 0.608. The column diameter calculated was 0.61 at maximum pressure gradient possible for distillation columns and 0.66m for minimum pressure gradient, which was then scaled up to 0.65m. This was a reasonable decision as it may be helpful when the plant capacity increases. The column has a height of 8m. Feed location for the arrangement of packing is at stage 3 from the top of the column. Pall rings constructed out of stainless steel with a size of 25mm is used for packing. The vessel thickness of the column is around 5mm, constructed out of stainless steel also to avoid corrosion. A preliminary design on the condenser for this distillation column was also carried out. The type of condenser is a fixed plate with a 1 shell and 1 tube pass. The tubes are stainless steel, 119 in number, 2.44m in length, and with a square pitch arrangement. The overall heat transfer coefficient was also calculated as 486.026W/m2C. The pressure drop on the tube side was 7.306 N/m2 (almost negligible) as only one tube pass is used with a very short length. The pressure drop on the shell side was 46.64 N/m2 The next section details on the Piping and Instrumentation over the column. The control system used for better efficiency of the units is also featured in the same P and ID.. The control mainly used for this, is the cascade control for the temperature and product composition, also in the varying of the bottom product flow rate to control the level at the bottom of the column. The variables
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Butadiene is the raw material used [2] in the making of various synthetic rubbers and polymer resins as well as a few chemical intermediates. It is mainly used to make styrene butadiene rubber (SBR) which is used to make automobile tyres. It is also used in adhesives, sealants, coatings and rubber article such as shoe soles. SBR is has a high molecular weight, as it has excellent resistance to abrasion, it is widely used in the automobile tyre industry. Various other uses of butadiene are detailed in the table attached in Appendix I Section (b).
1.2 Production:
Butadiene is produced commercially by three main processes:[3] Steam Cracking of Paraffinic Hydrocarbons: In this process, butadiene is a co-product in the manufacture of ethylene (the ethylene co-product process). Catalytic Dehydrogenation of n-Butane and n-Butene (the Houdry process). Oxidative Dehydrogenation of n-Butene (the Oxo-D or O-X-D process).
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Figure 3 : graph to show Production Capacity and Output of Butadiene in China, 2001-2008 (Unit: 10,000 tons)http://www.researchinchina.com/UpLoads/Article/2008112601.gif It was decided that the best place locate the butadiene plant in China which can satisfy the demands of its market in near future is in Lanzhou, the capital of the Gansu province which is in north western china.
While deciding the plant location several factors were taken into consideration:
Productivity - Since 1949 Lanzhou has been transformed from the capital of a poverty-stricken province into the centre of a major industrial area. The GDP per capita of Lanzhou was 25,566 Yuan (RMB) (US$3,681) in 2008, ranked no. 134 among 659 Chinese cities. Richie Gandhi SUN-075909279 Page 8
River - Lanzhou is situated at the upper course of the Yellow River. The river can provide water to the plant as the process requires large quantities of water for scrubbing and cooling. Also the river provides hydropower to the industries and cities in Gansu. A large multipurpose dam has been built in the Liujia Gorge on the Yellow River above Lanzhou. The river also helps in transportation.
Natural Resources - Lanzhou has many natural resources which include coal, gold, silver, nickel, manganese, clay and dolomite. The Coal is obtained from Qinghai which provides thermal power. The catalyst for our process is nickel which will be cheaper to buy and will be available in large quantities.
Cheap Labour - Due to the presence of the Yellow river the site is a residential area for more than 3.3 million people. Cheap labour is available for the plant. There are many top ranked universities in this province which means qualified staff will be available at the site.
Industrial area - Gansu has one of the largest oil refineries in the country and Lanzhou itself is the centre of the province's petrochemical industry. The main industries include rubber, petrochemical, oil refinery and machinery industry. Butane which is the raw material for our process is readily available and also Butadiene (product) can be sold to the neighbouring industries. Also, the machinery parts will be available from the neighbouring industries which will reduce the cost of transportation and energy and time.
Transportation - Lanzhou is very well interconnected to various cities and provinces through highways, railways and airlines. There are 3 major national highways namely China National Highways 212,213 and312, connecting Lanzhou to different provinces of the country. Transportation is cheap and easy. The Lanzhou Sustainable Urban Transport Project in China aims at improving the transport infrastructure and urban road networks. The total Asian Development Bank contribution is estimated at US$150 million. This project is under planning and is expected to get its approval by 11th Dec; 2010.This will greatly enhance the transportation of our product to different provinces when our plant is ready for production.
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2.1Technical Objectives:
Chemical engineering design to achieve the following outcomes is to be done Understanding solving a complex engineering design problem Design a distillation column according to the engineering standards To design a distillation column to meet the desired criteria Gain an understanding of chemical engineering unit operations
Description of a control system for the distillation column for best possible results is to be done To study concepts of process control including principles of feedback and feed forward, apply these concepts to the design of instrumentation and control system for a distillation column. Propose a control system which will execute the desires of the process functionality
Piping and Instrumentation Diagram for the distillation column is obligatory Exhibit an understanding of engineering codes, standards and regulations Develop skills through use of computer software such as Microsoft Visio
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Economic appraisal (group work) for the full process on production of 1,3 Butadiene in order to gain the following outcomes Work effectively in the group to enhance team work skills To estimate the costs and benefits of production of products using the desired process route To study the economic feasibility of the production of products
Written report preparation based on the selected design to achieve the following Assemble and use relevant background information Provide Complete Referencing Appendices containing lengthy derivations, calculations, large drawing, computer printouts etc.
