Académique Documents
Professionnel Documents
Culture Documents
Session: 2010-2014
Project Supervisor
Engr. Khaqan Javed
Project Co-Supervisor
Engr. Aamir Ali
Submitted by
Beenish Younis Cheema
2010-UET-ShCET-LHR-CE-10
Muhammad Usama
2010-UET-ShCET-LHR-CE-12
Bilal Ahmad
2010-UET-ShCET-LHR-CE-26
Muzammil Muzaffar
2010-UET-ShCET-LHR-CE-27
Bachelor of Science
In
Chemical Engineering
Session 2010-2014
External Examiner:
________________
________________
Co-Supervisor:
Chairman:
________________
________________
DEDICATION
This project work is dedicated to our beloved parents, respected teachers and
to all those people, who are working to make our motherland Pakistan a
Prosperous country.
Acknowledgment
We take on the initiation with the prestiges name Almighty ALLAH, lord,
designer, builder of the most complex processing plants; the human body. Its
accurate and sophisticated fluid transportation, gas absorption, filtration,
chemical reactions and electronic control systems with partial mechanical
structural capillaries is a product of HIS engineering that we strive to understand
and duplicate WHO gave us caliber, incentives and courage to complete this
project within prescribed limits and to the HOLY PROPHET MOHAMMAD (S.A.W)
who showed light of knowledge to the humanity as a whole.
The ideas of report writing are usually attributable to all of the group members
and the sources, which helped us a lot to compile it. This is all due to the
illuminated guidance of our teachers as they are builders of our academic
carrier, all this could not have been done without their enlightened supervision
and coaching. For this we are very much grateful to them, especially Engr.
Khaqan Javed and Engr. Aamir Ali who spared a lot of their precious time in
advising and helping us throughout our project.
It is with great pleasure and extreme feelings of obligation that we thank
professor, Dr. Khalid Qamar (Director of Sharif College of Engineering and
Technology (affiliated with UET), Lahore) and Dr. Anwar-ul-Haque (Head of
Chemical Engineering Department SCET) for their constructive criticism and
valuable suggestions during our academic carrier.
Last but not Least, we owe immense sense of gratitude to our parents who not
only supported us financially throughout our education but gave us the strength
of character and would always remain as beacon of light for us.
Preface
The design report on the production of Linear Alkyl Benzene (LAB) from Crude Oil
is a very useful process used worldwide for the production of LAB, we chose this
project as there is no plant in Pakistan which produces LAB.
The design report of our project is made very carefully and honestly, so hopefully
the content is adequate for the basic understanding of the process as each
and every aspect is discussed in detail with clear visual graphics. All the
designing and calculations are done by using up to date correlations of heat
transfer, mass transfer and equipment design. This report should also be useful to
the engineers in the chemical engineering department.
All the calculations are done in English units and the cost estimation is done in
dollars. The references are given in detail at the end of the report so each can
be accessed easily.
Separate chapters are devoted to each of the step for the designing of a
project including introduction, process description, material and energy
balances and equipment design. For the good operation and safety purpose,
the instrumentation of equipment is done and explained in a separate chapter.
Also, the project cost evaluation is done in the other chapter. Environmental
impacts are also discussed in the last chapter.
Authors
Table of Contents
1. INTRODUCTION ... 11
1.1
1.2
1.3
1.4
Synopsis ....... 11
Refineries . 12
List of refineries in Pakistan . 13
Properties and uses of product . 13
3. PROCESS DIAGRAMS 18
3.1
3.2
3.3
3.4
Introduction .................................... 83
The Importance of Process Control ......... 83
Learning objectives .................... 84
Process control ........................... 84
Process variables ...... 85
8
6.6
6.7
6.8
6.9
Objectives ...... 85
Process Control over Fractionating Column-1 ..... 86
Cascade Control .......... 87
Feedback Control ........ 88
7. COST ESTIMATION .. 89
7.1
7.2
7.3
7.4
8. HAZOP STUDY 98
8.1
8.2
8.3
8.4
8.5
8.6
REFERENCES .. 109
List of Figures
Fig. 1.1a
Fig. 3.1a
Fig. 3.2a
Functional Diagram .. 19
Fig. 3.3a
Fig. 3.4a
Fig. 4.1a
Fig. 5.1a
Fig. 5.2a
Fig. 5.2b
Fig. 5.2c
Fig. 5.4a
Fig. 6.7a
Fig. 8.5a
10
Chapter 1
Introduction
1.1 Synopsis
Current statistics shows an ever increasing demand for Linear Alkyl Benzene
(LAB). There is no plant in Pakistan that produces LAB. Statistics show that 150-200
metric tons/day of LAB is being imported in Pakistan. These statistics inspired us
to prefer this project over other projects. Regional LAB capacity statistics are
shown in the figure mentioned below:
Figure 1.1a
Pakistan is the one which has no plant to produce LAB as it is a very large scale
industry and this plant is expensive to install as well. According to the emerging
needs of LAB it is necessary to install a plant in Pakistan as well. We have tried to
work on the project so that we can contribute towards the progress of our
country. This project is an integration of petroleum and chemicals therefore it
comes under the category of petrochemical industries.
