PD II First Draft

PRODUCTION OF
21,000 MTPA OF
ETHYLENE OXIDE
PROCESS & PLANT DESIGN II
BKC 4934
By:
JASMIN A/P TRAMARAJH
KA12006
MOHD HAFIZS BIN FIRDAUS
KA13137
NURUL ATIKA BINTI MOHD YATIM
KA12049
NURAMIRA FATEHA BT SUKOR
KA12068
AIIZAT IKHWAN BIN ABDUL JALIL
KA12078
TABLE OF CONTENTS
CHAPTER 2 ................................................................................................................ 2
PROCESS FLOW DIAGRAM .................................................................................... 2
CHAPTER 3 ................................................................................................................ 3
HEAT EXCHANGER NETWORK ............................................................................ 3
3.1
Introduction ................................................................................................... 3
3.2
Pinch Technology .......................................................................................... 4
3.3
Stream Identification ..................................................................................... 4
3.4
Concept of Composite Curve ........................................................................ 5
3.4.1
Original Composite Curve ..................................................................... 7
3.4.2
Selection of Minimum Approach Temperature ..................................... 8
3.4.3
Shifted Composite Curve ....................................................................... 8
3.5
Construction of Temperature Interval Diagram ......................................... 10
3.6
Construction of Cascade Diagram ............................................................... 11
3.7
Grand Composite Curve .............................................................................. 13
3.8
Heat Exchanger Network (HEN) Analysis and Design .............................. 14
CHAPTER 4 .............................................................................................................. 16
PROCESS EQUIPMENT SIZING AND COSTING ................................................ 16
4.1
Introduction ................................................................................................. 16
4.2
Equipment Sizing and Costing .................................................................... 17
4.2.1
Distillation Column .............................................................................. 17
4.2.2
Storage Tank and Intermediate Tank ................................................... 23
4.2.3
Heat Exchanger .................................................................................... 26
4.2.4
Compressor .......................................................................................... 33
4.2.5
Mixer .................................................................................................... 35
4.2.6
Membrane Separator ............................................................................ 36
4.2.7
Reactor ................................................................................................. 38
PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

4.2.8
Ethylene Oxide Absorber ..................................................................... 40
4.2.9
Carbon Dioxide Absorber .................................................................... 45
4.2.10
Carbon Dioxide Stripper ...................................................................... 48
APPENDICES ........................................................................................................... 51
LIST OF FIGURES AND TABLES

Figure 1 Process Flow Diagram ................................................................................... 1
Figure 2 Heat Transfer from Hot Stream to Cold Stream ............................................ 3
Figure 3 Original composite curve ............................................................................... 8
Figure 4 Shifted composite curve ................................................................................ 9
Figure 5 Infeasible cascade diagram .......................................................................... 11
Figure 6 Feasible cascade diagram ............................................................................ 12
Figure 7 Grand composite curve after pinch analysis ................................................ 13
Figure 8 Heat exchanger network based on pinch technology .................................. 15
Figure 9 Sieve plate contactor .................................................................................... 18
Figure 10 Schematic of a membrane with thickness t used to separate O2 from N2 .. 36
Figure 11 Mc-Cabe Thiele graphical method for absorption column number of trays
determination.............................................................................................................. 42
determination.............................................................................................................. 46
determination.............................................................................................................. 49
Table 1 Summary of the hot and cold streams ............................................................. 5

Table 2 Hot and cold streams summary. ...................................................................... 7
Table 3 Summary of the shifted hot and cold streams ................................................. 9
Table 4 Temperature interval table ............................................................................ 10
Table 5 Summary on sizing and costing for the distillation columns ........................ 21
Table 6 Summary of sizing and costing for the storage tanks ................................... 23
Table 7 Table of Design for Compressor ................................................................... 34
Table 8 Table of volume of each component in each stream ..................................... 35
Table 9 Summary of Mixer Design ............................................................................ 36
Table 10 Summary of Membrane separator ............................................................... 37
Table 11 Reactor Sizing ............................................................................................. 39
Table 1 Table of Temperature and Pressure at each Inlet Stream.............................. 95
Table 2 Table of Tc and Pc value for each component involved................................. 95
Table 3 Table of Tr and Pr values for each component at each stream ...................... 96
Table 4 Table of Z0 and Z1 values for each component at each stream ..................... 96
Table 5 Table of values for each component ......................................................... 97
Table 6 Table of correlation Z value for each component ......................................... 97
Table 7 Table of molar volume for each component at each inlet stream ................. 98
Table 8 Table of volume of each component in each stream ..................................... 99
CHAPTER 2
PROCESS FLOW DIAGRAM
Figure 1 Process Flow Diagram
CHAPTER 3
HEAT EXCHANGER NETWORK
3.1
Introduction
Heat integration is designed to conserve energy by re-using available waste

heat. It determines whether the plant is economic in term of energy consumption and
also optimizes the use of energy by doing heat integration. This may be achieved by
using interchangers between process streams, and heater or cooler is supplied with
utilities. The maximum load handled by any particular heat-transfer unit may be
constrained by the maximum allowable temperature approach between hot and cold
streams, known as Tmin.
Tin process
outH2Oout
Tout process
Tmin
inH2Oin
Figure 2 Heat Transfer from Hot Stream to Cold Stream

3.2
Pinch Technology
Pinch technology method is applied to determine the heat integration of the

process plant design. Two elements of Pinch Technology are:
(i)
Targeting maximum energy recovery which influents the best possible

performance of the heat exchanger network to be designed for a
specified process flowsheet.
(ii)
Design of heat exchanger network to fulfill the set target.
Below are the steps in using pinch technology:
i.
The hot and cold streams are identified and the respective values of H, T
and Cp for each stream involved are determined.
ii.
The Tsource (Ts) shifted and Ttarget (Tt) shifted are calculated where for the hot
streams, Ts shifted is Ts Tmin, and for the cold streams, Tt shifted is Tt
Tmin.
iii.
The minimum heating requirement, QH, min, and minimum cooling requirement,
QC, min and pinch temperature, Tpinch are determined from the heat table cascade.
iv.
Pairing of streams are determined from the Minimum Energy Recovery (MER)
method where for the above pinch region, Cp_Cold > Cp_Hot and below pinch
region, Cp_Hot > Cp_Cold.
v.
The utility consumption and heat exchanger area are calculated.
vi.
Comparison of utilities consumption and area before and after MER is done to
determine the MER efficiency.
3.3
Stream Identification
The analysis of the heat exchanger network first identities sources of heat
(termed hot streams) and sinks (termed cold stream) from the process flow. The
summary of the hot and cold streams in the plant which can be used to achieve the
maximum energy recovery for the process plant is presented in the table below.

Table 1 Summary of the hot and cold streams
Temperature
Temperature
of source (C)
of target (C)
E-100
-13.23
35
E-101
178.675077
80
E-102
256.657137
120
E-103
137.28034
230
E-104
25
70
E-105
67.251316
50
E-106
230
170
E-107
46.6747243
10
Equipment
3.4
Concept of Composite Curve
The analysis of heat exchanger network identifies both excess of heat stream
(termed hot stream) and heat sink stream (termed cold stream) from the material and
energy balances. Therefore, by plotting hot and cold streams on temperature versus
enthalpy axes this can identify the maximum heat recovery. This method is called
composite curve for energy recovery in the process.
This method can be performed for maximum energy recovery by using the
methodology as follows:
i.
The temperature axis is divided into ranges defined by the supply and target
temperature of the streams.
ii.
Within each temperature range the stream is combined to produce a composite

hot stream and composite cold stream.
5

iii.
The composite hot stream has a Cp in any temperature range that is the sum of
the individual streams. In any temperature range, the enthalpy change of the
composite is the sum of the enthalpy changes of the individual stream. The
composite stream represents how the individual streams would behave if it
were a single stream. Similarly, the composite curve for the cold stream for the
problem can be obtained.
iv.
The composite hot and cold curves can now be plotted on the same axes.
Heat can be rejected vertically from the hot streams, which comprises the hot
composite curve into the cold streams, of which comprises also cold composite curves.
The way in which the composite curves are constructed (i.e., monotonically decreasing
hot composite curve and monotonically increasing cold composite curves) allows
maximum overlap between the curves and hence maximum energy recovery.
Where the cold composite curve extends beyond the start of the hot composite
curve, heat recovery is not possible, and the cold composite curve must be supplied
with an external hot utility such as steam. This represents the target for hot utility
(QHmin).
Where the hot composite curve extends beyond the start of the cold composite
curve, heat recovery is again not possible, and the hot composite curve must be
supplied with an external cold utility such as cooling water. This represents the target
for hot utility (QCmin).
The region of overlap between these two streams in the composite curve
method identifies the amount of heat recovery possible, QREC.
3.4.1
Original Composite Curve

Once the hot and cold streams are identified, the respective values of H, T
and Cp for each stream involved are determined. The detailed calculation method will
be shown in appendix F. These values are tabulated in Table 2.
Table 2 Hot and cold streams summary.
Equipment Temperature Temperature
Heat
Cp
Duty
(kW/C)
Type of
T (C)
of source
of target
(C)
(C)
E-100
-13.23
35
374.1666
7.757965
Cold
48.23
E-101
178.675077
80
662.5
6.713955
Hot
98.67508
E-102
256.657137
120
203.6925
1.490537
Hot
136.6571
E-103
137.28034
230
337.2519
3.637329
Cold
92.71966
E-104
25
70
1611.111
35.80247
Cold
45
E-105
67.251316
50
1029.20
59.65929
Hot
17.25132
E-106
230
170
232.2860
3.871433
Hot
60
E-107
46.6747243
10
170.8693
4.65905
Hot
36.67472
(kW)
stream
The composite curve is a way to incorporate all of the hot and cold streams
onto a temperature-enthalpy diagram. The maximum amount of heat recovery and hot
and cold utilities can be found from the hot and cold composite curves, as shown in
Figure 3-2 below.

Original Composite Curve
300
Temperature (C)
250
200
150
Hot Stream
100
Cold Stream
50
0
-50 0
1000
2000
3000
Heat Duty (kW)
4000
5000
6000
Figure 3 Original composite curve
3.4.2
Selection of Minimum Approach Temperature
Minimum temperature represents the smallest temperature difference that two

streams leaving or entering a heat exchanger can have. The composites curves obtained
will show a minimum temperature difference, Tmin at the pinch. Therefore, Tmin =
10oC is chosen to represent the minimum approach of temperature as this is the
smallest difference in temperature shown in the composite curve in Figure 3-2.
For Tmin = 10oC:
1
The shifted temperature of a hot stream, Tmin = - 5C

2
1
The shifted temperature of a cold stream, Tmin = + 10C

2
3.4.3
Shifted Composite Curve
The shifted composite curve is also plotted using the shifted temperatures
shown in Table 3.
Table 3 Summary of the shifted hot and cold streams
Equipment Temperature Temperature
Heat
Duty
(kW)
Cp
(kW/C)
Type
of
T
(C)
of source
(C)
of target
(C)
E-100
-8.23
40
374.1666
7.757965
Cold
48.23
E-101
173.675077
75
662.5
6.713955
Hot
98.675
E-102
251.657137
115
203.6925
1.490537
Hot
136.657
E-103
142.28034
235
337.2519
3.637329
Cold
92.7196
E-104
30
75
1611.111
35.80247
Cold
45
E-105
62.251316
45
1029.20
59.65929
Hot
17.251
E-106
225
165
232.2860
3.871433
Hot
60
E-107
41.6747243
170.8693
4.65905
Hot
36.674
stream
Shifted Composite Curve

300
Temperature (C)
250
200
150
Hot Stream
100
Cold Stream
50
0
0
-50
1000
2000
3000
4000
5000
6000
Heat Duty (kW)
Figure 4 Shifted composite curve
The shifted composite curves touch at the pinch point. The problem is divided
on either side of the pinch point. Above the pinch point, the cold flow is greater than
9

the hot flow and the hot utilities must be supplied to make up the difference. As shown
in Figure 3-3, the cold composite extends farther along the x-axis (heat flow) than the
hot composite, therefore requiring a heating duty. Below the pinch point, the hot flow
is greater than the cold flow and cold utilities must be supplied. The cold composite
curve trails the hot composite, requiring an external cooling duty. Using shifted
temperatures does not affect the values of the heat recovery, cooling duty or heating
duty, as seen by comparing Figure 3-2 and Figure 3-3, because the hot composite is
being shifted down and the cold composite is being shifted up by the same value.
3.5
Construction of Temperature Interval Diagram

In this step, all streams are presented by a vertical line, where cold stream
(represented in blue line) and hot stream (represented on red line) are placed in the grid
diagram. The cold and hot duty for each temperature interval as shown in Table 3-4 is
calculated. The difference in cold and hot duty is then calculated and the result is
represented as deficit for (+) value and surplus for (-) value. This step is essential as
the difference in heat duty obtained will be used to construct the cascade diagram at
the following step.
Table 4 Temperature interval table
Temperature (C)
Stream Population
Cold
Hot
Cold-Hot
Surplus/
Deficit
251.657137
0
24.82808 -24.8281 SURPLUS
235
Cp = 6.71395
165
142.28034
115
Cp = 1.490537
173.675077
Cp =3.871433
36.37329 14.90537 21.46792 DEFICIT
Cp = 3.637329
225
186.6856 275.2027 -88.5171 SURPLUS

31.55411 104.7596 -73.2055 SURPLUS
82.63888 186.4033 -103.764 SURPLUS
0
223.8213 -223.821 SURPLUS
268.5582 -268.558 SURPLUS
75
Cp = 35.8025
45
41.6747243
Cp =
59.65929
456.4344
62.251316
456.4344 DEFICIT
617.6397 1029.201 -411.562 SURPLUS

119.0531
119.0531 SURPLUS
Cp =
7.75797
30
Cp =
4.65905
59.95927 7.802625 52.15664 DEFICIT

40
435.6043 46.5905 389.0138 DEFICIT

0
193.9491 116.4763 77.47288 DEFICIT
0
102.6379
0
102.6379 DEFICIT
-8.23
Grand Composite Curve
10

3.6
Construction of Cascade Diagram
The cascade diagram simply shows the net amount of energy in each
temperature interval presented in the previous step. If there is excess energy in a given
temperature interval, this energy can be cascaded down to the next temperature level.
The heat flow showed in this cascade diagram has to be positive throughout the course,
if negative value is present along the cascade diagram; normalization is required to
convert the negative flow to positive flow.
The heat flow is determined as show in shown in the heat flow calculation
shown in the cascade diagram in Figure 3-4.
T (C)
251.6571
235
225
173.6751
165
142.2803
115
75
62.25132
45
41.67472
40
30
5
-8.23
Hot utility Duty (kW)