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Enhance Team-working Skills: HAZOP and Economic Appraisal have to be carried out as a group. The group members are required to co-operate with each other, share and listen to ideas and take constructive criticism from group members. This will encourage each member to provide advice and feedback. Professional report writing: At the end of our project I wish to able to deliver a professionally laid out report.
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Get feedback on report/presentation and 1 mass and energy balance from Dr. Titiloye Submit project plan. 19/01/10 22/01/10
Tutor meeting and discussing the topic. Gathering relevant information from 1st term project 25/01/10 29/01/10
Discuss findings with tutor Put together a list of all the equations required to design a Distillation Column for the process Start Designing the Distillation Column in the Butadiene production process. 01/02/10 07/02/10
Calculating diameter and size of Distillation Column along with the flow though them thereby completing the design Review the mass balance and calculating other dimensions
08/02/10
19/02/10
22/02/10
5/03/10
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Piping and instrumentation diagram Control and instrumentation research Calculating cost and profit
1/03/09
10/03/10
HAZOP
10/03/10
19/03/10
01/03/10
15/03/10
25/01/10 13/03/10
17/03/10 17/03/10
Ensuring completion of all section Submit report Review with tutor Make changes
20/03/10
21/03/10
10
22/03/09
26/03/09
To complete the objectives of the project various sources would be utilised for research work. The main source of information used will be university library, Birmingham city library, Aston Universitys access to online journals, internet and contacting co mpanies in relation to scope of the project. Discussions would be carried out with Dr. Titiloye to check the track of the work and to ensure correct research is carried out.
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3 The Revised Process: Phillips OXO-Process [3] The n-butene, steam and air react at 590-650C on a fixed bed heterogeneous catalyst (probably a ferrite (iron or iron alloy) with Zn, Mn or Mg). Addition of steam controls the selectivity. With butane conversions between 75-80%, the butadiene selectivity reaches roughly 88-92%.
C4H8 + O2
It is a one step process, where Butene gets oxidised straight away, without the need of butane dehydrogenation. Since our plant is close to an oil refinery plant, where butane can be obtained at a cheaper price in abundance, a decision to integrate the conversion of Butane to Butene in our process was made. This reaction would take place in the first reactor and then the produced butene is fed into the second reactor for further processing. The catalytic dehydrogenation of Butane to Butene is not a part of our OXO process which we had considered in the previous report.[3] The same method was carried out in the first project, but it was not stated clearly stated in literature.
Tubular Rector
C4H10 + O2
1Atms/590 C Cromina-Alumina
C4H8 + H2O.................................(2)
Equation (1) gives 100% completion; higher conversions at lower temperatures are possible with fewer side reactions and improved yields. It is also easier to remove the hydrogen as it is now present as water vapor and can be condensed out. It is an exothermic reaction; heat input to the reactor is thus eliminated as heat is recovered to generate high pressure steam. By feeding stream and air to the reactor it is possible to carry out continuous in-situ catalyst regeneration. The steam also absorbs some heat released by a small amount of hydrocarbon oxidation and has a beneficial effect on butene selectivity to butadiene. In general, the equipment used is smaller and utilities usage is reduced for a given throughout compared with the conventional dehydrogenation process. A typical flow goes from the feed stream, with a composition of butene feedstock, 90% n-butene, Richie Gandhi SUN-075909279 Page 15
A revised Flow Sheet is attached in Appendix III. A compressor is added after the extractive distillation column, in the new flow sheet that increases the pressure of the process before it can be sent to the Propane Distillation Column for further purification. I assume the mass balance to be correct as it was based on many assumptions which were acceptable. A Copy of the Mass Balance done in the previous project is attached in Appendix IV.
4 The Chemical Design: The design chosen for this project is a continuous distillation column. The separation of the liquid mixture by distillation depends on differences in volatility between the components. The separation becomes easier if the differences in the volatilities between the components are massive. Figure 5 shows a basic distillation column. The liquid mixture is heated up and routed into the distillation column. The feed when enters the column flows down. Heat is vaporise the volatile components is provided by the reboiler. The components with lower boiling points vaporise and rise to the top of the distillation column. Vapour flows up and the liquid flows counter currently down the column. These two phase come in contact with each other on a surface which can be trays or packing. The composition of the vapour above the liquid differs from the liquid composition. The vapour is then separated and condensed into a liquid; it becomes richer in the lower boiling component(s) of the original mixture. Part of the condensate from the condenser is returned to the top of the column which provides liquid flow above the feed point and part of the liquid from the base of the column is vaporised in the reboiler and returned to provide vapour floe rate. [5]
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Figure 5: Basic Distillation Column http://wpcontent.answers.com/wikipedia/commons/e/e0/Distillation_Column.png The highlighted distillation column in the flow sheet in Appendix III is the Propane/Butadiene distillation column which is considered to be designed. The main objective of this unit is to get rid of propane from the process. The distillation is a multi-component distillation thereby it involves more than two components. It operates at very high pressure of 13.5 bars and consists of three streams. The feed enters the distillation column at a temperature of about 350C. On distillation, the Propane vapour leaves the top of the column to the condenser and collected in the reflux drum. Partial amounts of 1,3 Butadiene is also lost at the top of the column. The bottom product majorly comprises of 1, 3-Butadiene, 1, 2-Butadiene and Pentane.