1.2 Refineries
Different types of refineries are as follows:
Lube oil Refineries
Fuel oil Refineries
Petroleum to Petrochemical Refineries
A refinery breaks down crude oil into its various components (petroleum
products). These components are then selectively changed into new products.
Refinery has always been very alluring for Chemical Engineers. There is a lot to
become skilled at in refineries for Chemical Engineers. It has an assortment of
Unit Operations and Processes. So, as Chemical Engineers we are inclined
towards a refinery project. In an interview with James Murphy (Process Design
Engineer for the Richmond Refinery) he advised students and I quote:
12
14
Chapter 2
Process Description
2.1 Brief Overview of Process
Starting with Crude Oil, it is transformed into its fractions from there on higher
carbon chains in Kerosene are estranged as they are requisite for LAB
production. Carbon chains then go through two reactors to remove most of the
impurities. In the end with the help of Gas Separator impurities are estranged.
Preferred Carbon chains are then sent to Molex Unit. After Molex Unit it goes into
Alkylation Unit from where we attain LAB. We are restricting our project till the
production of n-Paraffins. To design all the process in such a short period is not
an achievable goal.
16
Molex Unit
Alkylation Unit
We will be working on the following units as to cover the whole production unit
was beyond our ranger and also there is not enough time.
Atmospheric Distillation Unit
N-paraffin Production Unit
In atmospheric distillation unit we get fractions at different boiling points as
crude oil is separated into its fractions and from there on undesired fractions are
cooled down and sent to further treating units whereas desired carbon chain
from kerosene goes further to N-paraffin production unit where it is treated to
give us required chain of N-paraffin to be utilized in the production of Linear
Alkyl Benzene.
17
Chapter 3
Process Diagrams
3.1 Input/ Output Diagram
Figure 3.1a
18
Figure 3.2a
Figure 3.3a
19
Figure 3.4a
20
Chapter 4
Material and Energy Balance
4.1 Material and Energy balance over equipments
Material and energy balances are fundamental to many engineering
disciplines and have a major role in decisions related to sustainable
development. Material and energy balances are very important in an industry.
Material balances are fundamental to the control of processing, particularly in
the control of yields of the products. The first material balances are determined
in the exploratory stages of a new process, improved during pilot plant
experiments when the process is being planned and tested, checked out when
the plant is commissioned and then refined and maintained as a control
instrument as production continues. When any changes occur in the process,
the material balance needs to be determined again.
The increasing cost of energy has caused the industries to examine means of
reducing energy consumption in processing. Energy balances are used in the
examination of the various stages of a process, over the whole process and
even extending over the total production system from the raw material to the
finished product.
21
Figure 4.1a
23
24
25
26
Furnace-1 (F-1)
27
28
Stripper-1 (ST-1)
29
Stripper-2 (ST-2)
30
31
32
Mixer-1 (MX-1)
33
34
35
36
37
38
39
40
Chapter 5
Equipment Design
5.1 Plug Flow Reactor (PFR-1) Design
The plug flow reactor (PFR, sometimes called continuous tubular reactor CTR,
or piston flow reactors) is a model used to describe chemical reactions in
continuous, flowing systems of cylindrical geometry. The PFR model is used to
predict the behavior of chemical reactors of such design, so that key reactor
variables, such as the dimensions of the reactor, can be estimated.
A tubular reactor is a vessel through which flow is continuous, usually at steady
state, and configured so that conversion of the chemicals and other dependent
variables are functions of position within the reactor rather than of time. In the
ideal tubular reactor, the fluids flow as if they were solid plugs or pistons, and
reaction time is the same for all flowing material at any given tube cross section.
Tubular reactors resemble batch reactors in providing initially high driving forces,
which diminish as the reactions progress down the tubes. On the coming page
a general schematic diagram represents a tubular reactor in which along the
length concentration changes:
41
Figure 5.1a
(Schematic diagram of an ideal plug flow reactor)
Characteristic of an ideal plug flow:
Perfect mixing in the radial direction (Uniform cross-section concentration)
No mixing in the axial direction or segregated flow.