0
-24.82807784
24.82808
21.46792234
3.360156
-88.51707447
91.87723
-73.20546908
165.0827
-103.7643791
268.8471
-223.821322
492.6684
-268.5581892
761.2266
456.4343654
304.7922
-411.5615109
716.3537
119.0530805
597.3007
52.1566407
545.144
389.013843
156.1302
77.47287901
78.65729
102.637881
-23.9806
Cold Utility
Figure 5 Infeasible cascade diagram

11
From the cascade diagram, it can be seen that the negative flow is obtained
only at -8.23oC. To normalize the cascade to obtain a feasible cascade diagram by
reaching zero heat transfer, a new cascade diagram is constructed by using this value
as the new initial heat flow as shown in Figure 3-5.
T (C) Hot utility
251.6571
-24.828078
235
21.4679223
225
-88.517074
173.6751
-73.205469
165
-103.76438
142.2803
-223.82132
115
-268.55819
75
456.434365
62.25132
-411.56151
45
119.05308
41.67472
52.1566407
40
389.013843
30
77.472879
5
102.637881
-8.23
Cold Utility
Duty (kW)
23.980589
48.808667
27.340745
115.85782
189.06329
292.82767
516.64899
785.20718
328.77281
740.33432
621.28124
569.1246
180.11076
102.63788
0
Figure 6 Feasible cascade diagram
12
From the normalized cascade diagram, the feasible design is seen to be reached
at a pinch temperature of -8.23C. The results obtained will be used to design a Heat
Exchanger Network (HEN). Since both hot and cold streams temperatures are above
its pinch temperature, therefore an above pinch Heat Exchanger Network is designed.
3.7
Grand Composite Curve
Based on the feasible cascade diagram, the grand composite curve is drawn as
in Figure 3-6.
Figure 7 Grand composite curve after pinch analysis
13
3.8
Heat Exchanger Network (HEN) Analysis and Design
In this step, the heat integration between the heat duties of each equipment take place
and a new heat exchanger network is achieved. This heat integration is done based on the pinch
temperature, -8.34 C, which is determined at the previous step. Following that a hot pinch
temperature and a cold pinch temperature is calculated. The formulae used is as below:
THot pinch = Pinch Temperature + 1/2Tmin = -8.34 + 10/2 = -3.34 C

TCold pinch = Pinch Temperature -1/2Tmin = -8.34 -10/2 = -13.34 C
Heat integration falls under two categories, which is below pinch temperature where
integration occurs only for temperature which is below the pinch temperature and above pinch
temperature where integration only occurs for temperature which is above the pinch
temperature. No integration between temperature at below pinch and above pinch is permitted.
Besides that, in order to perform the heat integration correctly, a few pinch analysis criteria
have to be obeyed.
The criteria include:
CPout CPin
N stream IN N stream OUT
Integration between above pinch and below pinch temperature is not allowed
If CP value is too large for either of the stream, try to split the stream
Set maximum heat recovery
The remaining heat duty is to be covered by using heater or cooler
All this criteria is applied and the design of HENs based on pinch is shown in Figure 3-7. From
the figure, we can discover the Maximum Energy Recovery (MER), minimum cooling heat
duty (Qc min) and minimum heating heat duty (Qh min).
14
Pinch at -8.23
Cp
-13.23
10
25
35
46.67472
50
67.25132
70
80
120
137.2803
170
178.6751
230
256.6571 Q (kW)
6.713955
662.5
1.490537
203.6925
Cp=29.7
59.65929
3.871433
Cp=30
23.0797
7.757965
98.696
1029.201
232.286
193.9491
3.637329
581.909
337.2519
35.80247
1611.111
4.65905
170.8694
Figure 8 Heat exchanger network based on pinch technology
From the above pinch Heat Exchanger Network analysis, it is found that;
QC
= 98.696 kW
= QC, min (verified)
Qh
= 605.000 kW
= QH, min (verified)
15

CHAPTER 4
PROCESS EQUIPMENT SIZING AND COSTING
4.1
Introduction
Equipment sizing is a crucial part in plant design. It affects the profitability of a plant
where the choice of material used and size of the units determine feasibility of a plant. In the
following section, equipment sizing for all units in our Ethylene Oxide plant will be conducted.
In the Ethylene Oxide production plant, it involves a total of 36 units in the set-up of the plant.
Generally, the units comprise of the Reactor, Distillation Columns, Heat Exchangers, Mixers,
Pumps, Compressors, Membrane Separator, Storage Tanks and Intermediate Storage Tanks.
Valve is exempted from sizing as t is readily available in the market.
All the calculated data are tabulated in this chapter. The detailed calculation of sizing
for each unit operation is presented in Appendix E. Only the summary of the equipment
specifications and conditions will be considered here.
16
4.2
Equipment Sizing and Costing
4.2.1 Distillation Column

Distillation is the most common method of separating homogenous mixtures. The
separation of liquid mixtures by distillation depends of the differences in volatility between the
components. The greater the volatility of a component easier to separated. Vapour flows up to
the top column and the liquid flows counter currently down to the bottom of the column. The
vapour is brought into intimate contact with the liquid on every plate. The design of distillation
columns in this production of 21 000 MTA of ethylene oxide is based on the typical design
procedures as stated in Chapter 11 of both Transport Processes and Separation Process
Principles (Geonkoplis, 2003) and Chemical Engineering, Volume 6 (Sinnott, 2009).
For the column sizing and plate design, a trial and error approach has been used to
obtain an optimum and satisfactory design. Each design variable is set and calculated from the
design formula and based on the recommended values. By checking the key performance
factors, the design parameters have been revised or otherwise determined.
4.2.1.1 Determination of the type of column

There are two common types of distillation column used in the industries that are plate
or packed column. It is important to choose the right type of distillation column in order to
obtain the most efficient and cost effective separation process. The most suitable type of
column must be determined for desired separation process because these two columns have
their own uses. In this project, a sieve plate has been selected. Among the reasons why we
considered to choose the tray distillation column for the design of our Ethylene Oxide
production plant include:
i)
Liquid dispersion difficulties which are present in packed column, are absent in
tray column.
ii)
Tray column tower has a high residence time which allows the distillation
process to be carried out in longer time. This also means that higher conversion
of product can be achieved.
17
iii)
Tray Column Tower has low maintenance cost as it is much easier to be cleaned
compared to the packed tower.
iv)
Tray columns can be designed for wide ranges of liquid rates without flooding.
v)
If periodic cleaning is required, man holes will be provided for cleaning. In

packed columns, packing must be removed before cleaning.
vi)
For large column heights, weight of the packed column is more than plate
column. Tray column is used because design information for plate column is
more readily available and more reliable than that for packed column
vii)
If there are any temperature changes, packing tower may be easily damaged
compared to tray tower.
Sieve plate is the simplest type of cross-flow plate. The vapour passes up through
perforations in the plate; and the liquid is retained on the plate by the vapour flow. There is no
positive vapour liquid seal, and at low flow-rates liquid will weep through the holes, reducing
the plate efficiency. The perforations are usually small holes, but larger holes and slots are
used. The typical layout of sieve plate is shown below.
Figure 9 Sieve plate contactor
18
4.2.1.2 Plate Spacing

Plate spacing is the important for determined overall height of column. Plates spacing
from 0.15m to 1m are normally used. The spacing chosen depends on the columns diameter
and operating conditions. For columns above 1m diameter, plate spacing 0.3m to 0.7m will
normally be used, and 0.6m can be taken as the initial assumption. This will be revised to see
whether the assumption is acceptable.
4.2.1.3 Column Diameter

The principle factor on determining the column diameter is the vapor flowrate. The
column diameter can be calculated by calculating the top and the bottom net area at its
maximum volumetric flowrate. The velocity is normally between 70 to 90% of what which
cloud cause flooding.
4.2.1.4 Height of the Column

The height of column in the distillation column is calculated by determining the number
of actual stages using a series of calculation steps as mentioned by Geonkoplis (2003).
4.2.1.5 Design Procedure

Since there are three components in the feed of distillation column in our plant opration,
the multicomponent mixtures method for distillation is used. The calculation for material
balances from Chapter 2 is used for this chapter, with component Ethylene Oxide being the
light key (L) and Water being the heavy key (H).
The general outlines of the design procedures are as below;
a) Calculation of fraction of components in feed, distillate and bottom
b) Finding Psat for each component using Antoine Equation and its respective K value
c) Plotting K vs T graph.
d) Determination of Dew Point
19

e) Determination of Bubble Point
f) Determination of the number of theoretical stages for total Reflux
g) Determination of the height of column
h) Determination of the boiling point of the feed liquid
i) Determination of the value of Rmin.
j) Determination of operating reflux ratio, R and the number of theoretical trays used.
k) Determination of the feed-plate location
l) Determine the vapor and liquid rate, based on the reflux ratio and feed condition.
m) Collect or estimate the system physical properties.
n) Select a trial plate spacing.
o) Based on flooding condition, the column diameter is determined.
p) Decided the liquid flow pattern on the plate.
q) Try to make a plate layout with downcomer area, active area, hole diameter, hole area,
weir weight, weir length, and plate thickness.
r) Check the weeping rate.
s) Check the plate pressure drop.
t) Check the down-comer backup.
u) Determine plate layout details.
v) Confirm on the percentage flooding based on the chosen column diameter.
w) Check for entrainment.
x) Optimize the design parameters for column diameter and plate spacing.
y) Determine the column wall thickness and column head selection.
z) Finalise the design with the drawing and data specification sheet.
20

Table 5 Summary on sizing and costing for the distillation columns
Column
E-25
E-27
206
125
169
110
210
197.5
Temperature
Feed temperature at saturated liquid condition (C)

Dew point (C)
Bubble point (C)
Column
Material of construction
Column diameter, Dc (m)
Column cross-sectional area, Ac (m2)
Column height, ht (m)
Stainless Steel Stainless Steel

1.6
1.0
2.01088
0.7855
7.71
7.50
0.6000
0.6000
4.9~5
5.6~6
37.8856
44.8764
12
2.3590
9.7643
Sieve
Sieve
6.6272
0.2223
9.9407
0.3334
5.0000
5.0000
Trays
Tray spacing (m)

Minimum number of trays
Efficiency (%)
Actual number of trays
Feed-plate location (trays from top)
Type
Reflux
Minimum reflux ratio

Actual reflux ratio
Provisional Plate Design
Plate thickness, tp (mm)

Plate area
i. Down comer area, Ad (m2)
ii. Net area, An (m2)
21

iii. Active area, Aa (m2)
0.2880
0.0944
iv. Hole area, Ah (m2)
1.7092
0.6293
1.4076
0.5967
0.1408
0.0298
1.28
0.7487
50.000
50.000
47.0281
19.4807
37.0757
12.2721
4.0242
3.7086
70% max rate
5.5478
13.2969
70% max rate
5.0000
1.96 *10-5
7169
13.25
5.0000
1.96 *10-5
1520
18
118.4921
149.0508
40.0000
0.0512
25.5786
0.2311
3.4690
40
0.0299
1.8181
0.2896
8.7218
93o
2.5159
0.1258
0.1095
1.1723
100o
1.6581
0.0829
0.0697
0.4441
Weir Design
Weir length, lw (m)

Weir height, hw (m)
Weir liquid Crest
i. Maximum, how (mm liquid)
ii. Minimum, how (mm liquid)
Weep Point
Minimum, Uh (m/s)
Actual, Ua (m/s)
Turn down
Hole Design
Hole diameter, dh (m)
Area (m2)
Number of holes
Hole pitch (mm)
Plate Pressure Drop
Total pressure drop (mm liquid)
Down comer Design
Apron height (mm)
Area under apron (m2)
Downcomer head loss (mm)
Height of liquid backup (m)]
Residence time, tr (s)
Plate Layout
Angle, c
Mean length (m)
Unperforated, AU (m2)
Calming area, AZ (m2)
Perforated area, AP (m2)
22
4.2.2 Storage Tank and Intermediate Tank

4.2.2.1 Storage Tank
Storage tank can be sized with known parameters such as operating pressure and
temperature, fluid flow rate and days of inventory. The detailed design of storage tank is shown
in Appendix.
Table 6 Summary of sizing and costing for the storage tanks
Tank
E-17
20% Potassium
Component to
be stored
E-37
Water
Carbonate
solution
E-28
Ethylene
Oxide
E-14
Ethylene
Pressure (bar)
2.5
30
Shape of tank
Cylindrical
Cylindrical
Cylindrical
Spherical
Carbon Steel
Carbon Steel
Carbon Steel
Stainless Steel
Fixed Cone
Fixed Cone
Fixed Cone
Closed
Closed
Closed
Material of
construction
Roof
Type
Open/closed
Height (m)
3.66
6.252685605
N/A
5.57
Period of
inventory
600
3000
2000
1500
11.31
19.29
17.21
14.20
(week)
Volume (m3)
Tank Diameter
(m)
23

Liquid Height
(m)
Design Stress
(N/mm2)
5.65532
10.211
8.247
12.78
120.00
150.00
474.00
1575.07
4.76
4.76
4.76
4.76
13.57
23.147
20.646
6.76
2,531,508.60
1,460,122.00
1,753,748.51
7124557.721
Minimum Wall
Thickness
(mm)
Total Wall
Thickness
(mm)
Updated Bare
Module Cost
(RM)
4.2.2.2 Intermediate Tank

Intermediate tanks are placed preceeding the unit operations which have liquid feed to
store the flowing liquid for a certain amount of period, in case of any unplanned maintenance
work is needed in the plant. The detailed calculation of the design of the intermediate storage
tank is shown in Appendix E.
Table 4- 1 Summary on sizing and costing of the intermediate tanks
Tank
E-23
E-29
E-34
Temperature (C)
52.02
45.80
107.5
Pressure (bar)
19.00
17.00
18.00
Shape of tank
Cylindrical
Cylindrical
Cylindrical
Carbon Steel
Carbon Steel
Carbon Steel
Material of
construction
24