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Table 1 (b): Distillate: Components Propane 1,3 Butadiene Total Flow rate (kg/h) 424.23 237.6 661.83 Kmols/hr 9.64 4.4 14.04 Kmols fraction 0.687 0.313 1
Table 1 (c): Bottom: Components 1,3 Butadiene 1,2 Butadiene Pentane Total Flow rate (kg/h) 11667.16 500.00 138.84 12306.00 Kmols/hr 216.06 9.26 1.93 227.25 Kmols fraction 0.951 0.041 0.0085 1
The boiling points of the feed components at 1 atmospheric pressure are as below: Propane: 42.09 C 1,3 Butadiene: -4.4 C 1,2 Butadiene: 10.8 C Pentane: 36.1 C Looking at the temperature differences it can be said that the components can be separated easily by reducing the temperatures but since in tangible situations, it is very expensive to reduce down the temperatures in the plant for continuous process we have to increase the pressure inside the
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4.1 Calculations:
Basis: 1hr Units: 1 Kg Propane boiling point: 40C/313K @ 13.5 bars Specifications Feed condition: Cold Liquid under pressure Feed inlet temperature @35C/308K Temperature of Top of distillation column @ 45C/318K Temperature of Bottom of distillation column @ 95C/368K Therefore column Temperature will be taken as the average @ 70C/343K The detail distillation design was performed by using the main steps below Determination of reflux ratio and number of stages required for the distillation Calculation of the column diameter and determining the type of column to be used, Packed or trays Column design in detail Page 20
Figure 6: Generalised graph between number of theoretical stages V/S Reflux Ratio http://www.separationprocesses.com/Distillation/DT_Chp04n.htm
Calculations: The minimum reflux ratio is calculated by using Underwood method. [8]
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Light Key: Most Volatile component in the Bottom Product Heavy Key: Least Volatile component in the Top Product. [8] Hence, from the table 1 (b) and (c); Heavy Key (HK) 1,3 Butadiene Light Key (LK) 1,3 Butadiene This will cause a problem in the calculation, since both the HK and LK are the same component therefore an unreasonable reflux ratio will be obtained. Therefore to trounce this problem, a small amount of Propane was added to the bottom product, making Propane the LK. I assume that 99% mole of propane and 2% mole of 1,3 Butadiene is now in the Distillate and the remaining are the bottom product. Revised Balance over the distillation column is as follows: Table 2 (a); FEED Feed Flow rate Components Propane 1,3 butadiene 1,2 butadiene Pentane Total 500.00 138.84 12967.83 1.93 241.29 0.01 1 11904.76 9.26 0.04 (kg/h) 424.23 9.64 220.46 Kmols/hr Kmol Fraction 0.04 0.91
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Therefore new key components are: HK 1,3 Butadiene LK Propane The next step is to find the relative volatilities of each component with respect to the HK which in this case is 1, 3 Butadiene. The calculations are attached in the Appendix V, Section (b) and are tabulated below: Table 3: Components Propane 1,3 Butadiene 1,2 Butadiene Pentane =2.724 = 1 = .66 = .31
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Therefore,
Table 4: Latent Heat of the Components inside the Column [9] Components Latent Heat in KJ/Kg Relative Molecular Mass Propane 1,3 Butadiene 1,2 Butadiene Pentane 229.93 335.55 387.38 333.24 44 54 54 72 229.93*44 335.55*54 387.38*54 333.24*72 10116.92 18119.7 20918.52 23993.28 Calculation Latent Heat in KJ/Kmol
Latent Heat = (10116.92* 0.04) + (18119.7* 0.91) + (20918.52* 0.038) + (23993.28* 0.008) Latent Heat = 17880.454 J/mol or KJ/Kmol Table 5: Specific Heat of the Components inside the Column [9] Components Specific Heat in KJ/KmolK Propane 1,3 Butadiene 1,2 Butadiene Pentane 81.84 138.78 136.08 182.88
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q = 1.267 Using the above value of q in the Underwood Equation (1), is obtained;
Therefore; by using excel spread sheet: = 2.67; which is acceptable as the value for should lie between the values obtained for relative volatility of heavy key and light key. Next, proceed to calculate Rmin.
Rmin +1=1.468, therefore Rmin = 0.468. Reflux ratio is generally between 1.1 -1.5 times the minimum reflux ratio based on practical values but there is no relationship between Rmin and the optimum value.[8] R = 1.1*0.468= 0.515 To find the number of theoretical stages using FENSKE EQUATION [11]
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Therefore,
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From the above observations it is clear that increasing the reflux ratio reduces the number of stages. But it is seen that increasing the minimum reflux ratios by 1.4 to 1.5 does not changes the number of theoretical stages. There are two options available to decide which reflux ratios could be used in our design. Either a line can be drwan from the origin of the graph as shown below which means that the best available technique is a mid way between the number of stages and the reflux ratio or this can be debated on the basis of economic costs.