Flow in tubular reactors can be laminar, as with viscous fluids in small-diameter
tubes, and greatly deviate from ideal plug-flow behavior, or turbulent, as with
gases. Turbulent flow generally is preferred to laminar flow, because mixing and
heat transfer are improved. For slow reactions and especially in small laboratory
and pilot-plant reactors, establishing turbulent flow can result in inconveniently
long reactors or may require unacceptably high feed rates.
Catalytic hydrogenation is done in a tubular plug-flow reactor (PFR) packed
with supported catalyst. The pressures and temperatures are typically high,
although this depends on the catalyst.
This is the reason we chose tubular plug-flow reactor and the catalyst used is
Nickel (Ni)
42
Reaction
C4H4S
3H2
C4H8
H2S
Where;
r = Rate of Reaction
k = Rate Constant
CT = Concentration of Thiophene
CH = Concentration of Hydrogen
Rate Constant
Using Arrhenius Equation to calculate rate constant
[5]
Concentrations
= .
43
Type of Catalyst
Catalyst used is Palladium Sulfide (PdS), as it is a very commonly used catalyst to
carry out hydrogenation reactions. Some physical properties are:
Where,
= 1.238
Rate Constant= K1
= 0.0186
Reactant Concentration=
= 0 .77
=1
Conversion= XA
= 0.66
44
= .
.
.
= .
Where;
Space Time=
Volume of Reactor=
= 9.62 ft3
= 29088.7
Reactor Geometry
Length of Tube= Lt
= 9 ft
= 0.17 ft
= 0.13 ft
. .
.
= .
Pressure Drop
To calculate pressure drop [7] for tube side we use Eurgen equation;
Where;
=[
][
][
= 0.55
Particle Diameter= DP
= 0.054 ft
Feed Density = f
= 0.032
Viscosity of Feed =
= 0.000021
Length = Lt
= 9 ft
+ .
46
gc
= 32.17
=
=
. .
= .
= .
=
.
= .
Putting all the above values in Eurgen equation to calculate pressure drop;
=[
.
.
][
=[
Material of Construction
][
][
][
.
.
+ .
]
+ .
The reactor tubes are suggested to be of stainless steel so that any kind of
corrosion is avoided.
Where,
= [
+ ]
= [
= [
=
= .
Shell Height
= .
+ ]
. + ]
As assumed above;
Length of Tube= Lt = 9 ft
To calculate Shell height we leave 20% space above and below. So;
=
Pressure Drop
.
.
.K
48
.
.
Where;
= 2.41 ft
= 80
= 0.17 ft
=
[ .
= .
]
.
49
=[
=[
= 3.14 ft
=
=
=
Viscosity of Water= 0.00059
.
.
=
=
=
Where;
=
.
. .
Pressure drop= PS
50
= 1544.4
Length of Tube= Lt
= 9 ft
Baffle Spacing= B
= 1.3 ft
= 0.0015
Equivalent Diameter= De
= 3.14 ft
= 2.41 ft
Specific Gravity= s
= 0.998
Shell Thickness
= 83
=1
= .
.
.
.
.
(Negligible)
Where,
= 2880000
51
Di = Shell diameter
= 2.41 ft
= 5079
C = Corrosion allowance
Material of Construction
= .
+
+ .
52
Shell Side
Tube Side
Length = 9 ft
ft2
No. of Tubes = 80
Pitch = Triangular
Temperature = 513 K
Catalyst
Weight = 243.5 lb.cat
Volume = 4.33 ft3
Bed Void Fraction= 0.33
Particle Diameter= 0.0196 ft
53
Figure 5.2a
54
Figure 5.2b
Sequence for desired distillation is selected on the basis of some classifying rules.
Rule of thumb for Distillation Sequence
Remove thermally unstable, chemically corrosive, or chemically reactive
components early in the sequence.
Remove final products one-by-one as distillates (the direct sequence).
Separate early in the sequence, those components of greater molar
percentage parentage in the feed.