Roof
Type
Open/closed
Height (m)
Fixed Cone
Closed
Fixed Cone
Closed
Fixed Cone
Closed
0.352
0.667
0.594
Period of storage
(hour)
2.80
6.00
2.80
Volume (m3)
170.00
25.00
120.00
7.60
3.99
6.70
3.63
1.91
3.23
1130.00
534.00
530.00
4.76
4.76
4.76
9.08
4.79
12.65
761402.2071
159958.4469
598264.6757
Tank Diameter
(m)
Liquid Height (m)
Design Stress
(N/mm2)
Minimum Wall
Thickness (mm)
Total Wall
Thickness (mm)
Updated Bare
Module Cost, RM
25

4.2.3 Heat Exchanger
4.2.3.1 Introduction
The heat transfer between two mediums is done by using the heat exchanger. The
common heat exchanger is one that the hot and cold fluids do not come into contact to each
other directly but by the tubes and the shell that surrounds the tube. For shell and tube type heat
exchanger, Kerns method is popular to be used as reference. The Kerns method was based in
experimental work on commercial exchangers with standard tolerances and will give
reasonably satisfactory prediction of the heat transfer coefficient for standard designs.
According to Chemical Engineering Series, Volume 6 by Coulson and Richardson
(2005), a design procedure was listed as a guideline for shell and tube design as following:
a) Specification and define duty
b) Collect physical properties
c) Assume value of overall coefficient Uo,ass
d) Decide number of shell and tube passes. Calculate Tlm, correction
e) factor,F and Tm
f) Determine heat transfer area required, Ao
g) Decide type, tube size, material layout. Assign fluids to shell or tube side
h) Calculate number of tubes
i) Calculate shell diameter
j) Estimate tube side heat transfer coefficient
k) Decide baffle spacing and estimate shell side heat transfer coefficient
l) Calculate overall heat transfer coefficient, Uo,calc
m) Estimate tube and shell side pressure drops
n) Estimate cost
o) Accept or optimization
26
4.2.3.2 Design of Heat Exchanger

Chemical Design Specification Sheet
Heat Exchanger E-7
Specification Sheet : Heat Exchanger

Identification
: Heat Exchanger Unit
Item No.
: E-7
Function
: To cool down the temperature from stream S2
Operation
: Continuous
Geometry
Tube to Shell Side Flow
: Counter-current
No. of tubes pass per shell :
Shell Side Stream Feed
: Gases
Number of Shell
Tube Side Phase
: Cool Water
Process Specification
Heat Duty
: 242.79 kW
Product Flow : Gases
Heat Transfer Area
: 19.017 m2
Cool Water In
: 25 C
Cool Water Out
: 75 C
Equipment Sizing
Tube Material
: Carbon Steel
Shell Material
: Carbon Steel
Tube Length
: 2m
Shell Diameter
: 615.002 mm
Outside Diameter
: 30 mm
Bundle Diameter
: 555.002 mm
Tube Inside Diameter : 25 mm
Baffle Spacing
Number of tubes
: 172
Tube Pitch
Tube Arrangement
: Triangular Pitch
: 123 mm
: 37.5 mm
Equipment Cost (RM) : 13546.05
27

Heat Exchanger E-8

Identification
Item No.
: E-8
Function
Operation
: Continuous
Geometry
: Counter-current
: Gases
Number of Shell
Tube Side Phase
: Cool Water
Heat Duty
: 336.250 kW
Heat Transfer Area
: 17.198 m2
Cool Water In
: 25 C
Cool Water Out
: 100 C
Equipment Sizing
Tube Material
: Carbon Steel
Shell Material
: Carbon Steel
Tube Length
: 2m
Shell Diameter
: 582.61 mm
Outside Diameter
: 30 mm
Bundle Diameter
: 522.609 mm
Baffle Spacing
: 116.52 mm
Number of tubes
: 148
Tube Pitch
Tube Arrangement
: Triangular Pitch
: 37.5 mm
28

Heat Exchanger E-4

Identification
Item No.
: E-4
Function
: To heat up the temperature from stream S9
Operation
: Continuous
Geometry
: Counter-current
: Gases
Number of Shell
Tube Side Phase
: Hot Water
Heat Duty
: 71.645 kW
Heat Transfer Area
: 17.198 m2
Hot Water In
: 70 C
Hot Water Out
: 20 C
Equipment Sizing
Tube Material
: Carbon Steel
Shell Material
: Carbon Steel
Tube Length
: 2m
Shell Diameter
: 300.93 mm
Outside Diameter
: 30 mm
Bundle Diameter
: 240.93 mm
Baffle Spacing
: 60.19 mm
Number of tubes
: 31
Tube Pitch
Tube Arrangement
: Triangular Pitch
: 37.5 mm
29

Heat Exchanger E-13

Identification
Item No.
: E-13
Function
: To heat up the temperature from stream S12
Operation
: Continuous
Geometry
: Counter-current
: Steam
Number of Shell
Tube Side Phase
: Gases
Heat Duty
: 344.61 kW
Heat Transfer Area
: 33.46 m2
Steam In
: 300 C
Steam Out
: 210 C
Equipment Sizing
Tube Material
: Carbon Steel
Shell Material
: Carbon Steel
Tube Length
: 2m
Shell Diameter
: 717084 mm
Outside Diameter
: 30 mm
Bundle Diameter
: 640.014 mm
Baffle Spacing
: 143.57 mm
Number of tubes
: 153
Tube Pitch
Tube Arrangement
: Triangular Pitch
: 37.5 mm
30

Heat Exchanger E-21

Identification
Item No.
: E-21
Function
Operation
: Continuous
Geometry
: Counter-current
: Gases
Number of Shell
Tube Side Phase
: Water
Heat Duty
: 360.903 kW
Heat Transfer Area
: 14.979 m2
Cool Water In
: 25 C
Cool Water Out
: 95 C
Equipment Sizing
Tube Material
: Carbon Steel
Shell Material
: Carbon Steel
Tube Length
: 2m
Shell Diameter
: 495.917 mm
Outside Diameter
: 30 mm
Bundle Diameter
: 420.087 mm
Baffle Spacing
: 99.183 mm
Number of tubes
: 60
Tube Pitch
Tube Arrangement
: Triangular Pitch
: 37.5 mm
31

Heat Exchanger E-36

Identification
Item No.
: E-36
Function
Operation
: Continuous
Geometry
: Counter-current
: Gases
Number of Shell
Tube Side Phase
: Water
Heat Duty
: 900.217 kW
Heat Transfer Area
: 68.012 m2
Cool Water In
: 25 C
Cool Water Out
: 40 C
Equipment Sizing
Tube Material
: Carbon Steel
Shell Material
: Carbon Steel
Tube Length
: 2m
Shell Diameter
: 1414.125mm
Outside Diameter
: 30 mm
Bundle Diameter
: 1338.295 mm
Baffle Spacing
: 282.83 mm
Number of tubes
: 774
Tube Pitch
Tube Arrangement
: Triangular Pitch
: 37.5 mm
32
4.2.4 Compressor
Compressor is used to compress gases from one point to another point. Each
compressor is generally a function of the gas capacity, action and discharge head.
There are three general types of compressor: Axial flow compressor used for high flow
rates and moderate differential pressure, centrifugal compressor for high flow rates and by
staging for high differential pressure and reciprocating compressor can be used over a wide
range of pressures are required at relatively low flow rate.
In this plant, the type of compressor used is centrifugal compressor. Compressor
efficiencies are usually expressed as isentropic efficiencies, i.e., on the basic on an adiabatic
reversible process. Isothermal efficiencies are sometimes quoted, and design calculations are
simplified when isothermal efficiencies are used.
The work of compressor and single stage compressor can be calculated by assuming
the compressor is operated ideally under adiabatic compression.
33
4.2.4.2 Design of Compressor

Table 7 Table of Design for Compressor
Identification
Compressor 1
Compressor 2
Compressor 3
Compressor 4
Item No
E-6
E-9
E-11
E-2
Function
To provide the
system the
pressure
required
To provide the
system the
pressure
required
To provide the
system the
pressure
required
To provide the
system the
pressure
required
Material of
Construction
Carbon Steel
Carbon Steel
Carbon Steel
Carbon Steel
Pressure Inlet
8.7
Pressure
Outlet
21
22
Temperature
Inlet (K)
298
298.5
318
210.9
Actual Work
(kW)
1740.356
1743.276
1422.905
893.12
Price of
Equipment
(RM)
6909721.67
6506036.25
5423374.723
4113307.86
34
4.2.5 Mixer
In this process, the usage of the mixer is to ensure all the components from ethylene feed stream,
air feed stream and recycle feed stream are being in one stream before entering heat exchanger.
4.2.5.2 Design of Mixer

The sizing calculation for mixer are based on the gas volumetric value for all the inlet
streams. The generalized compressibility-factor correlation is used. The required correlation is
the reduced temperature, Tr and reduced pressure Pr which can be obtained from the Appendix
in Introduction to Chemical Engineering Thermodynamics book as reference. Pitzer
correlations for the compressibility factor for any pressure also calculated to determine the gas
volumetric value. The detail calculation for the mixer are shown in the Appendix. Table 8
shows the total volume of all the components.
Table 8 Table of volume of each component in each stream
Volume (m3)
Components
C2H4
Stream 11
Stream 37
0.694982474
0.079157016
Stream 8
O2
0.125727445
1.8531791
N2
0.10184469
0.14738546
H2O
8.84977E-05
CO2
0.012668512
The volume for each component at each stream then be sum up and total of 2.0 m3 is obtained.
The mixer volume is decided to be 2.0 m3.
An assumption for the shape of the mixer is made. The form of the mixer is a vertical cylindrical
tank with diameter of 0.7m. From the total volume of mixer obtained, the height of the mixer
is to be 5.3m. From the value calculated, the sizing and costing have been estimate and shown
as in Table below.
35

Table 9 Summary of Mixer Design
Mixer
E-3
Function
Ensure all the ethylene inlet, air inlet and

recycle outlet stream be in one stream before
entering heat exchanger, E-4
Material of Construction
Carbon Steel
Actual Work
408 kW
Price of Equipment
RM 8,401.95.
4.2.6 Membrane Separator

Gas separation membranes are often packaged in hollow fiber modules. As air flows under
pressure into the module through the bores of the hollow fiber, some of the air gases permeate through
the wall of the fibers into the shell of the hollow fiber. The gas in the shell side of the fibers leaves the
module as the permeate stream. In the process, the oxygen is the to be as permeate product since the
oxygen is used to be as raw material to produce ethylene oxide. A further calculation and information
for the membrane separator is shown in the Appendix.
P
>
p
P
>
P
O
2
N
2
y
,p
N
O
2
1
y
N
N
2
t
x
,P
1
x
Figure 10 Schematic of a membrane with thickness t used to separate O2 from N2
36
4.2.6.2 Design of Membrane Separator

Table 10 Summary of Membrane separator
Membrane Separator
E-40
Membrane material
Dimethylsilicone Rubber
Membrane separator shell dimensions

Diameter
Length
Total area of membrane
0.2 m
3.0 m
396 m2
Number of tubes required
2,986
Number of shells required
16
Costing for membrane
RM 108,747.74
37

4.2.7 Reactor
4.2.7.1 Reactor Flow Steps Calculation
General Procedures of reactor sizing (E-5)
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Step 10
Step 11
Step 12
Step 13
Collection of physical property data require for the sizing, either from
the literature or if necessary, by estimation.
Initial selection of reactor conditions and suitable catalyst to give the
desired conversion and yield.
Calculate the volume that needed for reaction occurs.
Assume N number of tube. The molar flowrate, as well as volumetric
flowrate (which are extracted from ASPEN), must be
divided by N number of pipes.
Calculate the length of pipe used.
Tube length suitability checking.
Calculate the tube-side heat transfer coefficient, hi.
Calculate the mean temperature difference, using LMTD method.
Calculate the shell-side heat transfer coefficient, ho, using Bell's method.
9.1Determine the ideal tube bank heat transfer coefficient, hoc
9.2Determine Fn
9.3Determine Fw
9.4Determine Fb
9.5Determine FL
9.6Determine shell bank heat transfer coefficient, ho
Evaluate the overall heat transfer coefficient, Uo.
Evaluated the total heat transfer area.
Determine number of pipe used: N = Atotal/Apipe, for checking purpose.
Selection of suitable materials of construction.
The detail calculation is shown in the Appendix.
38
4.2.7.2 Reactor Specification

The summary of reactor sizing is tabulated in Table 11.
Table 11 Reactor Sizing
REACTOR R 1
Equipment
Reactor
Tag no.
R1
Type of reactor
Function
Operation
Operating Pressure
Operating Temperature
CATALYST INFORMATION
Catalyst
Particle Diameter
Bulk Density
Void Fraction
DESIGN DATA
Diameter
Length
Volume
Type of tube
Number of tube
Outside diameter of tube
Wall thickness of tube
Inside diameter of tube
Packed-bed Reactor
To produce ethylene oxide from ethylene
Continuous
21.7 bar
190, isothermal
MECHANICAL DESIGN
Design Pressure
Design Temperature
Baffles thickness
MAWP of wall
Type of end
Reactor Closures & Domed Head
Silver alumina
0.008 m
1000 kg/m3
0.7
Stainless Steel
11.15 m
3.36 m
18.37 m3
Stainless steel 2-in diameter schedule 40 tubes
1500
3.540 m
0.012 m
3.366 m
31 bar
250
0.0523 m
13.73 N/mm2
Tori spherical head
0.012 m
EQUIPMENT ESTIMATED COST: RM 1,397,981.66
39

4.2.8 Ethylene Oxide Absorber
There are two main types of absorber that are widely used; tray type absorber and packed type
absorber. There are many reasons that we have considered to choose the tray type absorber
instead of the packed type absorber for the design of our Ethylene Oxide production plant.
These are among the reasons:
i)
Liquid dispersion difficulties which are present in packed column, are absent in
tray column.
ii)
Tray column tower has a high residence time which allows the distillation
process to be carried out in longer time. This also means that higher conversion
of product can be achieved.
iii)
Tray Column Tower has low maintenance cost as it is much easier to be cleaned
compared to the packed tower.
iv)
Tray columns can be designed for wide ranges of liquid rates without flooding.
v)
If periodic cleaning is required, man holes will be provided for cleaning. In

packed columns, packing must be removed before cleaning.
vi)
For large column heights, weight of the packed column is more than plate
column. Tray column is used because design information for plate column is
more readily available and more reliable than that for packed column
vii)
If there are any temperature changes, packing tower may be easily damaged
compared to tray tower.
40
4.2.8.2 Number of Trays

The theoretical number of trays for absorption column was using the graphical determination
method of packed tower for absorption, named Mc-Cabe Thiele method (Geankoplis,
2003).The composition of ethylene oxide in gas and liquid phase was obtained from material
balance as follow.
Liquid in
xA2=0
Gas in
yA1=0.23016
Gas out
yA2=0
Liquid out
xA1=0.23357
Based on the equilibrium data Ethylene Oxide-Water (Devi. et al, 2012) :

= 0.9128 mol frac,
=
471.7
760
1atm = 0.6207 atm @ = 0.6207
the equilibrium relation of = = 0.6875 can be used (Geankoplis, 2003).