The increase in the reflux ratio reduces the number of stages in a distillation column. But energy costs shoot up which has to be considered as well. Since the Distillation column is almost running
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If the Feed is assumed to enter the column at its boiling point there is a huge difference in the reflux ratios 4.1.2 Determination of the Diameter of the Column: FAIR CORELLATION (1961)[10] is used to calculate the diameter of the column. To find the diameter, velocity of the fluids has to be calculated. The calculations are detailed below: Internal Traffic [11]: L =RD ; 0.608*661.83 = 402.39kg/hr L = L + qF ; 402.39+(1.267*12967.83) = 16832.63 kg/hr V = L+D ; 402.39+661.83 = 1063.22 kg/hr V = V (1-q)F ; 1063.22 (1-1.267)* 12967.83= 4525.63 kg/hr FLV = L/G (V/L)0.5
[18]
where;
L = Liquid mass flow rate, kg/s G = Vapour mass flow rate, kg/s Vapour density, kg/m3 = V Liquid density, kg/m3 = L The calculation of L and v (see section (C) of Appendix V) L = 599.69 Kg/m3 and v = 30.324 kg/m3 The Flooding correlation is calculated at both the sides of the column because it can be a stepped column. Therefore, the flooding correlation above the feed
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Using the CHART flooding velocity, sieve plates, in Graph 2 and taking a generalized plate spacing of 0.6m:
Hence,
Taking percentage flood @ 80% based on good design considerations, therefore velocity @ flooding: uf (top) = 0.8*0.4333 => 0.34664 m/sec
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Allowing 10% for down comer and 10% for support rings; There total area = 0.028*1.1*1.1 = 0.034 m2 Hence column diameter above the feed point;
Using the CHART flooding velocity, sieve plates in Graph 2; taking a generalized plate spacing of 0.6m: K1 (bottom) = 5*10-2 The velocity can now be calculated by;
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Taking percentage flood @ 80% based on good design considerations, therefore velocity @ flooding: uf (bottom) = 0.8*0.21665 => 0.17332 m/sec
Allowing 10% for down comer and 10% for support rings; There total area = 0.237*1.1*1.1 = 0.288 m2
4.1.3Feed Location: The number of stages is greatly affected by the subsequent position of the feed into the column. The feed should enter the column at a point that matches best with the composition of the feed. It is always a wise decision to provide two or three feed point nozzles around the predicted feed point which will account for the changes in the feed compositions after the start up. The propane Distillation column is operating under high pressure. Hence, the feed is either compressed or pumped into the column. It can be made to compress to a slightly higher pressure Richie Gandhi SUN-075909279 Page 31
4.1.3 Calculation of the Feed Position: Krickbride(1994)[13] can a practical equation to calculate the feed point location
Where, Nr = number of stages above the feed, including any partial condenser Ns = number of stages below the feed, including the reboiler B = Molar Flow Bottom Product D = Molar Flow Top Product XfHK = concentration of the heavy key in the feed XfLK = concentration of the light key in the feed XbLK = concentration of the light key in the bottom product XdHK = concentration of the heavy key in the Distillate
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Substitution the value of Nr from Equation (A) in equation (B), We get, Ns = 12.8 ( 13) which means, there are 13 stages below the feed position which includes the reboiler as well. Since, the feed location is almost at the top of the column leaving 3 stages, the design of a stepped column is pointless. It is made with an overall diameter of 0.6m.
4.2.1 Types of Packing: A packing should always fulfil the following requirements: [14] Provide a large interfacial area between the gas and the liquid. Should have an open structure for low resistance to gas flow. Should provide consistent liquid distribution on the packing surface Promote unvarying vapour gas flow across the column cross section
Hence, keeping the above requirements into consideration, the packing is broadly classified as Structured Packing: These are packing with standard geometry made of wire mesh or perforated metal sheets which are folded and arranged together. Some metal structured packing commonly used in distillation columns are shown in the figure 10. They have low height of equivalent theoretical plates (HETP) and low pressure drops. They are generally used in difficult separations which require many stages, like separating isotopes or in high vacuumed distillation columns. Using structured packing can also used to increase the capacity and reduce the reflux ratio requirements.
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Raschig rings are the oldest types of random packing whose length is equal to the diameter. These are cheaper compared to any of the random packing structures but not as efficient as others. These were then modified to Pall rings which have openings made by folding strips of the surface into the ring. This increases the liquid distribution by increasing the surface area. Other types of random packing are, Berl Saddle Ceramic, Intalox Saddle Ceramic, Metal Hypac and Super Intalox Ceramics.
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Packing Size [15]: The largest size of packing suitable for any size of column should not exceed more than 50mm. This is because the larger packing sizes would cause flooding due to poor liquid distribution. Very small sizes are also available but are much more expensive than the larger ones. The sizes recommended for different column diameters are: Table 7: Packing size depending on the Column Diameter Column Diameter < 0.3m 0.3 m to 0.9m > 0.9m Packing Size < 25mm (1inch) 25mm to 38mm (1inch to 1.5 inches) 50mm to 75mm (2 inch to 3 inches)
Hence, for the Propane distillation column Metallic Pall rings with a size of 25mm is used. Richie Gandhi SUN-075909279 Page 36
Column Diameter (capacity)[16]: A distillation column is always designed to operate at height economical pressure drop. This ensures good liquid and gas distribution. For random packing the pressure drop normally does not exceed more than 80mm of H2O/m of the packing column. A distillation columns design values for pressure gradients are between 40 -80 mm Hg/m packing.