55
Figure 5.2c
56
K
Xi,f
Xi,d
549
C1
0.002302 0.002326
C2
0.018419 0.018606
C2=
0.020722 0.020931
527
523
260
C3
0.07598
0.076748
C4
0.08519
0.086051
C5
0.004605 0.004651
C5=
0.001151 0.001163
C6
0.010361 0.010466
iC6
0.008059
0.00814
n-C7
0.02145
0.0214
i-C7
0.013673
0.0136
n-C8
0.014401
0.0143
n-C9
0.019917
0.0199
n-C10
0.029694
0.0296
i-C10
0.010948
0.0109
n-C11
0.013837
0.0137
C-11=
0.01325
0.0132
i-C11
0.004182
0.004
175
102
101.3
68
67.3
51
50.7
34
26.06667
19.83333
19.66333
13.03333
12.86333
12.46667
10.2
n-C12
n-C13
(H.K)
0.017313
0.012
0.01202
0.0119
7.026667
57
6.233333
n-C14
0.043232
0.0431
n-C15
i-C15
(L.K)
0.034545
0.0345
0.021414
0.0214
C16
0.046869
0.0468
C17
0.033636 0.033976
C18
0.027374
C19
0.028889 0.029181
C20
0.013131 0.013264
C21
0.017071 0.017243
C22=
0.012323 0.012448
C23
0.030505 0.030813
C23=
0.018788 0.018978
4.533333
4.363333
3.343333
2.096667
1.87
0.02765
1.53
1.133333
1.02
0.793333
0.566667
0.555333
0.51
C24
0.048485
C25
0.067879
C26
0.04202
C27
0.019394
C28
0.022626
C29
0.025859
C30
0.032323
C31
0.006465
0.436333
0.357
0.226667
0.187
0.147333
0.130333
0.113333
Column-1
Calculation of Number of Plates [10]
58
X X
ln LK HK
X HK d X LK
Nm
ln LK
Nmin = 2.59
Ideal Number of Plates from graph = 3
Calculating minimum reflux ratio using Colburns equation [10]:
Rmin
X dL
X
AB dH
X nH
( AB 1) X nL
1
Rmin = 0.99
Net Area [11]
An = mv/un
Where
mv= Vap flow rate(ft3/s) = 1.87 ft3/s
un= Actual vapor velocity(ft./s) = 0.2182 ft3/s
An = 2.179 ft2
Column Area
Down comer area = 15% * Cross Sectional Area
59
Ac = 2.394 ft2
Diameter of column
Ac = (pi/4)*(Dc)2
Dc = 1.74 ft
Downcomer Area
Ad = 0.15*Ac
Ad = 0.2155 ft2
Active Area [10]
Aa = Ac-2*Ad
Aa = 1.963 ft2
Hole Area [11]
Ah = (Ah / Aa) * Aa
Ah/Aa =0.1
Ah = 0.1374 ft2
Specification Sheet
Column-1
Sequence
Indirect
60
Column temperature
673.5 F
Column pressure
4 psi
Column diameter
1.74 ft
2.59
3.01
Type of column
Tray
Tray type
Sieve
Tray spacing
0.5
Active Area
1.96 ft2
Hole Area
0.137 ft2
Material of construction
Carbon steel
Column-2
Calculation of Number of Plates
61
X X
ln LK HK
X HK d X LK
Nm
ln LK
Nmin = 13.8
Ideal Number of Plates from graph = 15.3
Calculating minimum reflux ratio using Colburns equation:
Rmin
X dL
X
AB dH
( AB 1) X nL
X nH
1
Rmin = 0.5
Net Area
An = mv/un
Where
mv= Vap flow rate(ft3/s) = 1.97 ft3/s
un= Actual vapor velocity(ft./s) = 0.3182 ft3/s
An = 3.302 ft2
Column Area
Down comer area = 15% * Cross Sectional Area
Ac = 3.71 ft2
62
Diameter of column
Ac = (pi/4)*(Dc)2
Dc = 2.086 ft
Downcomer Area
Ad = 0.15*Ac
Ad = 0.3339 ft2
Active Area
Aa = Ac-2*Ad
Aa = 3.04 ft2
Hole Area
Ah = (Ah / Aa) * Aa
Ah/Aa =0.1
Ah = 0.2129 ft2
Specification Sheet
Column-2
Sequence
Indirect
Column temperature
630 F
63
Column pressure
5 psi
Column dia
2.08 ft
13.8
15.3
Type of column
Tray
Tray type
Sieve
Tray spacing
0.5
Active Area
3.04 ft2
Hole Area
0.21 ft2
Material of construction
Carbon steel
Column-3
Calculation of Number of Plates
Calculating minimum number of plates using Fenskees equation:
64
X X
ln LK HK
X HK d X LK
Nm
ln LK
Nmin = 3
Ideal Number of Plates from graph = 4.1
Calculating minimum reflux ratio using Colburns equation:
Rmin
X dL
X
AB dH
( AB 1) X nL
X nH
1
Rmin = 0.45
Net Area
An = mv/un
Where
mv= Vap flow rate(ft3/s) = 1.77 ft3/s
un= Actual vapor velocity(ft./s) = 0.291 ft3/s
An = 2.233 ft2
Column Area
Down comer area = 15% * Cross Sectional Area
Ac = 2.627 ft2
Diameter of column
65
Ac = (pi/4)*(Dc)2
Dc = 1.755 ft
Downcomer Area
Ad = 0.15*Ac
Ad = 0.236 ft2
Active Area
Aa = Ac-2*Ad
Aa = 2.15 ft2
Hole Area
Ah = (Ah / Aa) * Aa
Ah/Aa =0.1
Ah = 0.1508 ft2
Specification Sheet
Column-3
Sequence
Indirect
Column temperature
540 F
Column pressure
5.7 psi
66
Column dia
1.75 ft
4.1
Type of column
tray
Tray type
sieve
Tray spacing
0.5
Active Area
2.15 ft2
Hole Area
0.15 ft2
Material of construction
Carbon steel
69
70
LMTD
350 133.45
= 222.29oF
T2 T1
8.064
t 2 t1
t 2 t1
0.015
T1 t1
Ft [23]
1-2 exchanger: Ft (possible)
The four 1-2 exchangers in series are more adequate for heat transfer.