1 =
1 0.23016
=
= 0.3348
0.6875
= 0,
= 0.6875 (0) = 0
Plot the equilibrium line with points (0,0) and (0.3348, 0.23016). In the same graph, plot the
operating line with points (0, 0) and (0.23357, 0.23016) as shown in Figure C.2.1.
From Figure 11, the number of trays was determined. Hence, the number of trays for absorption
column was:
No. Stages = 8.2 9 trays
41
determination.
0.25
0.2
0.15
Equilibrium line
Operating line
0.1
0.05
0
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
4.2.8.3 Diameter, Height and Cost Calculation
From material balance and simulation result:

No. of trays, N
Top product rate, D
4976.744 kg/hr
Bottom product rate, B
51476.31 kg/hr
Vapor flow rate, V
1.3824289 kg/s
Liquid flow rate, L
14.298975 kg/s
Density of vapor, v
19.13 kg/m3
Density of liquid, L
1008 kg/m3
42

Steps used to calculate the diameter of the column, the height and also the cost of the equipment
include:
i) Liquid vapor flow factor,
ii) Flooding vapor velocity,
iii) Column area and column diameter
iv) Selection of liquid flow arrangement
v) Weeping checking
vi) Plate pressure drop
vii) Down comer back-up
viii)
Check entrainment
ix) Perforated area

x) Number of holes
xi) Column height
xii) Cost of equipment (vessel-vertical oriented, stainless steel material)
Liquid vapor flow factor,
Column area,
Column diameter,
1.425 kg/h.m3
0.4852 2
Type of flow = cross flow

(single pass)
0.8
0.72
0.576
2 0.90(25.4 )
1/2
2.9814 /
0.7
1.3268 /
Weir length, lw
Minimum vapor velocity,
Actual
minimum
vapor
velocity,,
Total pressure drop,
Down comer back-up,
+ ( + , ) +
[ + ( + ) + ] 103
119.654
0.296
43
Number of holes,
(.
Column height
1942
9.045
1)( )
+ 2( )
+ (. )( )
+ ( )
+ ( )
Total
cost
of
1 + 2
567398.01$
equipement,
*Details calculation can be referred to the Appendices
44
4.2.9 Carbon Dioxide Absorber

The theoretical number of trays for absorption column was using the graphical determination
2003).The composition of carbon dioxide in gas and liquid phase was obtained from material
balance as follow.
Liquid in
xA2=0
Gas in
yA1=0.0691
Gas out
yA2=0.0021
Liquid out
xA1=0.0424
Based on the equilibrium data CO2, aqueous K2CO3 (Kim. et al, 2011):
= 0.410 mol frac,
55.996
= 1.01325102 1atm = 0.5526 atm @ = 0.5526

1 =
1 0.0691
=
= 0.0509
1.3576
= 0,
= 1.3576 (0) = 0
operating line with points (0, 0.0021) and (0.0424, 0.0691) as shown in Figure C.2.1.
column was:
No. Stages = 9.2 10 trays
45

determination.
0.08
0.07
0.06
0.05
equilibrium line
0.04
operating line
0.03
0.02
0.01
0
0
0.01
0.02
0.03
0.04
0.05
0.06
* Diameter, Height and Cost Step Calculation for Carbon Dioxide Absorber are the same as Ethylene
Oxide Absorber

No. of trays, N
10
Top product rate, D
1897.438 kg/hr
36749.09 kg/hr
Vapor flow rate, V
0.527066 kg/s
Liquid flow rate, L
10.20808 kg/s
Density of vapor, v
19.25 kg/m3
1018 kg/m3
46

2.663 kg/h.m3
0.328 2
Column area,
Column diameter,
0.647
Type of flow = cross flow

(single pass)
0.72
12.281
2 0.90(25.4 )
1/2
3.788 /
0.7
0.774/
Weir length, lw
Minimum vapor velocity,
Actual
minimum
vapor
velocity,,
+ ( + , ) +
Down comer back-up,
113.928
[ + ( + ) + ] 103
0.281
1262
Number of holes,
(.
Column height
12.070
1)( )
+ 2( )
+ (. )( )
+ ( )
+ ( )
Total
cost
of
1 + 2
580800.67$
equipement,
47
4.2.10 Carbon Dioxide Stripper

The theoretical number of trays for stripper column was using the graphical determination
2003).The composition of carbon dioxide in gas and liquid phase was obtained from material
balance as follow.
Liquid in
xA2=0.06568
Gas in
yA1=0
Gas out
yA2=0.05707
Liquid out
xA1=0.00221
Based on the equilibrium data CO2 aqueous K2CO3 (Kim. et al, 2011) :
= 0.410 mol frac,
55.996
= 1.01325102 1atm = 0.5526 atm @ = 0.5526

2 =
2 0.05707
=
= 0.0420
1.3576
= 0,
= 1.3576 (0) = 0
operating line with points (0.00221, 0) and (0.06568, 0.05707) as shown in Figure C.2.1.
column was:
No. Stages = 6 trays
48

determination.
0.06
0.05
0.04
Operating line
0.03
Equilibrium line
0.02
0.01
0
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
* Diameter, Height and Cost Calculation for Carbon Dioxide Stripper are the same as Ethylene Oxide
Absorber

No. of trays, N
Top product rate, D
4788.527 kg/hr
50003.36 kg/hr
Vapor flow rate, V
1.3301464 kg/s
Liquid flow rate, L
13.889822 kg/s
Density of vapor, v
6.718 kg/m3
1017 kg/m3
49

Column area,
Column diameter,
0.849 kg/h.m3
0.807 2
1.073
Type of flow = cross

flow (single pass)
0.72
0.74
2 0.90(25.4 )
1/2
6.412 /
0.7
1.951 /
Weir length, lw
Minimum
vapor
velocity,
Actual minimum vapor
velocity,,
+ ( + , ) +
Down comer back-up,
107.407
[ + ( + ) + ] 103
0.245
3618
Number of holes,
(.
Column height
4.780
1)( )
+ 2( )
+ (. )( )
+ ( )
+ ( )
Total
cost
of
1 + 2
425669.35$
equipement,
50
APPENDICES
Distillation Column Calculations

Distillation Column
= /
xw = 0.977
xEO = 0.0235
xE = 0.0000125
= .
= . /
yw = 0.29
yEO = 0.707
yE = 0.0003
= .
ETHYLENE
OXIDE
COLLUMN
= /
xw = 0.999
xEO = 0.001
= .
=
Figure 4- 1 Flow Diagram of Distillation Column for EO

*The values shown in Figure 3-1 are obtained from Aspen simulation. The values calculated
manually would differ slightly due to the differences in the conditions considered for the
calculations.
Since there are 3 components in the feed, the calculation of multicomponent mixtures for
distillation are used. For the manual calculation, the feed to the column is taken to enter the
column with a molar flow rate of 2740 kmol/hr in a saturated liquid state, whereas the overhead
product contains 87.99 kmol/hr vapour and the bottom contains 2652 kmol/hr liquid.
The calculation for material balances from Chapter 2 is used for this chapter, with component
Ethylene Oxide being the light key (L) and Water being the heavy key (H). Calculation steps
listed in Chapter 4 of the report are implemented.
51
a)
Calculation of fractions of components in feed, distillate and bottom
Table 4-1 shows material balances with respective fractions for each of the component in the
process.
Table 4- 2 Mole Balance
feed
Label
distillate
bottom
Component
Xf
yD=xD
xW
heavy key
Water
0.976629
2675.990
0.292337
25.72162
0.999332
2650.269
light key
Ethylene
0.023357
64.00138
0.707274
62.23034
0.000667
1.771046
1.24594E-05
0.034139
0.000388
0.034139
2740.026
87.98610
2652.040
Oxide
Ethylene
light
component
Total
b)
Finding Psat for each component using Antoine Equation and its respective K
value
* The relationship between the equilibrium K values for every components and the temperature
is drawn in graph to determine the dew point and boiling point for distillate and bottom
products.
Antoine Equation: () =
()+
Table 3.3 shows that the parameters used for the components in the Antoine Equation:
Table 4- 3
Antoine Equation
Component
Ethylene Oxide
7.26969
1114.78
243.301
Water
8.14019
1810.94
244.485
Ethylene
6.96636
649.806
262.73
Parameters for
52

Table 4-2 shows the saturated pressure of acetone at different temperatures and its equilibrium
K values. The K value is calculated using the formula:
=
Where Pi = Psat of components, P = Pressure of the column (14251 mmHg)

Table 4- 4 Saturated Pressure and Equilibrium K Value for each component at different
temperatures
Temperature
Ethylene
Ethylene Oxide
Water
(C)
-10.000
-5.000
0.000
5.000
10.000
15.000
20.000
25.000
30.000
35.000
40.000
45.000
50.000
55.000
60.000
65.000
70.000
75.000
80.000
85.000
90.000
95.000
100.000
105.000
110.000
115.000
120.000
125.000
130.000
135.000
Psat
24843.508
27867.214
31122.583
34615.096
38349.687
42330.751
46562.144
51047.200
55788.736
60789.069
66050.032
71572.992
77358.866
83408.144
89720.903
96296.833
103135.257
110235.147
117595.150
125213.605
133088.564
141217.812
149598.885
158229.091
167105.523
176225.085
185584.497
195180.323
205008.977
215066.744
Ke
1.743
1.955
2.184
2.429
2.691
2.970
3.267
3.582
3.915
4.266
4.635
5.022
5.428
5.853
6.296
6.757
7.237
7.735
8.252
8.786
9.339
9.909
10.497
11.103
11.726
12.366
13.022
13.696
14.385
15.091
Psat
310.027
390.532
487.297
602.641
739.062
899.233
1085.996
1302.356
1551.472
1836.653
2161.341
2529.108
2943.640
3408.727
3928.252
4506.176
5146.528
5853.391
6630.893
7483.187
8414.447
9428.852
10530.577
11723.777
13012.583
14401.088
15893.337
17493.321
19204.965
21032.122
Keo
0.022
0.027
0.034
0.042
0.052
0.063
0.076
0.091
0.109
0.129
0.152
0.177
0.207
0.239
0.276
0.316
0.361
0.411
0.465
0.525
0.590
0.662
0.739
0.823
0.913
1.011
1.115
1.228
1.348
1.476
Psat
2.613
3.788
5.408
7.612
10.570
14.495
19.640
26.314
34.882
45.775
59.499
76.641
97.876
123.978
155.826
194.414
240.857
296.401
362.429
440.469
532.201
639.464
764.260
908.764
1075.324
1266.469
1484.910
1733.547
2015.466
2333.947
Kw
0.000
0.000
0.000
0.001
0.001
0.001
0.001
0.002
0.002
0.003
0.004
0.005
0.007
0.009
0.011
0.014
0.017
0.021
0.025
0.031
0.037
0.045
0.054
0.064
0.075
0.089
0.104
0.122
0.141
0.164
53

140.000
145.000
150.000
155.000
160.000
165.000
169.000
170.000
175.000
180.000
185.000
189.500
190.000
195.000
197.000
200.000
201.500
205.000
206.000
210.000
215.000
220.000
225.000
230.000
235.000
c)
225349.790
235854.176
246575.873
257510.772
268654.694
280003.404
289226.941
291552.616
303298.010
315235.232
327359.908
338428.764
339667.652
352154.067
357197.677
364814.761
368646.297
377645.345
380231.463
390641.442
403798.695
417112.765
430579.343
444194.150
457952.941
15.813
16.550
17.302
18.069
18.851
19.648
20.295
20.458
21.282
22.120
22.971
23.747
23.834
24.711
25.064
25.599
25.868
26.499
26.681
27.411
28.334
29.269
30.214
31.169
32.134
22978.567
25047.988
27243.980
29570.042
32029.566
34625.841
36803.460
37362.043
40241.232
43266.351
46440.224
49426.127
49765.549
53244.905
54680.328
56880.741
58002.356
60675.382
61453.563
64631.029
68749.751
73033.496
77484.081
82103.202
86892.428
1.612
1.758
1.912
2.075
2.248
2.430
2.582
2.622
2.824
3.036
3.259
3.468
3.492
3.736
3.837
3.991
4.070
4.258
4.312
4.535
4.824
5.125
5.437
5.761
6.097
2692.460
3094.670
3544.431
4045.792
4602.990
5220.452
5760.904
5902.788
6654.793
7481.438
8387.868
9276.261
9379.399
10461.508
10920.972
11639.834
12012.955
12920.164
13188.990
14308.432
15810.712
17433.209
19182.251
21064.284
23085.862
0.189
0.217
0.249
0.284
0.323
0.366
0.404
0.414
0.467
0.525
0.589
0.651
0.658
0.734
0.766
0.817
0.843
0.907
0.925
1.004
1.109
1.223
1.346
1.478
1.620
Plotting K vs T graph.
Graph of K values at different temperatures for each component is plotted using Excel
Spreadsheet:
54
K vs T Graph for Ethylene

35
30
25
Ke
20
15
10
5
0
-50
50
100
150
200
250
Temperature (C)
Figure 4- 2 K vs T graph for ethylene
K vs T Graph for Ethylene Oxide and Water

7
6
K value
5
4
Ethylene Oxide
Water
2
1
0
-50
50
100
150
200
250
Temperature (C)
Figure 4- 3 K vs T graph for ethylene oxide and water
55
d)
Determination of Dew Point
The components are classified as below:

Ethylene Oxide
Light Key (L)
Water
Heavy Key (H)
Ethylene
Light component
K values from the graph above are used to determine the dew point of the distillate (top
temperature) using trial and error method as shown as below.
=
yi / i
(yi/i)
Taking T=50oC for the first trial:

Table 4- 5 Calculation of dew point of the distillate (First Trial)
Label
Heavy key
Light key
Light
component
Component
Water
Ethylene
Oxide
yD
0.29233733
0.70727465
Ki
0.00686790
0.20655423
Ai
1
30.0752980
yi/ai
0.29233733
0.02351679
xi
0.92554395
0.07445449
0.00038800
5.42824582
790.378927
4.9091E-07
1.55423E06
Ethylene
Kw
0.31585462
The calculated Kw value of 0.3159 corresponds approximately to a temperature of 160oC.