[17]
These values are almost halved when the liquid starts to foam. The proposed design has a
diameter of 0.61m with trays. Since random packing is now considered a new diameter has to be calculated.
Pressure gradient over the enriching section using column diameter as 0.61m
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Now,
Where, Fp = Wet Packing Factor; Appendix V; section (d) = Ratio; (density of water/Density of Liquid inside the column) L = Liquid Viscosity of 1,3 butadiene is considered in the calculations, as major fraction of the liquid comprises of 1,3 Butadiene g = Gravitational constant
Hence;
From the Graph 3; the flooding line is calculated at 6, which is 81 mm Hg/meter. This result is acceptable since the pressure gradient calculated above, 6mm Hg, it is concluded that the system is expected to run at very extreme pressure gradients.
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From the same graph above a new value of is plotted at 40mmHg/m is now calculated. Hence the Flooding line would be,
As 13.6 mm Hg is the specific gravity of mercury. axis in now 0.015. Again using Equation on the Y axis in Graph 3; a new gas flow rate per area is calculated which would give the new diameter. Since,
Therefore,
Since the gas flow rate per area in decreased; the diameter has to be increased. Hence,
Since, the change in diameter is not drastic the packing used can still be suitable for this diameter. The capacity of the column can be anything between 0.61m 0.66m depending on the flooding line. Hence, it has been concluded that the capacity will be 0.65m; which can also be helpful when the production capacity of the plant increases. The flooding like can be changed accordingly.
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Table 8: The recommended HETPs for Pall rings Size of the Pall Ring in mm 25mm 38mm 50mm HETP in m 0.4m 0.5m 0.6m 0.75m 0.75m 1.0
Hence, HETP for the propane distillation column is 0.5m as the size for pall rings used is 25mm.
This means, one stage is 0.5m since there are 16 stages calculated earlier, total height of the column = 0.5*16 = 8m Flooding is prevented due to the tall height of the column. Since the feed stream is put after 3 stages; the position of the feed stream is (0.5m*3 stages) 1.5 m at the top and the length below it is 6.5 m.
Choice of material used for construction: The column is decided to be made up of stainless steel (18Cr/8Ni, Ti stabilised)(321). Steel is a very strong metal with high ductility and high malleability which can withstand high stress. Since the column has to with stand high pressures and high temperatures, poor choice of material should not be used. Also the column is very tall. Also stainless steel does not corrode. It is more expensive than carbon steel, but it one time investment is affordable. Also the column is required for purification purposes; hence any corroded metal in the product would not be appreciated.
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The thickness of the cylindrical section of the column can be calculated by a formula from British standards PD 5500:
Where, Pi = Internal pressure s = Design Stress for stainless steel @ 1000C; Appendix V; section (e) e = minimum thickness of the material Hence,
Allow 1mm for corrosion; Hence the thickness of the cylindrical section should be 4mm.
The thickness of the Domed Section of the column can be calculated by:
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A tank diameter of less than 15m should have a minimum allowable thickness of 5mm [16]. The thickness obtained from calculation would hold the weight of content in the vessel, but would not stand depression or dent. Therefore, a 5mm minimum allowable thickness was given for any vessel less than 1m because this can withstand depression. Hence, the results obtained are acceptable.
Diameter and Thickness of the Pipes: It is decided to use Pipes made of Stainless Less because they have high tensile strength and are ductile. These twp parameters are matter much as the system is operating at high pressures. The diameter is calculated by equation 19[20] and the thickness is calculated from equation 20[20] For Stainless steel;
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And;
And,
And,
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Packing Support: The support plate carries the weight of the random structures inside the column. A poorly designed of the support plates causes flooding or very high pressure drops inside the column. A simple Grid or a perforated plate support can be used. The only disadvantage with such kind of support systems is that the liquid and the gas have to vie through the same openings. Hence, wide spaced grids are used to avoid this problem and increase the flow area. The larger sizes packing are dumped into the column first if wider grids are used, which support the smaller random packing. (As shown in Figure 13)
The best design for packing support is the gas injection type of support. The gas inlets are provided above the level where the liquid flows from the bed. The problem of local flooding and high pressure drops is solved with the application of these support rings. These supports are available in a variety of sizes and materials, like plastics, ceramics and metals. Figure 14; shows design for the gas injection supports and Figure 15 shows the Principle of gas injection packing support
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Liquid Distributors:
Uniform flow of liquid throughout the column and good initial liquid distribution is a very essential factor for good performance of a column. A central open feed pipe or a pipe with a spray nozzle is best suited for proper distribution of liquid in small diameter columns. But for larger diameters, more elaborate designs are required. The two most common type of distributors used are orifice type and weir type. The orifice type has holes in the plate which allows passage for the liquid and it has short stand pipes, through which the gas flows. Sizing of gas pipes are compulsory as it provides sufficient area for the gas flow without letting the pressure to drop significantly. The holes should be of an appropriate size, neither too small nor too big so that at lowest liquid flow rate, there should be a level of liquid always present on the plate and at highest flow rates, the liquid distributor does not over flows. Figure 16 shows the C.S and the T.S of an orifice distributor.