Tm = (.97) x (222) =229 oF
tc = 137.4 - 133.4 = 3.72 oF
th = 380 - 350 = 30 oF
tc/th = 0.124
Kc = 0.344
Fc = 0.21
Tc = T2 + Fc (T1-T2) = 360.5 oF
Tc = t1+Fc (t2-t1) = 134.29 oF
Tube Specifications [24]
71
Length = 6 ft
OD, BWG, pitch = 3/4in, 16 BWG, 1in Square pitch
Passes = 2
Outside surface area per linear ft. = a = 0.1963 ft2
Flow area of tube, at = 0.302 in2
Ud = 32 (for dirt factor of .003 and allowable pressure drop 5 to 10 psi)
Estimation of Heat Transfer Area [25]
A = Q/ Ud *Tm = 32.13
No. of tubes = Nt = A/ a*L = 28 (for 1 exchanger)
Nearest Count =Nt = 32
Shell ID = 8 1/2 in
Baffle spacing = 5 in
New Area = (outside surface area/linear foot x no. of tubes x tube length)
= (.1963 x 32 x 6)
= 37.68 ft2 (For One Heat Exchanger)
Hot Fluid (Tube Side) [26]
= 1+2/2=365
ab 0.302 in2
at
Ntat
144 n
72
= 0.334 ft2
Gt
W
at
=3616411 lb/hr.ft2
Tc = 360.5 oF
= 8.712 lb/ft.hr
Re = DGt/
= 0.0156*3616411/8.712 =21249
Jh = 80
For = 0.23 cp and 70 o API
ho
J h k Cp
1/ 3
(
k )
De
K*(C/k)1/3 = 0.398
s = 1
hi = 616.49 Btu/hr.ft2 oF
h io = ho x ID/OD
= 616.49 x 0.012
=509.44 Btu/hr.ft2 oF
Cold Fluid (Shell Side)
as
ID C B
144 Rt
73
as
8 ..1875 1.6
= 0.333 ft2
144 1
Gs = W/as
= 11800/0.333 = 354000 lb/hr.ft2
At tc = 421oF
= 0.23 lb/ft.hr
De DGt/
Re
0..0458 354000
= 29150.2
0.23
jH = 98
Cp = 0.69 Btu/lb oF
1/ 3
k C
ho jH
De k
= 363.49 Btu/hr.ft2 oF
Clean overall coefficient for preheating Uc
[26]
74
Tube side
Re = 21429.39
f = 0.00024 ft2/m2
Specific gravity
= 0.7
fGt2 Ln
Pt
5.22 1010 DeSt
= 9.34 psi
Shell Side
Re = 29150.4
De =0.62 in= 0.0516
f = 0.0010
No. of crosses = N + 1 =12 Lp/B
= 6*12/5
D=8/12= 0.666 ft
= 0.44 Psi
Specification Sheet
Area
32.17ft2
75
Diameter of shell
8 in
Number of Tubes
32
Type of tube
Plain
Tube length
6 ft
Material of construction
Carbon steel
Dirt factor
0.031(hr)(ft2)( F)/Btu
0.446psi
9.43 psi
76
Figure 5.4a
FEED
176.66
TOP
335
BOTTOM
350
11800
7540
4259
Composition
0.03
0.01
78
n-C8
n-C9
n-C10
i-C10
n-C11
i-C11
n-C12
C12=
n-C13
n-C14
n-C15
i-C15
n-C16
n-C17
n-C18
C4H4S
472
1144.6
2124
472
1416
354
1062
212.4
944
1062
354
47.2
1180
247.8
129.8
106.2
0.04
0.097
0.18
0.04
0.12
0.03
0.09
0.018
0.08
0.09
0.03
0.004
0.1
0.021
0.011
0.009
TP
n-C7
i-C7
n-C8
n-C9
n-C10
i-C10
n-C11
i-C11
n-C12
C4H4S
Cmpstn
0.03
0.01
0.04
0.097
0.18
0.04
0.12
0.03
0.09
0.002
Press (psi)
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
k
(335F)
5.99
5.73
2.97
1.73
1.05
1.01
0.44
0.39
0.24
0.20
Vap Press
(600F)
95
61
52
33.5
32
k
(600F)
6.46
4.15
3.54
2.28
2.18
x (dew
pt)(335F)
0.01
0.00
0.01
0.06
0.17
0.04
0.27
0.08
0.38
0.01
1.02
Cmpstn
0.018
0.08