Since this is quite far from the predicted value of 50oC, a second trial is carried on with T =
169oC.
Taking T = 169oC for the second trial:
56

Table 4- 6 Calculation of dew point of the distillate (Second Trial)
Label
Heavy key
Component
Water
Ethylene
Oxide
Light key
Light
component
yD
Ki
Ai
yi/ai
Xi
0.292337339 0.404240688
1
0.292337339 0.725302246
0.707274656 2.582486501 6.388487296 0.110710818 0.27467858
0.000388005 20.29495781 50.20513372 7.72839E-06
1.91745E-05
Ethylene
0.40305588
Kw
The calculated Kw value of 0.403 matches the Kw for the estimated temperature of 169C,
which is 0.404. Thus, the dew point of the distillate can be said to be 169C.
e)
Determination of Bubble Point
For the bubble point of the bottoms, the calculation is shown below.
Taking T=195oC for the first trial:
yi = ()
Table 4- 7 Calculation of boiling point at the bottom (First Trial)
Label
Component
wD
Ki
Ai
Aixi
Yi
Heavy key
Water
0.99933219
0.73408054
0.99933219
0.99661039
Light key
Ethylene
0.00066780
3.73617716
5.0896011
0.00339886
0.00338960
24.7105332
33.6618829
n/a
n/a
1.00273105
Oxide
Ethylene
Light
component
Total
Kw = 1.0027 = 0.99728
57

Referring to the graph above, the calculated Kw of 0.99728 is quite far from the initial value
of Kw = 0.734, which is the K value for the temperature of 195C. Therefore, a second trial is
carried out with T=210C.
Table 4- 8 Calculation of boiling point at the bottom (Second Trial)
Label
Component
wD
Ki
Ai
Aixi
Yi
Heavy key
Water
0.999332
1.0040179
0.99933219
0.99699059
Light key
Ethylene
0.000667
4.5351376
4.51698886
0.00301646
0.00300825
27.411179
27.3014847
n/a
n/a
1.00234866
0.9999988
Oxide
Ethylene
Light
component
Total
Kw = 1.00235 = 0.9977
The calculated Kw value of 0.9977 matches the Kw for the estimated temperature of 210C,
which is 0.9993. Thus, the bubble point of the bottom can be said to be 210C.
f)
Determination of the number of theoretical stages for total reflux
The average value must first be calculated in order to determine the number of theoretical
stages in the column.
LD = 6.388487296
LW = 4.535137694
Average value, L,av = ( LD)( WD)
= (6.388487296)(4.535137694)
= 5.38262664
The Theoretical stages for the distillation column are calculated by using the equation below:
Nm =
log[( )( )]
log(,)
58

The value of the , is substituted into the equation and the number of theoretical stages is
determined.
87.98610581)(0.999332195 2652.040273)]
log[(0.292337339
0.707274656 87.98610581 0.000667805 2652.040273
Nm =
log(5.38262664)
= 4.87 theoretical stages
= 3.87 theoretical trays + 1 reboiler
g)
Determination of the height of the column
The height of the distillation column is determined by using the equation below:
H = n (HETP)
where
n = number of stages
HETP = height of the column.
HETP is first calculated using the formula:
HETP =
where
Eo = efficiency of the trays = 0.492( )0.245
T = tray spacing
The average viscosity of the components is obtained from Aspen which is 0.5389cp
The Efficiency of the tray, Eo = 0.492( )0.245
59

Eo = 0.492((0.5389)(5.38262664))0.245
Eo = 0.378856248
T is taken to be 0.6m:
0.6
HETP = 0.3789
= 1.5837 m
Thus,
Height = n (HETP)
= (4.87) x (1.5837)
= 7.71 m
The height of the distillation column is 7.71m.
h)
Determination of the boiling point of the feed liquid
Average boiling point temperature = 130C

Water is selected as the base component.
Table 4- 9 Boiling point calculation for multicomponent liquid (First Trial)
Label
Component
Heavy Key
Water
Light Key
Ethylene
XF
KF
0.976629594 0.524969991
KF/Kw = F
FxF
0.976629594
0.023357946 3.035985424 5.783159943
0.13508274
Oxide
Light
Ethylene
1.24594E-05 22.11995092 42.13564832 0.000524984
Component
Total
n/a
n/a
1.112237318
1
= 0.8991
1.11223
The calculated value of Kw of 0.8991 corresponds to 205 oC, which is quite apart from the
predicted temperature of 180 oC. Thus, iteration is done to confirm this temperature by using
a temperature of 206C.
60

Table 4- 10 Boiling point calculation for multicomponent liquid (Second Trial)
Label
Component
XF
KF
KF/KIPA = F
FxF
Water
Ethylene
Oxide
Ethylene
0.976629594
0.023357946
0.925467009
4.312176001
1
4.659459452
0.976629594
0.108835404
1.24594E-05
26.68071476
28.8294607
0.000359197
n/a
n/a
1.085824195
Heavy key
Light key
Light
component
Total
1
= 0.921
1.0858
The calculated value of Kw of 0.921 corresponds to 206 oC, which is the predicted
temperature. Thus, the feed enters the distillation column at its boiling point of 206 oC as
saturated liquid.
i)
Determination of the value of Rmin.
Since the feed enters at its boiling point, q = 1.

An average temperature of 189.5C (average of top and bottom temperature) is taken.
Table 4- 11 Values for the calculation of minimum reflux ratio
Component
XIF
XID
Ki
XIW
0.999332195
Water
0.976629594
0.292337339 0.650912147
Ethylene
0.023357946
0.707274656 3.468214814 5.328237965
1.24594E-05
0.000388005 23.74743336
0.000667805
Oxide
Ethylene
36.4833157
\
Equation 11.7-19 from Geonkoplis Transport Processes and Separation Process Principles is
applied.
1 =

Since q=1 for feed at the boiling point, 1-1 = 0.
Thus,
1-q = 1-1= 0 =
1(0.9766)
1
0=
5.328(0.0234)
0.9766
1
5.828
0.1245
5.828
36.483(0.0000124)
36.483
0.000455
36.4833
61
Table 4- 12 Determination of
(Assumed)
4
5
4.9
4.85
4.839
.

-0.325543198
-0.244157399
-0.250417845
-0.253670024
-0.254396873
.
.
1.39936E-05
1.44381E-05
1.43924E-05
1.43696E-05
1.43647E-05
.
.
0.093700602
0.379166062
0.290625089
0.260240102
0.254388877
SUM
-0.231828603
0.135023102
0.040221637
0.006584447
6.36921E-06
The determined value is 4.839
+ 1 =
The final value of =4.839 is substituted into the equation above to solve for Rm:
+ 1 =
1(0.2923)
1 4.839
5.328(0.7073)
5.3284.839
36.4833(0.000388)
36.48334.839
= .
j)
Determination of operating reflux ratio, R and the number of theoretical trays

used.
The reflux ratio of R that we use for this project is R = 1.5Rm. Thus,
= 1.5(6.627)
= 9.94
62
Figure 4- 4 Erbar-Maddox Correlation
(Lo/V1): +1 = 0.909
(Lo/V1m): +1 = 0.869
(Sm/S):
= 0.60
4.868
= 8.11
N = 7.11 trays + 1 reboiler
*N = 8 trays + 1 reboiler
0.60 =
k)
Determination of the feed-plate location
The formula below is used to determine the feed plate-location of the column:
= 0.206 [( ) ( \)^2]
The values are substituted into the equation:
0.977 2652.04 0.00067
= 0.206 [(0.023) 87.9861(
0.99
)^2]
= 0.44949
63
= 0.355227
Ne = 0.355227Ns
9 = Ns + 0.355227Ns
Ns=6.64
Ne = 9 6.64 = 2.36
* The feed tray is 2.36 m from the top.
Steps (l) to (z) are carried out below for both bottom and top parts of the column.
Bottom Column
Distillate rate, D
3206.9
kg/hr
0.89
kg/s
73438
kg/hr
20.40
kg/s
Ln + D
7.13
kg/s
Liquid density, L
1015
kg/m3
Vapor density, v
9.556
kg/m3
Liquid rate, Lm
Vapour rate, Vm
64

Surface tension,
5.432
dyne/cm
0.005432
N/m
*The values above are obtained from the simulation results.
a) Column diameter, Dc
From equation 11.82 (Chemical Engineering Volume 6, R.K.Sinnott), Liquid-Vapor factor,

FLV:
FLV
Ln
Vn
20.40
7.13
0.278
The tray spacing is taken as =
v
L
9.556
1015
0.60
From figure 11.27 (Chemical Engineering Volume 6, R.K.Sinnott):

K1
0.07
This K1 can only can be applied when liquid surface tension is 0.02 N/m. Other than that
corrected surface tension should be calculated by;
K1,c

K1
0.02
0.005432
0.07
0.02
0.2
0.2
0.054
65
The flooding velocity is estimated such as follow:

Uf
L v
K 1, c
1015 9.556
0.054
9.556
0.553
m/s
The column is designed for 85% flooding at maximum flowrates.
Therefore,
Uv
0.85U f
0.85 x 0.553
0.470
m/s
Maximum vapor volumetric flowrate,
Qvmax =
Vn
7.127
9.556
0.746
Net area required, An =
m3/s
MaximumVaporVolumetricFlowrate
Uv
0.746
0.47
1.586
m2
Downcomer area is taken to be 15% of total:

Cross sectional area,
Ad
=
=
0.15An
0.15 1.586
0.238
m2
66

Total cross sectional area,
Ac
=
=
An + Ad
1.586 0.238
1.824 m2
Column diameter,
DC
4 Ac
4(1.824)
3.142
=
=
1.524
Thus, the larger value of 1.6m diameter will be taken as the design value.
Top Column
From the previous manual calculation:

Reflux ratio, R
9.94
From the results of Aspen simulation:

Bottom rate, B
Vapor rate, Vm
Liquid rate, Lm
47782
kg/hr
13.27
kg/s
25655
kg/hr
7.13
kg/s
Vm + B
6.24
kg/s
67

Liquid density, L
868.3
kg/m3
Vapor density, v
8.764
kg/m3
Surface tension,
4.864
dyne/cm
0.004864
N/m
a) Column diameter, Dc
From equation 11.82 (Chemical Engineering Volume 6, R.K.Sinnott), Liquid-Vapor factor,

FLV:
FLV
Lm
Vm
6.236
7.127
0.088
The tray spacing is taken to be
v
L
8.764
868.3
0.60

K1
0.1
This K1 can only can be applied when liquid surface tension is 0.02 N/m. Other than that
corrected surface tension should be calculated by;
K1,c

K1
0.02
0.004864
0.1
0.02
0.2
0.2
0.0754
Estimate the flooding velocity,

Uf
L v
K 1, c
868.3 8.764
0.0754
8.764
68

=
0.746
m/s
The column is designed for 85% flooding at maximum flowrates.
Therefore,
Uv
0.85U f
0.85 x 0.746
0.634
m/s
Maximum vapor volumetric flowrate,
Qvmax =
Vn
7.127
8.764
0.813
Net area required, An =
m3/s
MaximumVaporVolumetricFlowrate
Uv
0.813
0.634
1.282
m2
Downcomer area is taken to be as 15% of total:

Cross sectional area,
Ad
=
=
0.15An
0.15 1.282
0.192
m2
Total cross sectional area,

Ac
=
=
An + Ad
1.282 0.192
1.474
m2
69

Column diameter,
DC
4 Ac
41.474
3.142
=
=
1.370
Since bottom column diameter is bigger than top column diameter, we choose the bottom
column diameter for our design:
Dc
1.6
As the column diameter has been decided, the suitability of the column height is then checked
as below:
Ht
Dc
Check:
7.71
1 .6
4.81875 (satisfactory if
Ht
< 20)
Dc
Thus, the height of the column is suitable for the diameter of the column.
Liquid Flow Pattern
Maximum volumetric liquid rate,

Lmax
Lm
20.400
1015
0.020 m3/s
From figure 11.28 (Chemical Engineering Volume 6, R.K.Sinnott), the recommended liquid
flow pattern is for this specification is cross flow, single pass tray.
Provisional Plate Design
Column diameter, Dc =
1.6
m
70
Column area, Ac
D 2
4
3.142 1.6
2
=
=
Downcomer area, Ad =
Net area, An
Active area, Aa
4
2.011
m2
15% of Ac
0.15 x 2.011
0.302
Ac - Ad
2.011 0.302
1.709
Ac 2Ad
2.011 2 x 0.302
1.408
m2
m2
m2
Take 10% as first trial:

Hole area, Ah =
Ad
Ac
At ratio
10% of Aa
0.10 x 1.408
0.1408
15%
m2
From figure 11.31 (Chemical Engineering Volume 6, R.K.Sinnott)
Therefore,
lw
Dc
0.8
lw
0.8 x 1.6
1.28
The recommended values are used:

Weir height, hv
50
mm
Hole diameter, dh
mm
71

Plate thickness
mm
Figure 4- 5 Structure showing the cross-sectional area of the column
5.1.1.5 Check Weeping
Maximum liquid rate,

Lmax
20.400
kg/s
Minimum liquid rate (at 70% turn down),

Lmin
Lmax x 70%
20.400 x 0.70
14.280
kg/s
From Francis Weir formula (eq. 11.85), weir liquid crest:

Maximum, how=
L
750 max
L lw
72
20.4
750
1015 1.28
47.028
Minimum, how =
mm liquid
L
750 min
L lw
14.28
750
1015 1.28
37.076
mm liquid
At minimum rate,
=
hw + how
50 + 37.076
87.076 mm

K2
30.80
From eq. 11.84, minimum vapor velocity through the holes is given by:
Uh
=
=
K 2 0.925.4 d h
v
30.8 0.925.4 0.005
1
9.566 2
4.024
m/s
Actual minimum vapor velocity

=
0 .7
Maximum volumetric flowrate
Ah
0 .7
x 0.746
0.141
3.709
m/s
Plate Pressure Drop
73

Dry plate drop;
Maximum vapor velocity through holes,
Uh
For,
i)
ii)
Maximum volumetric flowrate

Ah
0.746
0.141
5.298
plat diameter
hole diameter
Ah Ah
A p Aa
m/s
1.00
0.10 (10%)

Co
0.84

U
51 h
Co
5.298 9.566
51
0.84 1015
19.101
From equation 11.88;