In the Weir types the liquid flows over the notched weirs in the gas stand-pipes. These stand an upper grade over the orifice type in handling wider range of liquid flow rates. The column designed Richie Gandhi SUN-075909279 Page 45
Liquid Redistributors:
The main purposes of redistributors are to collect liquid that has moved to the column walls and redistribute it evenly over the packing also redistributors will even out any maldistribution that has occurred within the packing.
A full distributor shown in figure 18 combines the function of packing support and liquid distributor. The maximum bed height that should be used without liquid redistribution lies solely on the type of packing and the process. The wall-wiper type is mainly used in small columns of less than 0.6m in diameter. This operates in a mechanism were a ring collects liquid from the column wall and redirects it into the centre packing.
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Installing Packing: The column is filled with water and the packing is dumped into the water ensuring the level of water always being above the packing at all times. Metal and Ceramic packing are generally deserted into the column WET. This ensures ran dom distribution and prevents any damage to the packing. In case of DR packing the packing should be lowered into the columns in buckets or other containers.
Concept Drawing: The Concept Drawing Details the application of column internals more in detail. Bit-Map is used to create the column showing every possible detail and dimension. The non calculated values are assumed to British standards.
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5.0 CONDENSER: Condensers are units similar to heat exchangers, which are used to condense the vapours to their liquid state. Condensers vary in size ranging from hand handled units to large industrial scale units. For condensers used in distillation columns, the process fluid generally flows through the shell side and the cooling fluid is made to flow through the tube side. The two fluids never come in contact with each other. The diagram below shoes a one tube pass condenser.
Figure 20: One pass tube side condenser http://upload.wikimedia.org/wikipedia/commons/c/cd/Straight-tube_heat_exchanger_1pass.PNG Four condenser configurations are possible:[23] Horizontal, with condensation in the shell, and the cooling medium in the tubes Horizontal, with condensation in tubes Vertical, with condensation in shell Vertical, with condensation in the tubes
Horizontal shell side and vertical tube side is widely used as condensers. The other two are usually used in arrangements for heaters and vaporisers using steam as the heating medium.
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Basis: 1 hour Flow rate entering the condenser; V V = L+D; 402.39 + 661.83 = 1063.22 kg/hr
mL due to phase change, since it is a complete condenser where phase change occurs; and mCpT due to increase in the energy per degree rise in temperature.
Latent heat of Vaporisation of Propane (1,3 Butadiene is ignored as it would not bring a vast difference)= L = 322.76 kJ/Kg Therefore,
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It is assumed earlier that the chilled water enters the condenser @ 150C and leaves @ 450C. Hence T = 300C Hence,
From the diagram above it now becomes easier to TLM. The Log mean temperature difference is given by:
Where, TLM = log mean temperature TIN = inlet temperature of process fluid Richie Gandhi SUN-075909279 Page 50
To begin with the design, we assume an approximate overall coefficient. This is done in aid with Graph 4; where the fluid in the process side are classified as Paraffin and the fluid in the service side is taken as River, Well or Sea Water. Hence, the assumed overall coefficient = 600 W/m2 0C
Graph 4: Overall Coefficients (join process side to the service side and read U values from the centre line)
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Where, Q= Heat Transfer per unit Time U= Heat Transfer Coefficient A= Area TLM = Log Mean Temperature difference
Usually the plant standards require tubes of: The outer diameter is 20mm The inner diameter is 16 mm The length is taken to be 2.44 m (8 ft) The tubes are made of arbitrary brass. The arrangement is a squared pattern.
Hence, the surface area can now be calculated from the above data specified.
Therefore,
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Where, Nt = number of tubes K1 and n = constants obtained from table 9[25] Do = Outer diameter Table 9: K and n constants for square arrangements: Square pitch, Pt = 1.25 do Number of Passes K1 n1 1 0.215 2.207 2 0.156 2.291 4 0.158 2.263 6 0.0402 2.617
Hence,
We take it as 12 tubes as the number of tubes should be even and divisible by 4 as the arrangement is a square pitch.
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Mean temperature:
Hence, the wall temperature is 350C. Table 10: Physical Properties of Propane @ 350C[26] Liquid Density (L) @ 350C Liquid Viscosity (L) @ 350C Liquid Thermal Conductivity (kL) @ 350C 514.13 Kg/m3 0.11321 centi-poise 0.095W/m K
Vapour Density @ 40 0C mean vapour temperature (V) = 28.6 Kg/m3 Using Kerns Method [27], the mean transfer coefficient for the tube bundle is given by: ( [ Where, )
( )
Wc = Flow rate of the distillate in Kg/sec L = Length of the tubes Nt = Number of tubes
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( )
The value obtained is close enough to the value assumed (1500W/m 2K), hence the estimated Tw is acceptable.