0.09
0.03
0.004
Press (psi)
14.7
14.7
14.7
14.7
14.7
y (bbl pt)
0.12
0.33
0.32
0.07
0.01
79
n-C16
n-C17
n-C18
C4H4S
0.1
0.021
0.011
0.007
14.7
14.7
14.7
14.7
24
19
14
3.3
1.63
1.29
0.95
0.22
Vap Press
(350F)
100
99.3
48
29
17
16.4
8.7
8.4
5.3
4.9
3.1
2
1.4
1.1
0.7
0.5
0.31
0.04
k
(350F)
6.80
6.76
3.27
1.97
1.16
1.12
0.59
0.57
0.36
0.33
0.21
0.14
0.10
0.07
0.05
0.03
0.02
0.00
0.16
0.03
0.01
0.00
1.05
FEED
n-C7
i-C7
n-C8
n-C9
n-C10
i-C10
n-C11
i-C11
n-C12
C12=
n-C13
n-C14
n-C15
i-C15
n-C16
n-C17
n-C18
C4H4S
Cmpstn
0.03
0.01
0.04
0.097
0.18
0.04
0.12
0.03
0.09
0.018
0.08
0.09
0.03
0.004
0.1
0.021
0.011
0.009
Press (psi)
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
14.7
y (bbl pt)
0.20
0.07
0.13
0.19
0.21
0.04
0.07
0.02
0.03
0.01
0.02
0.01
0.00
0.00
0.00
0.00
0.00
0.00
1.01
80
Nm
X X
ln LK HK
X HK d X LK
ln LK
81
Column Area
Down comer area = 15% * Cross Sectional Area
Ac = 3.627 ft2
Diameter of column
Ac = (pi/4)*(Dc)2
Dc = 1.317 ft
Downcomer Area
Ad = 0.15*Ac
Ad = 0.10 ft2
Active Area
Aa = Ac-2*Ad
Aa = 0.98 ft2
Hole Area
Ah = (Ah / Aa) * Aa
Ah/Aa =0.1
Ah = 0.18 ft2
Height of Column
82
Total Height = ((no. of trays -1) Tray spacing) + (no. of trays width of tray +
(0.25diameter) + 1
Total Height = 11.31 ft
Specification Sheet
1.317
12
Reflux Ratio
2.56
14.7
11.31
Tray Type
Sieve
0.7
1.17
0.98
0.18
0.10
Material of Construction
Carbon Steel
83
Chapter 6
Instrumentation and Process Control
6.1 Introduction
Control in process industries refers to the regulation of all aspects of the process.
Precise control of level, temperature, pressure and flow is important in many
process applications. This module introduces you to control in process industries,
explains why control is important, and identifies different ways in which precise
control is ensured. The following five sections are included in this module:
The importance of process control
Control theory basics
Components of control loops and ISA symbology
Controller algorithms and tuning
Process control systems
84
Ensure safety
6.6 Objectives
Define control loop
Describe the three tasks necessary for process control to occur:
Measure
Compare
86
Adjust
Process variable
Set point
Manipulated variable
Measured variable
Error o Offset
Load disturbance
Control algorithm
Figure 6.7a
87
In the above diagram two different type of control schemes are illustrated
which are:
Cascade Control
Feedback Control
88
PI controller is used
89
Chapter 7
Cost Estimation
7.1 Equipment Costs
Plug Flow Reactor
Material of Construction: Carbon Steel
Purchased cost (2004) [14]:
ost @
Where,
ost @
of construction).