Dry plate drop, hd
Residual head, hr
mm liquid
1.25 10 4
1.25 104
1015
12.315
mm liquid
Total plate pressure drop,

ht
hd + (hw + how) + hr
19.101 + 87.076 + 27.796
118.492
mm liquid
74
Downcomer Liquid Back-up
From equation 11.92 and 11.93 (Chemical Engineering Volume 6, R.K.Sinnott):

Take Apron Height, Hap
hw 10
50 - 10
40
mm
0.04
Hap x It
0.04 x 1.28
0.0512
Area under apron

Aap
m2
As this is less than Ad = 0.302 m2, use Aap = Am=0.0512 m2 in eq. 11.92 (Chemical
Engineering Volume 6, R.K.Sinnott):
Head loss in downcomer

hdc
L
166 max
L Am
20.400
166
1015 0.0512
25.579
mm
0.025579
Back-up downcomer,
hb
( hw how ) ht hdc
87.076 + 118.492 + 25.579
231.147
mm
75

=
0.231
The hactual should be less than

hactual
1
(plate spacing + weir height)
2
1
(0.6 0.05)
2
0.325
Since hb is lesser than hactual, the tray spacing taken is acceptable.
Check residence time,

tr
Ad hb L
Lmax
0.302 0.231 1015

20.400
3.469
s (>3 s, satisfactory)
Check Entrainment
Actual percentage flooding for design area,
Uv
% Flooding
maximum volumetric flowrate

An
0.746
1.709
0.436 m/s
Uv
x 100
Uf
0.436
x 100
0.553
78.86%

76

At, % flooding =
FLV
78.86 %
0.278
Fractional entrainment,
0.065
Since is less than 1, the condition is satisfactory.
Trial Layout
Cartridge-type construction is decided to be used. 50 mm unperforated strip round

plate edge and 50 mm wide calming zone is allowed.
Figure 4- 6 The trial layout
Perforated Area
From figure 11.32 (Chemical Engineering Volume 6, R.K.Sinnott,):

At
Iw
Dc
0.840,
93
77

Angle subtended at plate edge by unperforated strip,
180 - c
180 93
87o
Mean length, unperforated edge strips,

ls
(Dc hw) x 180
(2.931 0.005) x 180
2.516
87
Area of unperforated edge strips

Au
hw x ls
0.05 x 2.516
0.126
m2
Mean length of calming zone,

lz
(Dc - 0.05)sin 2
1.095
2(0.05lz )
2(0.005 x 1.095))
0.110
Area of calming zone,

Az
m2
Total area available for perforations,

Ap
Ah
Ap
Aa (Au + Az)
1.408 (0.126 + 0.110)
1.172
0.141
1.172
0.120
m2
From figure 11.33: (Chemical Engineering Volume 6, R.K.Sinnott,):
78

Dh
lp
2.75 (satisfactory, within 2.5 to 4.0)
2.75dh
2.75 x 0.005
0.01325
dh2 (4 )
0.0052 (4 )
0.000019635 m2
Ah
area of one holes
0.141
0.000019635
7169
Holes
Hole pitch, lp
Area of one hole ,
Number of holes,
holes
Plate Specification
Figure 4- 7 Plate specification
Plate no.
T-102
Column height
7.71
m
79

Number of trays
Hole size
5.00
mm
Hole pitch
13.25
mm
Active holes
7169
Holes
Turn-down
70 % max rate
Plate material
Carbon Steel
Downcomer material =
Carbon Steel
Plate spacing
0.60
Plate thickness
5.00
mm
Plate pressure drop
118.49
mm liquid
1.1
kPa
Pressure vessel
19
bar
Column height
7.71
Inside diameter
1.6
Number of trays
Sizing orientation
vertically oriented
Carbon Steel
Column Costing
From sizing result:
Economic data:
Present Cost Index (2014, Oct)
578.9
Base Cost Index (1996)
382
Cost Of Column (Vessel, oriented vertically)
Based on Figure A.4 ,Snythesis & Design of Chemical Processes, Turton R ,2009, at a
column diameter of 1.6m and height of 7.71m,
Purchase equipment cost for year 1996,

80

Cp,1996 =
Update Factor, UF
US$ 28, 000.00
Present cost index (2014)

Base cost index (1996)
579.8
\
382
1.517
CP2014 =
CP1982 x UF
28,000.00 x 1.51
US$ 42498.42932
From figure 5.45 (Sinnott, 2005) at a pressure of 19 barg:
Pressure factor, FP
2.00
From Table A.3 (Turton, 2009):

Material factor for stainless steel, FM =
4.00
Pressure factor-Material factor,

=
FP x FM
2.00 x 4.00
8.00
From figure 5.46 (Sinnot, 2005):

Bare Module Factor,
Fo BM =
Cost of vessel, CBM =
16.00
Cp,2014 x FoBM
42498.42932 x 16.00
US$ 679,974.8691
81
Cost Of Tray Stack (Sieve Tray)
From figure A.6 (Turton, 2005), for a column diameter of 1.6m:
Purchase equipment cost for year 1996,

Cp, 1996 =
US$ 420.00
Cp,2014 =
Cp, 1996 x UF
420.00 x 1.517
US$ 637.48
Equation A.1 from Turtons Synthesis and Design of Chemical Processes is applied:
= 1 + 2 log 10 3 (log ) 2
Where:
K1:
0.4771
K2:
0.08516
K3:
0.3473
N:
Fq:
1.27
Based on Table A.6 and Figure A.9 (Turton, 2009), for sieve tray:
FBM
1.9
Cp,2014 x FBM x N x Fq
637.48 x 1.9 x 9 x 1.27
US$ 13887.09
Cost of sieve tray,

CBM
Total Bare Module Cost

=
Cost of vessel + Cost of sieve tray
82

=
679,974.8691+ 13887.09
US$ 693861.96
RM 2810140.943
Storage Tank
Storage Tank and Intermediate Tank
Ethylene Storage Tank (Spherical Tank Design)
Properties of the tank
Storage Classification
Spherical tank
Stainless steel
Ethylene properties
Table 4- 13 Properties of Ethylene

MW
Molar flow rate
Mass flow rate
Density
Component
(kg/kmol)
(kmol/hr)
(kg/hr)
(kg/m3)
Ethylene
28
107.31
107.31
50.5678
Design for shell
Period of inventory
weeks
Liquid volume needed to be stored, VL =
Vdaily x Period of inventory
Volume per hour
2.122193 m3/hr
1 day inventory
VL
24 hr
50.93263 m3/day
83

356.5284 m3/week
1069.585 m3/3 weeks
Vstorage
Vvapor + VL (assuming 10% volume added for vapor flows)
1.1 VL
56.02589 m3
392.1812 m3/week
1176.544 m3/3 weeks
Volume stored
m3
1500
6V
6 1500
3.142
14.2
46.6
ft
D (since it is spherical pressure vessel tank)
Diameter of tank
For spherical tank,

V
D 3
6
D
Height of Tank
84
Figure 4- 8 Dimension of the tank
Stress of Tank
From equation 13.9 (Chemical Engineering, volume 6)

1, 2 =
PD
4t
(Eq. 13.9)
Where:
1
the meridional (longitudional), the stress acting along a
meridian
2
the circumferential or tangential stress acting along parallel
thickness of cylinder
pressure
circles
Minimum Shell wall thickness (source: Aboveground Storage Tank)
Table 4- 14 Shell plate thickness respective to the tank diameter

Nominal Tank Diameter (ft)
Minimum Shell Plate Thickness (in)
D < 50
3/16
50 < D < 120
4/16
120 < D < 200
5/16
D > 200
6/16
From Table 4-2, the minimum wall thickness is

85

t
3/16
in
0.00476
Thickness of the wall =
t + corrosion allowance
t+2
mm
4.763 + 2
6.763
mm
0.00676
As corrosion is being considered,
3000000 14.2
4 0.00676
1, 2 =
N/m2
1575068435
15750.68435 bar
Costing
As corrosion is considered,
P
1, 2
30
bar
PD/4t
1575068435
N/m2
15750.68435
bar
Equation A.1 from Turtons Synthesis and Design of Chemical Processes is

applied:
Where:
K1:
4.8509
K2:
-0.3973
K3:
0.1445
86

Log Cp,2001:
5.046690739
Cp, 2001 (US$):
111350.1328
CEPCI 2001
367
CEPCI 2014
579.8
Cp, 2014 ($) :
175915
(Source: Figure A-18, Students handbook process engineering economic)
According to Table A.3, for stainless steel,
Materal Factor,
FM
Referring to Figure A.5 for a pressure of 30 bar,

Pressure Factor,
FP
CBM
2.5
175915 x 4 x 2.5
US$ 1759150.055
RM 7124557.721
Ethylene Oxide Storage Tank (Cylindrical Tank Design)
Properties of the tank
Storage classification
Cylindrical tank
87

Carbon steel
Roof (open/close)
Close
Roof type
Fixed cone roof
Ethylene Oxide properties
Table 4- 15 Properties of Ethylene Oxide

MW
Molar flow rate
Mass flow rate
Component
(kg/kmol)
(kmol/hr)
(kg/hr)
Density (kg/m3)
Ethylene Oxide
44.05
62.23
2741.25
882
Design for shell

Period of inventory
weeks
Liquid volume needed to be stored, VL =
Vdaily X Period of inventory
Volume per hour
3.107989339 m3/hr
1 day inventory
VL
24 Hr
74.59174 m3/day
522.1422 m3/week
1566.427 m3/3 weeks
Vstorage
Volume stored
Vvapor + VL (assuming 10% volume added for vapor flows)
1.1 VL
82.05092 m3
574.3564 m3/week
1723.069 m3/3 weeks
2000
m3
88

Diameter of tank
For cylinder tank,

V
D 2 H
4
D
where, H = 1.5 D
4V
1.5
4 768.562
1.5
17.2
56.4
ft
Table 4- 16 H/D ratio for respective range of tank diameter

Tank Diameter
Ratio H/D
D < 60
0.5
95 < D < 60
0.4
175 < D 95
0.3
D > 175
0.25
From Table 4-4 (Ulrich, 1984), for D = 56.4 ft,
H/D
0.5
(D < 60 ft)
0.5 D
0.5 x 17.2
8.6
28.2
ft
Height of Tank
Hs
89
VV
D 2 H S H L H R / 3
4
Since, HR
D
Tan
2
Let =
HR
HL
10o
0.175
radian
8.673
Tan (0.175)
2
1.517
HS
H R 4VV
3 D 2
8.6
1.517 4 0.1 2000
3
3.142 17.22
8.247
Stress of Tank
From equation 13.7 & 13.8 (Chemical Engineering, volume 6)

1
PD
4t
(Eq. 13.8)
PD
2t
(Eq. 13.7)
Where:
90

1
the meridional (longitudional), the stress acting along a
meridian
2
the circumferential or tangential stress acting along parallel
thickness of cylinder
pressure
circles
Minimum Shell wall thickness (source: Aboveground Storage Tank)
Table 4- 17 Shell plate thickness for various ranges of tank diameters

Nominal Tank Diameter (ft)
Minimum Shell Plate Thickness (in)
D < 50
3/16
50 < D < 120
4/16
120 < D < 200
5/16
D > 200
6/16
From Table 4-5, the minimum wall thickness is

t
3/16
in
0.00476
As corrosion is being considered,

1
250000 17.2
4 0.00476
225778697.2 N/m2
250000 17.2
2 0.00476
451557394.3 N/m2
Design for Roof
91

According to code AP1650, the required minimum of self-supported fixed-cone roof, t
(Myers, 1997)
t
D
400 sin
17.2
400 sin 0.175
0.813
in
20.647
mm
Since the roof thickness is 20.647 mm, the thickness of the shell wall would be,
=
20.647 + corrosion, allowance of 4 mm
24.647
mm
Volume storage
2000
m3
Pressure
2.5
bar
Costing
Equation A.1 from Turtons Synthesis and Design of Chemical Processes is

applied:
Where:
K1:
5.9567
92

K2:
-0.7585
K3:
0.1749
Log Cp,2001:
5.358718899
Cp, 2001 (US$):
228411.9908
CEPCI 2001
367
CEPCI 2014
579.8
Cp, 2014 (US$)
360853.6
(Source: Figure A-18, Students handbook process engineering economic)
According to Table A.3 for carbon steel,
Materal Factor,
FM
Referring to Figure A.5 for a pressure of 2.5 bar,

Pressure Factor,
FP
CBM
1.2
360853.6 x 1 x 1.2
US$ 433024.3235
RM 1753748.51
93

*The sizing and costing of the storage tanks of both water and potassium carbonate to be used
in the absorbers and the intermediate tanks are calculated using the similar method as the
storage tanks for these
are also cylindrical. The
results are tabulated in Chapter 4
Mixer
Component kg/hr
C2H4
298.0741
O2
507.1419
N2
357.1756
H2O
12.83336
CO2
74.10228
1249.32724
kmol/hr
10.6265276
15.8481844
12.7501696
0.71235894
1.68376005
41.6210006
components
calculated
of this report.
Stream 37
Stream 11
Component kg/hr
kmol/hr
C2H4
3012.53 107.398574
3012.53 107.398574
Stream 12
MIXER
Component kg/hr
C2H4
3310.6041
O2
5689.5549
N2
716.5856
H2O
12.83336
CO2
74.10228
9803.68024
Stream 8
Component kg/hr
O2
5182.413
N2
359.41
5541.823
kmol/hr
118.0251016
177.7985906
25.58010095
0.712358939
1.683760055
323.7999122
kmol/hr
161.950406
12.8299314
174.780338
94
Table 1 shows the temperature (K) and pressure (bar) in each inlet stream which will be used
to determine the reduced temperature, Tr and reduced pressure, Pr.
Table 12 Table of Temperature and Pressure at each Inlet Stream
Temperature (K)
Pressure (bar)
Density (kg/m3)
Stream 11
308.15
22
24.09
Stream 37
361.94
21
20.95
Stream 8
542.65
22
15.46
Stream 12
418.65
21
18.27
Component
To obtain the value of reduced temperature, Tr and reduced pressure, Pr, first take the value of
Tc and Pc for each component involved from Table B.1 of Appendix B. J.M. Smith, Introduction
to Chemical Engineering Thermodynamics.
Table 2 shows the value of both Tc and Pc for component; ethylene, oxygen, nitrogen, water
and carbon dioxide.
Table 13 Table of Tc and Pc value for each component involved
Components
Tc (K)
Pc (bar)
C2H4
282.3
50.4
O2
154.6
50.43
N2
126.2
34
H2O
647.1
220.55
CO2
304.2
73.83
Equation 1 and equation 2 below is used to determine the value of Tr and Pr for each component
at each stream.
95
Equation 1
Equation 2
Table 14 Table of Tr and Pr values for each component at each stream