Where, hi = inside coefficient for water t = mean water temperature ut = water velocity di = tube inside diameter
ut can be calculated from the internal diameter of the tube Tube Cross- Sectional Area;
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Density of water at 27.50C (mean water temperature in the tubes) = 995.65 Kg/m3
Hence, substituting the values of velocity, the heat transfer coefficient of water inside the tube is;
Where, U = the overall coefficient based on the outside area of the tube, W/m 2 0C ho = outside fluid film coefficient, W/m 2 0C hi = inside fluid film coefficient, W/m 2 0C hod = outside dirt coefficient; fouling factor, W/m 2 0C hid = inside dirt coefficient; fouling factor, W/m 2 0C kw = thermal conductivity of the tube wall material, W/m0C di = tube inside diameter, m do = tube outside diameter, m
Fouling Factors: As neither of the fluid is heavily fouling, the dirt coefficient at both the sides has been assumed to be 6000 W/m 2 0C and kw is assumed to be 50 W/m0C
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The value obtained is significantly lower than the assumed value of 600 W/m2 0C The calculation has to be repeated using different values of Overall heat transfer coefficient by trial and error method; and the closest possible answer firms up the final design. The calculations are redone with a new value of 500 W/m2 0C
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Where,
And
Again using Eagle and Fergusons (1930) formula tube side coefficient is calculated. But the velocity of the water in the tubes changes;
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Hence, the new calculated value for the Tube Side Coefficient;
The results are satisfactory. The values obtained are close enough to the values assumed hence, the design is confirmed.
Pull through Floating head is used, no close clearance is required. 35% cut of the Baffle Spacing A condenser has wider baffle spacing, lB Ds
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Where, Jf = Friction factor L = Length of the tubes Lb = baffle Spacing All the unknowns are calculated below.
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Cross Sectional Area As for the hypothetical row of tubes at the Shell Equator
Linear Velocity us
Shell Side Equivalent Diameter; de The equivalent diameter for a square pitch arrangement is given by;
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Friction Factor; jf Friction factor is estimated from a graph in FIG; which is a correlation between Reynoldss number and baffle cut. Hence,
Graph 6: Shell side Friction Factor; Segmental Baffles From the graph Friction Factor is determined to be 4.8 *10-2
Substituting all the above calculated values in the pressure drop equation;
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The Pressure drop is negligible; hence more sophistication calculation is not justified.
Hence,
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Graph 7: Tube side Friction Factor Hence from the graph below, Jf = 9*10-3 Substituting the values in the pressure drop equation;
The pressure drop is almost negligible due to the following reasons: The flow is laminar as Re < 2000 The velocity of the cooling water is very low Only one tube pass is used, hence there is a straight pipe through which the pipe flows.
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6.0 REBOILER: Reboilers are used with the distillation column to vaporise a fraction of the bottom product. There are three different kind of reboilers used: [28] Forced Circulation; where the fluid is pumped through the exchanger. The vapour formed is separated and sent back to the bottom of the distillation column and rest is removed.
Figure 22: Forced Circulation Reboiler http://upload.wikimedia.org/wikipedia/commons/a/a7/ForcedCirculation.png Thermosyphon, unlike forced circulation it has natural circulation. The liquid circulation is maintained by the difference in densities of the two-phase mixtures of vapour and liquid. These kinds of Reboilers can have vaporisation on the tube side; when they are vertically placed or the vaporisation occurs on the shell side, when placed horizontally.
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In the above equation, the H (Heat of Vaporisation) is considered only for 1, 3 Butadiene as major fraction of the component entering the Reboiler comprises of 1, 3 Butadiene. Minor fractions of propane, pentane and 1, 2 Butadiene is ignored. This would not affect the result drastically as the Heat of vaporisation of the other components somewhere lies in the same range.
Hence, Assuming; that the bottom product is liquid at boiling point which enters the Reboiler at 368K.
Heat obtained by the process fluid is the heat lost by the steam entering the Reboiler. Richie Gandhi SUN-075909279 Page 66
After careful judgement, it is concluded that a Horizontal Thermosyphon Reboiler would be used with this distillation column, since the horizontal reboilers require less headroom. These are most economical type of reboilers for most application and are not suitable for high viscous fluids. The fluids in the column have very low viscosity. Also these reboilers are suitable for high temperatures and high pressure which fulfil the demands for this unit. The only disadvantage with this kind of reboiler is that a hydrostatic head is required for the thermosyphon effect which requires elevation of the column base. This problem can be overcome by using supporters at the distillation column is not huge.
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The Energy Balance over the column could not be calculated in the first part of the assignment as the Reflux Ratios were unknown. The Heat Duty over the Condenser and the Reboiler is calculated. It is summarised in the table below. Units Condenser Reboiler Total Energy Required - 421.826KW -323.392 KW Energy Released 98.434 KW -
The Negative Sign shows that the Energy is required to run the unit.
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8.0 Piping and Instrumentation Diagram The Piping and Instrument diagram (P and ID) shows the engineering details of the equipment, instruments, piping, valves and fittings and their arrangements which is not detailed in the process Flow sheet. It should include the following. [29] [30]
All process equipment identified by an equipment number. The equipment should be drawn roughly in proportion, and the location of nozzles shown. All pipes, identified by a line number. The pipe size and material of construction should be shown. The material can be included as part of the line identification number.
All valves control and block valves, with an identification number. The type and size should be shown. The type may be shown by the symbol used for the valve or included in the code used for the valve number.
Pumps identified by a suitable code number. All control loops and instruments, with an identification number. For simple processes, the utility (service) lines can be shown on the P and I diagram. For complex processes, separate diagrams should be used to show the service lines, so the information can be shown clearly, without cluttering up the diagram.