= $8347
ost @
index @
= 463 [15]
index @
=(
index @
) ost @
90
index @
= 1024 [15]
ost @
for reactor = $
ost @
for reactors = $
Heat Exchanger
Shell: Carbon steel
Tubes: Carbon Steel
Purchased cost (2004):
According to graph [16] for
Area
= 3.5 m2
Pressure
= 1.01 bar
Purchase Cost @ 2004 = Bare Cost * Type factor * Pressure factor
= $63000 (0.8) (1.0) = $50400
ost
index
index
ost @
91
ost
ost @
ost @
=
for . E = $
for . E = $
Vessel Height
= 8.37 m
Vessel Diameter
= 1.69 m
$900* 1.7
= $1530
22 plates
92
ost
index
index
ost
ost @
ost @
=
for . D. = $
Fractionating Column
Shell: Carbon Steel
Plates: Stainless Steel 410
Purchased cost (2004):
Vessel purchase cost according to graph [17] for
Vessel Height
= 3.44 m
Vessel Diameter
= 0.3991 m
$1000* 1.7
= $1700
12 plates
ost
=
ost
ost @
ost @
index
index
ost @
=
for . = $
for . = $
Centrifugal Pump
Material of Construction: Stainless Steel 316
Purchase Cost @ 2004 = $5000
Index @ 2004 = 463
Index @ 2015 = 1024
94
ost
index
index
ost
ost @
ost @
=
for ump = $
ost @
for
ump = $
Mixer
Material of Construction: Carbon Steel
Purchased cost (2004):
Purchase Cost of Tank @ 2004 = $996
Purchase Cost of Propeller @ 2004 = $319
Total cost of Mixer @ 2004 = 996 + 319= $ 1315
Present Cost (2015):
Index @ 2004 = 463
Index @ 2015 = 1024
ost
=
ost
index
index
ost @
=
95
ost @
for ixer = $
Gas Separator
Purchase Cost @ 2004 = $10,800
Index @ 2004 = 463
Index @ 2015 = 1024
ost
index
index
ost
ost @
ost @
for . = $
Equipment
No. of equipments
Cost ($)
36921
Heat Exchanger
891742
Atmospheric Distillation
99016
112794
Column
Fractionating Column
96
Centrifugal Pump
14
154812
Mixer
2908
Gas Seperator
23885
25% of total
= $ 396623
6.3% of total
= $ 99949
Instrumentation (installed),
6.4% of total
= $ 101535
Electrical installed,
4.6 % of total
= $ 72978
Piping (installed),
7.3 % of total
= $ 115814
4.6 % of total
= $ 72978
Yard improvement,
1.8% of total
= $ 28556
13.8% of total
= $ 218936
Land,
0.9% of total
= $ 14278
9.2% of total
= $ 155276
97
Construction expenses,
11 % of total
= $ 174514
Contractors fee,
1.8 % of total
= $ 28556
Contingency,
7.3 % of total
= $ 115814
98
Chapter 8
HAZOP Study
8.1 What Is a HAZOP Study?
A Hazard and Operability Study (HAZOP) is a systematic approach to
investigating each element of a process to identify all of the ways in which
parameters can deviate from the intended design conditions and create
hazards or operability problems.
A HAZOP Study typically involves using the piping and instrument diagrams
(P&ID), or a plant model, as a guide for examining every section and
component of a process. A HAZOP team consisting of experienced and
knowledgeable people, brainstorms potentially hazardous situations that could
arise in each section of pipe, each valve, and each vessel in the system.
The HAZOP team should be led by someone with an in-depth knowledge of the
process, but they do not need to be an expert in the technology used in the
process. The HAZOP team should include people with a variety of expertise
such as operations, maintenance, instrumentation, engineering/process design,
and other specialists as needed.
99
100
HAZOP reports are an integral part of plant and safety records and are
also applicable to design changes and plant modifications, thereby
containing accountability for equipment and its associated human
interface throughout the operating lifetime.
HAZOP technique is now used by most major companies handling and
processing hazardous material, especially those where engineering
practice involves elevated operating parameters:
Pharmaceuticals etc.
101
Figure 8.5a
102
SYSTEM:
DISTILLATION
COLUMN
PARAMETER
GUIDEWORD
CAUSE
CONSEQUENCES
HIGH level
Level
Controller
fault
LEVEL
TEMPERATURE
HIGH
LOW
PRESSURE
HIGH
Increased
re-boiler
duty.
More reflux
than
optimum.
Blockage
at outlets.
Composition can
be affected
SAFEGUARD
High level
alarm
Temperature
controller,
Control Reflux
ratio
Composition can
be affected
Control reflux
ratio
Pressure
controller and
alarm.
Pressure relief
valve
Composition
analyzer at
inlet.
COMPOSITION
Misdirected
Disturbed
column
feed
Inferior product
quality
Recycle
bottom
product.