Streams
Components
C2H4
Stream 11
Tr
Pr
Stream 37
Tr
Stream 8
Pr
Tr
Pr
1.091569 0.436507937 1.282111229 0.416666667
O2
2.341138422 0.416418798 3.510025873 0.43624826
N2
2.867987322 0.617647059 4.299920761 0.64705882
H2O
0.559326225 0.095216504
CO2
1.189809336 0.284437221
Table 3 shows the value of Tr and Pr calculated in order to obtain the value of Z0 and Z1 from
Tables E.1 and E.2. J.M. Smith, Introduction to Chemical Engineering Thermodynamics. The
interpolation in Table E.1 and E.2 for Z0 and Z1 values provides in Table 4.
Table 15 Table of Z0 and Z1 values for each component at each stream

Streams
Stream 11
Stream 37
Stream 8
Z0
Z1
Z0
Z1
0.8790
0.0026
0.9334
0.0266
O2
0.9959
N2
1.002
Components
C2H4
Z0
Z1
0.0292
1.0039
0.0221
0.0368
1.0071
0.0291
96

H2O
0.0184
-0.0081
CO2
0.9422
0.012
Equation 3 below is the equation used in order to determine the value of correlation Z.
= 0 + 1
Equation 3
The value of is obtain from Table B.1. J.M. Smith, Introduction to Chemical Engineering
Thermodynamics. Table 5 shows the value of for each component.
Table 16 Table of values for each component

Components
C2H4
0.087
O2
0.022
N2
0.038
H2O
0.345
CO2
0.244
From the equation 3, the value of correlation Z is calculated for each component at each stream.
Table 6 shows the value of correlation Z.
Table 17 Table of correlation Z value for each component

Components
C2H4
O2
Stream 11
Stream 37
1.0002262
0.9357142
0.9965424
Stream 8
1.0043862
97

N2
1.0033984
H2O
0.0156055
CO2
0.945128
1.0083058
Equation 4 below is used to determine the molar volume of each component from the three
inlet into the mixer. The universal gas constant value used is from Table A.2 Appendix A, R =
83.14 cm3.bar//mol.K.
=
Equation 4
Table 7 shows the molar volume for each component at each inlet stream.
Table 18 Table of molar volume for each component at each inlet stream
Molar Volume (m3/mol)
Components
C2H4
Stream 11
Stream 37
0.00116479
0.00134082
Stream 8
O2
0.001427983
0.00205972
N2
0.001437807
0.00206776
H2O
2.23617E-05
CO2
0.00135431
Next, the molar volume is to be convert into m3 per hour in order to determine the total volume
of inlet gas. The space time for the mixer is 20 seconds which equivalent to 0.0055556 hour.
Table 8 shows the volume of the component in each stream.
98

Table 19 Table of volume of each component in each stream
Volume (m3)
Components
C2H4
Stream 11
Stream 37
0.694982474
0.079157016
Stream 8
O2
0.125727445
1.8531791
N2
0.10184469
0.14738546
H2O
8.84977E-05
CO2
0.012668512
The volume for each component at each stream then be sum up and total of 2.0 m3 is obtained.
The mixer volume is decided to be 2.0 m3.
An assumption for the shape of the mixer is made. The form of the mixer is a vertical cylindrical
tank with diameter of 0.7m. From the total volume of mixer obtained, the height of the mixer
is to be 5.3m.
Costing
The power consumption by the mixer is 403 kW.

Equation 5 below is to calculate the update factor, UF.
=
=
(2014)
(1996)
Equation 5
579.8
382
= 1.518
From Figure A.15, Process Engineering Economics Handbook, when the value of power
consumption is 403kW;
99

= 2 $/
then,
1996 = $ 806
Equation 6 shows how to determine the Cp value in 2014;
2014
2014
= $ 1,223.35
1996
Equation 6
For a carbon steel mixer, the bare module factor, is 1.70.

Equation 7 shows the bare module cost for equipment at base condition.
=
Equation 7
= $ 2,079.69
= 8,401.95
The cost consumed for the design of the mixer is RM 8,401.95.
Membrane Separator
Component
Lf = 23,418.02 kg/hr
Component
mol %
kg/hr
mol %
kg/hr
kmol/hr
O2
Ypb
0.015228
272.21
8.51
N2
Ypc
0.984772
17603.98
628.41
Vp = 17,876.20 kg/hr
MEMBRANE
SEPARATOR
kmol/hr
O2
Xfb
0.232924212
5454.62
170.46
N2
Xfc
0.767075788
17963.40
641.24
Lo = 5,541.83 kg/hr
Component
mol %
kg/hr
O2
Xob
0.935145
5182.41
kmol/hr
161.95
N2
Xoc
0.064855
359.41
12.83
100

The fraction permeates, is calculated based on the equation 8 below. C.J. Geankoplis,
Transport Processes & Separation Process Principles (Includes Unit Operations).
Equation 8
The formula used to calculate the total membrane area required for the membrane separator is
shown as in equation 9. C.J. Geankoplis, Transport Processes & Separation Process Principles
(Includes Unit Operations).
=
( )( )
Equation 9
The value required are shown as follow;

Lf = 23,418.02 kg/hr = 8,751.13 m3/hr
yp = 0.015228
thickness, t = 0.000018 m
PA = 1.67422 x 10-6 m3(STP).m/hr.m2.bar
Ph = 3 bar
= 0.763352097
xf = 0.232924212
xo = 0.93514541
pl = 2.8 bar
Finally, the total membrane area required for the membrane separator is 396 m2.
For the membrane separator, the design used is shell and tube membrane separator. The
membrane chose is dimethylsilicone rubber.
Normally, the diameter of the membrane separator shell is to be 0.2m with length of 3m. C.J.
Geankoplis, Transport Processes & Separation Process Principles (Includes Unit Operations).
In one shell, there will be 2,986 tubes that can be fitted. From the total membrane are calculated
above, it has been decided that 16 shells are required to be the units of the membrane separator.
101

Costing
Type of material: Dimethylsilicone rubber

Price per m2: $ 68
Cost of total membrane area: $ 26,917.76
: RM 108,747.74
Absorbers and Stripper

Diameter, Height and Cost Calculation for Ethylene Oxide Absorber
No. of trays, N
Top product rate, D
4976.744 kg/hr
51476.31 kg/hr
Vapor flow rate, V
1.3824289 kg/s
Liquid flow rate, L
14.298975 kg/s
Density of vapor, v
19.13 kg/m3
1008 kg/m3
Liquid vapor flow factor, FLV

=
= 1.425
Assuming plate spacing = 0.6m, at

= 1.425
From Figure 11.27, Chemical Engineering Volume 6, 4th Edition pg 568:
a constant obtained, K1 = 0.029
102

Flooding vapor velocity, = 1
= 0.2085 /
For 80% flooding (assume), = 0.8 = 0.167 /

Maximum volumetric vapor flow rate, =
= 0.072 3/
Net area, = = 0.433 2
Take down comer area as 12% of total, so the down area, = 0.12 = 0.05202
Column area, = + = 0.4852 2
4
Column diameter, =
= 0.8
Maximum volumetric liquid rate, = = 0.0142 3/
Selection of liquid flow arrangement

From Figure 11.28, page 569 [Volume 6], at = 0.8 = 0.0142 3/
Type of flow = cross flow (single pass)
Provisional plate design:

Column diameter, Dc
0.8 m
Column area, Ac
0.4852 m2
Down comer area, Ad
0.0520 m2
Net area, An
0.4332 m2
Active area, Aa=Ac-2Ad
0.3813 m2
103

Hole area, Ah=0.10Aa
0.0381 m2
Weir height, hw
50 mm (standard)
Hole diameter, dh
5 mm (standard)
Plate thickness, tp
5 mm (standard)
Weir length, lw
Ad
100 = 10.7143
From Figure 11.31, [Volume 6],
0.72
= 0.576
Weeping checking
Maximum liquid flow rate, =14.299 kg/s
Minimum liquid flow rate at 70% turn down, =20.009 kg/s
Maximum height of liquid crest over down comer weir,

2
, = 750[
]3 = 63.4857

Minimum height of liquid crest over down comer weir,
2
, = 750[
]3 = 50.0504

So, minimum rate of liquid weir height, + , = 100.0504
K2 is found by using + , . From Figure 11.30, page 571 [Volume 6], 2 31
Minimum vapor velocity, =
2 0.90(25.4 )
1/2
Actual minimum vapor velocity,, =
0.7
= 2.9814 /
= 1.3268 /
< , minimum operating rate will be below weep point.
Plate pressure drop
Maximum vapor velocity through hole, = = 2.787 /
104

Assumption: Plate thickness/ hole diameter = 1.00
= 3.0 = 15 mm,
the normal range will be 2.5 to 4.0 of hole diameter (volume 6)
From Figure 11.33, value of
can be obtained
= 3.0
= 0.09
100 = 9
From Figure 11.34, [Volume 6], using
100
= 9, the orifice coefficient, 0.84
Pressure drop through dry plate, = 51[ ]2 = 4.9283 mm liquid
Residual pressure drop, =
1.25 103
= 1.24
Total pressure drop, = + ( + , ) + = 119.654
Down comer back-up

Down comer pressure drop, = 10 =
40 ( 10 )
Area under the down comer (under apron), = ( ) = 0.023 2
is smaller than , so use to calculate head loss in down comer
Head loss in down comer, = 166[

]2 = 62.926 mm liquid
=
= ( ) ( )
Down comer back-up, = [ + ( + ) + ] 103 = 0.296
105
Checking for correct tray spacing estimated:

0.5 (plate spacing + weir height) = 0.625
< 0.625, 0.6
Check residence time, =
= 1.085
Residence time should not be less than 1 seconds

Residence time is satisfactory
Check entrainment
Actual percent flooding for design area, = = 0.167 /
% Flooding = 100% = 80% = 1.42
From Figure 11.29 [Volume 6], Fractional entrainment = < 0.1 ()
Perforated area
Angle subtended by unperforated strip.
From Figure 11.32, [Volume 6], for = 0.72
Therefore, = 98
180 = 82
Mean length, unperforated edge strip = ( 0.05) (180

) = 1.073
Area of unperforated edge strips = 0.054 2

Area of calming zone = 2(0.05)[ 2(0.05)]
(0.05 m = 50 mm)
= 0.0476 2
Total area available for perforation,
= ( + ) = 0.280 2
106
= 0.136
Using value of by referring to Figure 11.33 [Volume 6],
= 2.7
Therefore, = 2.7 = 13
Number of holes
Area of holes, =
2
4
= 1.963 052
Number of holes, = = 1942
Total plate pressure drop, = 9.81 = 1183 2 1000 = 1.183 2 ()
Column height
Assume the stage efficiency = 90%
So, number of real stages =
(1)
0.90
= 9
Column height = (. 1)( ) + 2( ) +

(. )( ) + ( ) + ( ) = 9.045
Cost Calculation Ethylene Absorber

Vessel (vertical oriented)
Based on Figure A.4, Synthesis & Design of Chemical Processes, Turton R, 2009
At = 0.8 = 9.045
P = 19 barg
From Figure A.5, pressure factor, = 2.0
From Table A.3, for stainless steel vessel, = 4.0
Therefore, = 8.0
107
Based on Figure A.5,

16.4
10 = 1 + 2 10 () + 3 [10 ()]2
==
2
4
Based on Table A.1,

1
3.4974
0.4485
0.1074
4.5465 m3
6902.72$
=
= 113204.69$
1 =
11
= 117711.53$
96
Price of sieve trays

Based on Figure A.19, assumed tray is stainless steel,

61
10 = 1 + 2 10 () + 3 [10 ()]2
2
=
4
Based on Table A.1,
1
2.9949
0.4465
0.3961
0.5027 m2
108

787.74$
As there are 9 trays,
9 7089.66$
=
= 432469.26$
2 =
11
= 449686.48$
96
Total Cost of Equipment

= 1 + 2 = 567398.01$
Cost Calculation Carbon Dioxide Absorber

At = 0.647 = 12.070
P = 18 barg
Therefore, = 8.0

16.4
10 = 1 + 2 10 () + 3 [10 ()]2
==
2
4
Based on Table A.1,

1
3.4974
0.4485
0.1074
3.968 m3
109

6374.79$
=
= 104546.56$
1 =
11
= 108708.71$
96


61
10 = 1 + 2 10 () + 3 [10 ()]2
2
4
Based on Table A.1,

1
2.9949
0.4465
0.3961
0.3288 m2
744.29$
10 7442.9$
=
= 454016.9$
2 =
11
= 472091.96$
96

= 1 + 2 = 580800.67$
110

Cost Calculation Carbon Dioxide Stripper
At = 1.073 = 4.78
P = 18 barg
Therefore, = 4.0

9.5
10 = 1 + 2 10 () + 3 [10 ()]2
==
2
4
Based on Table A.1,

1
3.4974
0.4485
0.1074
4.32 m3
6695.56$
=
= 63607.82$
1 =
11
= 66140,14$
96


61
10 = 1 + 2 10 () + 3 [10 ()]2
2
4
111
Based on Table A.1,

1
2.9949
0.4465
0.3961
0.900 m2
944.71$
6 5668.26$
=
= 345763.86$
2 =
11
= 359529.21$
96

= 1 + 2 = 425669.35$
* Carbon Dioxide Absorber and Carbon Dioxide Stripper used the same calculation steps as shown
above.
112

Graphs referred for Absorbers and Strippers Sizing Calculation
113
114
115
116
Figure 11.32: Angle substended by unperforated strip
Heat Exchanger and Compressor

Compressor
Oxygen
Nitrogen
MW
32
28
Specific Heat Ratio, k = Cp/Cv
1.40
1.41
0C
29.17
29.92
100C
29.10
29.31
Cp.m.
117

Critical Conditions
Absolute Pressure Pc (bar)
50.3
39.9
Absolute Temperature, Tc (K)
154.4
126.7
Specific Heat Ratio,k
Critical Temperature, Tc
Critical Pressure, Pc
yi * ki
1.4079
yi * Tci
132.52 K
yi * Pci
42.084 bar
To find compressibility z, find Tri and Pri