Since the Process of Butadiene production is very complex which includes many units, the P and ID is only done over the Propane Distillation Column which is attached in Appendix, 6 (issue number 002) The basic units and symbols used in the P and ID are briefly described below: Control Valves [31]: The parameters such as temperature, pressure, flow and level are controlled by the control valve. Control Valves can be manual or automatic which are partially or fully open or closed. The action of the control valves are in response to the signals received from their respective controllers that compare the set-point to the process variables.
Gate Valve [32]: These valves are opens by lifting a round or rectangular wedge out of the path of the fluid. Gate valves are used when a straight-line flow of fluid and minimum restriction is desired. These valves should never be used as control valves unless those are specifically designed for it. Typical gate valves are designed to be fully opened or closed. There is very low frictional loss when the valve is fully open due to negligible obstruction. Gate valves are present before and after every control valve and pump which offers effortless maintenance during equipment failure.
Transmitters: These are sensors which monitor the changes in the process variables and simultaneously send signals to the controller.
T
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Drain Valve: As the name suggests, these valves are used to drain the components from the unit or pipelines. These are generally closed and are in operation usually during site or unit maintenance.
Relief Valve: The relief valve is a type of valve used to control or limit the pressure in a system or vessel which can build up by a process upset, instrument or equipment failure, or fire. The pressure is relieved by allowing the pressurised fluid to flow from an auxiliary passage out of the system. Since the distillation Column taken into consideration is operating under high pressures, a relief valve can act as a precautionary measure which would help to get rid out the extra pressure built up into the unit. It is built on the reflux drum, as building it over the column can lose its components in the vapour phase that is released. As it is the last stage the purified butadiene cannot be afforded to be wasted.
RV-1
Pneumatic Lines: The signals transmitted from a controller to the valve are generally shown by pneumatic lines on a P and ID.
Electric Lines: The dotted lines show the transmission of electric signal in the P and ID. The electric signal is send by the transmitter to the controller.
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FC 1: the feed pipe is installed with a flow controller, which helps to control the flow throughout the pipe. The flow rate is received as input to the FT-1, which then sends output signals to the flow controller FC, which then sends on information to the automated control valve CV-1. This ensures a steady state and control flow rate of feed to the distillation column. PC 1: The distillation column is operating under high pressures. The pressure is a very crucial variable and has to be controlled to avoid flooding. The pressure is read by a pressure gauge and this input is received by a PT1 which sends signal to the PC 1 which then forwards the information to the control valve on the condenser. The condenser would reduce the flow rate of water if the pressure drops; this intern increases the temperature of the distillate entering the reflux drum as desired heat exchange was not possible; which increases the Richie Gandhi SUN - 075909279 Page 69
LC 1: For desired separation to take place, it is important to maintain the ratio of the distillate to the reflux Liquid. Hence it is vital to maintain the level in the reflux drum. The level is read by a level indicator which sends the information to the LT 1 which further forwards the signal to the control valve on the pipe back to the condenser. If the level in the drum falls, the controller sends signal to close the valve which results in maintaining the level in the drum.
TC 1 and FC 2: The temperature should be well maintained inside the column to provide vaporisation of the volatile fluids for desired separation. Heat is provided by the steam flow in the reboiler. Hence a controller valve is installed on the pipe which carries steam to the reboiler. This controller receives signal from the flow transmitter (FT2) or the temperature transmitter (TT1). If the temperature inside the column reduces, the controller sends signal to the control valve to open slightly. This increases the flow rate of steam into the reboiler increasing the temperature of the column.
LC 2: Flooding is a problem commonly faced by distillation columns if the design is poor. Sometimes blockage in the support systems inside the column can cause obstruction to the passage of the liquid and the gases. This can increase the level in the column resulting in spillage of the valuable product. A level controller is installed in the pipe leaving the column at the bottom. This control valve receives signals from the level controller which gets its input from the level transmitter. If the level in the column falls down, the valve closes slightly to maintain the level and prevent it from becoming dry. Also when the level falls down too low or rises to high, the alarms blow up which would alert the operators to take serious actions immediately like evacuating the plant or shutting all the valves and stopping the flow rates.
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A combination of automated valves, flow and temperature indicators along with controllers are used to control the process. Investment in these instruments and the control system is required and is necessary. The control system along with the PID is then checked by senior manager and engineers over a HAZOP meeting. Changes are made to the control and the PID before the system is installed, in such a way money is saved and at the same time safety of the operator is ensured. Since Hazop was carried out on this section of the process, there were certain changes made from the previously designed control loop system. Issue 001 in Appendix VI shows the draft copy of the previously designed P and ID which was then improvised to Issue 002
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After calculating all the values over my distillation column I conclude that one distillation column can be used to separate propane and recover 1,3 butadiene. A stepped column can be used as the diameter for the pentane distillation column, (the unit where the 1,3 butadiene is pumped to for further purification.) is 2 m as suggested my group mate. Since the diameter for the propane distillation column is 0.65m the top part of the column can have this diameter and the lower part of the column should have a diameter of 2m. This can reduce the operating costs and also a significant amount of raw material to build the column would be reduced. Also a separator can be used instead of a distillation column, but the temperature has to be reduced too low, to obtain such separation. This can be more expensive than providing high pressure inside the column.
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