103
SYSTEM:
REBOILER
TEMPERATURE
High
Low
More steam
injection
Less steam
injection
Control valve
at steam inlet
More cost
Desired separation
will be affected.
Temperature
controller
Control Valve
SYSTEM:
CONDENSER
PRESSURE
High
High water
temperatur
e.
Excessive Pressure
Backup
cooling water
system
Increase
reflux.
No water.
TEMPERATURE
High
Low
Fault in
cooling
water
generator
Failure of
temperatur
e sensor.
Install tripping
system.
104
Chapter 9
Environmental Impact
This chapter aims to present the main environmental impacts of oil and gas
industry throughout the stages of hydrocarbon production, separation, new
deposits and oil refining. It also addresses the issue of environmental risks in
industry and possible accidents that may arise from occurring activities.
9.1 Introduction
Oil plays a vast and vital role in our society as it is organized today.oil represents
much more than just one of the main source of energy used by mankind.
Besides, being an important energy source, petroleum products serve as
feedstock for several consumer goods, thus playing a relevant and growing role
in humans life.
On the other hand oil industry holds major potential hazards for the environment,
and may impact it at different levels air, water, soils and consequently all living
beings on our planet.
Potential environmental
impacts
Mitigation measures
Limitations
Water contamination
SS (10g)
BOD (6g)
neutralization, evaporation,
Water contamination
due to discharges of
appropriate treatment.
contaminant to be removed.
(saline pollution)
TDS (50)
Nitrogen (40)
Phosphorus(10)
Chloride(50)
Grease(2g)
COD (50g)
Particulate emissions
than 0.1 to 3 kg )
106
generated during
operations at
0.2 to 0.1 kg )
others.
plants.
compounds gas
emissions from
production and refining
plant operations.
Occasional release of
Preventive maintenance of
potential hazardous
g)
materials, such as
107
ton of crude
contamination by
inappropriate disposal
of solid wastes resulting
from chemical industry
processes, including
processed )
effluent treatment,
collectors.
due to truck
circulation(including
dangerous cargos)
108
accidents.
Noise pollution caused
by equipment and
equipment or soundproofing
loud noise.
Daily exposure to
workers noise (3 dBA)
109
REFERENCES
[1] (Hellyer, n.d.). Article at profiles of chemical engineers. published on 27th
march 2010.
[2] Nelson. Petroleum Refineries. ch24. p889.
[3] Nelson. Petroleum Refineries. ch24. Fig. 24-1. p890.
[4] http://link.springer.com/article/10.1023/A%3A1011692118809#page-1
[5] http://www.chemguide.co.uk/physical/basicrates/arrhenius.html
[6] Octave levenspiel. Chemical Reaction Engineering. ch. 18. p411.
[7] Donald. Q. Kern. Process Heat Transfer. ch. 7. p151.
[8] http://www.slawinski.de/en/products/torispherical-heads/
[9] Byco Petroleum Pakistan Limited.
[10] JF, Richardson & Coulson JM. Coulson and Richardson's Chemical
Engineering. 4th ed. Vol. 6. ch. 11. p524.
[11] McCabe & Smith. Unit Operations of Chemical Engineering. 7th ed. ch. 21.
p704.
[12] Donald. Q. Kern. Process Heat Transfer. ch. 7. p149.
[13] George Stephanopoulos. Chemical Process Control.
110
[14] From Table 6.2 of Coulson & Richardsons volume 6. ch. 6. p259.
[15] http://cadiary.org/cost-inflation-index-capital-gain/
[16] JF, Richardson & Coulson JM. Coulson and Richardson's Chemical
Engineering. 4th ed. Vol. 6. Fig 6.7. p254.
[17] JF, Richardson & Coulson JM. Coulson and Richardson's Chemical
Engineering. 4th ed. Vol. 6. Fig 6.5b. p257.
[18] JF, Richardson & Coulson JM. Coulson and Richardson's Chemical
Engineering. 4th ed. Vol. 6. Fig 6.7. p258.
[19] Cox Chart.
[20] Octave levenspiel. Chemical Reaction Engineering. ch. 19. p429.
[21] Octave levenspiel. Chemical Reaction Engineering. ch. 5. p102.
[22] Octave levenspiel. Chemical Reaction Engineering. ch. 5. p106.
[23] Donald. Q. Kern. Process Heat Transfer. fig. 18. p828.
[24] Donald. Q. Kern. Process Heat Transfer. tab. 9&10. p842-843.
[25] Donald. Q. Kern. Process Heat Transfer. ch. 7. p150.
[26] Donald. Q. Kern. Process Heat Transfer. ch. 7. p150.
111