Tri
Ti/Tc
2.24876
Pi/Pc
0.023762
Zi
0.98
vi
24.28
vi * mi
24789.76 m3/hr
14590.71 ft3/min
0.732
Pri
Vi
Np
m3/kg mol
(Centrifugal Compressor)
118
1 ( 1)/
=
1
= 0.3958
Tr2
T2/Tc
3.41843
P2/Pc
0.07128
Z2
0.99
1+2
2
0.985
11
(1)
3341443 J/kgmol
Wcn
Ns
0.98
Nb
0.85
Ng
0.95
Wcn
5768387 J/kgmol
Pcp
Wcn* m
1635.957 kW
Pr2
Wp1
2 1
[(1)
1]
119
Pe
2193.853
Pcp/ne
2333.887 hp
1740.356 kW
Costing
Type
Centrifrugal Compressor
Power
1422.91 kW
Output Pressure
21 bar
With reference to costing method proposed by Turton R,

From Figure A.1 using the Power
1422.91 kW
Cp($)
341497.20
Fbm
2.7
Cbm
$ 922042.45
Escalate Price using CE plant cost index for 2001
CEPCI 2001
397
CEPCI 2015
578
120
CP2015
= Cp * (CEPCI 2015/CEPCI 2001)

= $ 1342419.49
= RM 5423374.72
121
Heat Exchanger
Cooler 2
Equipment Sizing
Heat exchanger type
2 shell and 6 tubes
Design type
Floating head
Heat exchanger orientation
Horizontal
Tube inlet direction
Horizontal
Tube Side
Cold Water
Shell Side
Gases
Heat duty
825.3
kW
23403.93
kg/hr
3.1.1.1 Prelimanary Calculation
Hot Stream Cold Stream

(shell side) (Tube side)
Tin (oC)
256.65
25
Tout (oC)
120
100
T1 :
inlet temperature to shell
T2 : outlet temperature from shell
122

t1 : inlet temperature to tube
t2 : outlet temperature from tube
T1 T2
t 2 t1
256.65 120
100 25
1.82
t 2 t1
T1 t1
100 25
256.65 25
0.32
From figure 12.19 (Chemical Engineering Vol. 6)

Ft
Tlm
0.98
T1 t 2 T2 t1
T t
ln 1 2
T2 t1
256.65 100 120 25

256.65 100
ln
120 25
123.27 oC
123

Tm
FtTlm
0.98 x 294.846
120.8
From Table 12.1, Chemical Engineering vol.6,
Assumption,U =
Povisional area, A
100
W/.m2 oC
Q
UTm
825.3
100 120.8
68.319
m2
Tube Rating
Material
Carbon Steel
Length of tube, Lt
Outer diameter, Do
30
mm
Inner diameter, Di
25
mm
Area of one tube, At
LtDo
124

=
2 x 3.142 x (30x10^-3)
0.189
m2
A
At
68.319
0.189
362.4
1.25 x Do
1.25 x (30x10^-3)
0.0375
K1
0.0743
2.499
N n
Do t
K1
363 2.499
0.0375
0.0743
748.338mm
Number of tube, Nt
Tube pitch, Pt
tubes ~ 363 tunes
From Table 12.4,
Bundle diameter, Db
From figure 12.10,

125
Shell bundle clearance

=
60
mm
Db + shell bundle clearance
808.338
Shell internal diameter,

Ds
mm
Tube Side Coeffient
Mean cold stream Temperature,
t1 t 2
2
25 100
2
62.5
Tube cross-sectional area,
Tube per pass
Total flow area =
d i 2
4
533.125mm2
number of tube
2
60.5
tube per pass x tube cross-sectional area
126
Cold stream flowrate
m2
0.032
Heat Duty
C p t 2 t1
2.631
kg/s
Cold stream mass velocity,
cold stream flowrate

total flow area
81.560
kg/s.m2
Cold stream linear velocity,
ut
cold stream mass velocity

density of cold stream
0.082
m/s
From equation 12.15 (page 538)
0.33
0.14
hi d i
kf
jh
heat-transfer factor
hi
inside coefficient, W/m2 oC
kf
fluid thermal conductivity, W/m2 oC
j h Re Pr
where;
127

di
inside diameter, m
fluid viscosity at the bulk fluid temperature, Ns/m2
fluid viscosity at the wall
Re
Reynolds number
Pr
u t d i
Prandtl number
Cp
kf
where;
ut
= fluid velocity, m/s
Cp = fluid specific heat, heat capacity, J/kgoC
From cold stream;
993.69
kg/m3
0.0000662
kg/m.s
Cp
4.243
kJ/kg.oC
kf
0.631
W/m.oC
Re
3080.067
Pr
4.389
128

L
di
80
From figure 12.23 (page 539),

jh
0.004
506.610W/m2 oC
neglect (/w) ,
hi
129
Shell side heat transfer coefficient
Cross flow area, As
pt d o Ds l B
pt
Where;
pt
tube pitch
do
tube outside diameter
Ds
shell diameter inside diameter, m
lB
baffle spacing, m
161.67
mm
0.0261
m2
As
Shell side mass velocity,
Gs
Ws
As
Gs
248.737kg/s.m2
Shell side equivalent diameter,
De
1.10 2
p t 0.917d o2
do
21.3015mm
Mean shell side temperature,

130

Tmean
T1 T2
2
188.325oC
From Simulation (Hot stream);
5.286
kg/m3
0.000024
kg/m.s
Cp
4.18
kf
0.0319
Re
Pr
kJ/kg.K
W/m.K
G s De
220769.78
Cp
kf
0.6989
Selecting 25% for baffle cut, from figure 12.29 (page 546),
131

jh
1.4 x 10^(-3)
Shell side heat transfer coefficient,
hs
j h Re Pr
de
1/ 3
kf
0.14
without the viscosity correction term,

hs
410.76 W/m2oC
Tube side Pressure drop

at Re
Fiction factor, jf
3080.067
0.006
132
Pt
N p 8 j f
di
u 2
2.5 t
2
Neglecting the viscosity correction term,

Pt
127.32 Pa
0.0012 atm
3.1.1.5 Shell side Pressure drop
Linear velocity,
Gs
47.056 m/s

at Re
Fiction factor, jf
Ps
220769.78
0.034
8 j f
lB
D s
d e
u s 2
2
Neglecting viscosity correction,

Ps
186.82
Pa
1.844
atm
133

Overall heat transfer coefficient,
ho
Actual Area, A =
235.92 W/m2.C
37.626 m2
Costing
Type
Shell and tube
Area
37.63 m2
Material
Carbon Steel
Feed Pressure
0.9 bar
With reference to costing method proposed by Turton R,

From Figure 7.4 for area
37.63
Cp($) =
9000
Cbm
Cp*(B1+B2*Fp*Fm)
m2
Fp =
1.00
Fm =
1.00
B1 =
1.63
B2 =
1.66
Cbm
$ 2961
Escalate Price using CE plant cost index for 2001
CEPCI 2001
397
CEPCI 2015
578
134

CP2015
= Cp * (CEPCI 2015/CEPCI 2001)

= $ 4310.98
= RM 17416.35
Reactor
Step 1
The characteristics for R-1 are stated as below:

Vapour phase, fixed bed multi-tubular reactor
Isothermal operation
Material of construction: Tube side: stainless steel
Shell side: carbon steel
Some assumptions are made for R-1 reactor
Steady state condition
No radial variation in concentration, in the reactor
The concentration of reactants and products are varies continuous in the
axial direction through the reactor
The fixed bed reactor can be designed as unit in large cylinder with
jacketed or cooling as needed. It can also be designed as multiple units with
heating or cooling between the separate beds to maintain the necessary
temperature levels. The design of unit of this type is often based on the
consumption of based on the assumption of ideal plug flow. The design of reactor
vessel is handled in a manner similar to that for heat exchanger (Peter and
Timmerhaus, 1991), where molten salt is used for cooling purpose in shell side
and the catalyst is packed in tubes.
135
Total Inlet and Outlet Flowrate (extracted from ASPEN)
Mole Basic, kmole/ hr
Mole Fraction
Component
Inlet
Outlet
Inlet
Outlet
64.001
0.0
0.07
Ethylene
119.201
11.920
0.125
0.0013
Oxygen
175.225
13387
0.184
0.015
Water
84.295
0.0
0.092
Carbon dioxide
86.558
0.0
0.094
Nitrogen
659.179
659.179
0.691
0.717
Total
953.604
3001.71
1.0000
1.0000
Ethylene oxide
136

Step 2
Reactor Conditions:
i. Properties of catalyst
Suitable catalysts for this process are supported catalysts consisting of spherical
inert (alumina) coated with a thin layer of catalytically active material. The
catalytically active material forming a 0.05 to 1mm thick coating on the support is
composed of 30% w/w of vanadium pentoxide and 70% w/w of titanium
dioxide. Following are the properties of the catalysts:
Physical form
Spherical beads
Life time of catalyst
4 year
Particle size
0.5 - 50 mm
Average pore diameter
100-1000
Residence time
20 s
3581. 654 kg/m3
Apparent density
Void fraction
0.7
Surface area
0.2 0.8m2/g
The spherical catalyst is chosen in order to increase the reaction area. This catalyst
has a very long life.
ii. Operating Conditions for R 1
190
Temperature
C
Pressure
21.05
137

atm
0.1-1.0
Pressure Drop
atm
Feed ratio: Air to Ethylene Oxide
The dimensions of catalyst used, Dp = 0.008 m

Stream properties from ASPEN,
= 15.923kg/m3
= 33.906 kg/m.s
kf
= 0.0434 W/m.K.
Cp = 42.22 kJ/kg.K
Duty = 126 kW
`Coolent used
: Water
From : From Table A.2-12, Transport Processes and Unit Operations, 4th Edition, Page 968
T inlet cooling water =
303.15
Pressure =
1.01325
bar
pw =
0.355
kg/m3
Cpw =
2.0156
kJ/ kg.K
mw =
0.00002226
kg/m.s
Pr =
0.9344
T outlet cooling water =
363.15
Step 3
Reactor Volume Calculation
138

Assume that the residence time,
Let 1/
required for reaction at 463.15 K is 20s.
180 hr-1
The relationship between residence time and reactor volume, V is given as

1/
= vo/V
Source: Elements of Chemical Reaction Engineering 3th Edition, page 58.

where,
V = reactor volume
vo = volumetric flow rate of fluid entering the reactor
From ASPEN result,

the feed (mass flowrate )
30014.71 kg/hr
and the density
15.92 kg/m3
so, the volumetric flowrate, Vo =
1884.96 m3/hr
Volume of reactor, V =
30014.71 / 180
=
10.47201929 m3
The calculated V is only the volume of reactant fluid (not including catalyst).
Consider the void fraction of the catalyst bed of the total volume of reactor is
approximately
0.7
Therefore, total tube volume, VR = V / e

VR
18.37196366 m3
Therefore the actual reaction volume required is

VR
7.899944373 m3
Step 4
Number of Tubes
Assume no of tube, N = 1500
139

Step 5
Dimensions of Standard Steel Pipe

Nominal
Outside
Schedule
Pipe Size
Diameter,
Number
(in)
do (in).
2.375
40
Source: Transport Processes and Unit Operations, 4rd Edition
Ac
0.0233 ft2
0.002165 m2
The length of pipe, L = W / (1- )Ac

W
bc
VR (1- )x
10472.019 kg
Weight of catalyst per tube = 6.981 kg per tube

L
10.744 m
11 m
Step 6
Average volumetric flow rate per tube, vave
vave
vo/N
1.256 m3/hr
Superficial velocity through tube

u
=
=
vave/ Ac
580.228 m/hr
140
u /(1/ )
3.223 m
Therefore the selected length is long enough for the reactant to react before leaving
the reactor
Step 7
Tube Reynold Number,
Re
hi D p
Re =
D p u
6.06E-04
= 0.37 Re 0.6
kf
for 17 < Re < 70,000

hi
0.37 x 0.00061 x 0.0434

0.008
2.36E-02 W/m2.K
Step 8
Shell
Cooling medium flow, Ws =

For single pass tube,
Tlm =
Tm =
2.36841 kg/s
Tlm
(463.15-363.15) - (463.15-303.15)
141

ln ((463.15-363.15)/(463.15-303.15))
=
127.66 K
Tm
The foremost thing to do is to determine the service fluid velocity in shell

side. To do so, the fundamental dimension, such as the area for cross flow, the
bundle diameter, pitch, shell inside diameter and baffle spacing, need to be
determined.
Step 9
The tube is tube/ pipe arrangement is in square pattern, and the pitch, pt = 1.25do
pt
1.25 x 2.875
in
2.96875 in
0.075406 m
From Table 12.4, Chemical Engineering, Vol. 6, page 592, for square pitch and
1pass,
K1
0.215
n1
2.207
Db = d o (
Db
=
=
N
K1
) 1 / n1
130.989 in
3.237 m
Use a fixed tube type, from Fig. 12.10, Chemical Engineering, Vol. 6 (page 590)
142
Bundle diametrical clearance
Shell diameter, Ds
39
mm
0.039
3.327 + 0.039
3.366
As baffle spacing, lB = 0.2-1.0 times Ds. Assume =

lB
0.2 x 3.366
0.673
0.2
As =
Cross-flow
area,
Ds l B pt d o
pt
0.453 m2
=
Mass velocity,
Gs =
Ws
As
5.225 kg/s.m2
Shell side velocity, based on the clearance area at the bundle equator
u
G s
m
=
Equivalent diameter, de
14.719 m/s
1.27(pt2-0.785do2)/do
=
=
Reynold Number,
0.0428
Re =
mu s d e
= 10055.292
Pr
(turbulent)
Cp /kf
143

2672.3
According to Figure 12.31, Chemical Engineering, Volume 6 (page 616),
at Re =
jh
10055.292
Assume
k f
3
h oc =
jh Re P r
d o
0.08
w,
w)
1.0
hoc =
566.236
Let theoretical baffle cut, Bc

Baffle cut height, Hc = Bc
0.14
0.21
=
Height between baffle tips = Ds - 2(Hc)
W/m2.K
=
Ds
0.706
1.95236
Hb = Height from the baffle chord to the top of the tube bundle,
Hb =
Db
Db 0.5 Bc
2
Hb =
0.698
Ncv = the number of constrictions, tube rows, encountered in the cross flow zone.
N cv =
Db H b
pt
Ncv =
(for single pass)

34.8570
According to Figure 12.32 in Chemical Engineering, Volume 6 (page 635),

at Ncv = 34.8570,
Fn =
Since Hc = Bc
1.05
Ds, where Bc is the baffle cut (reference: shell), then for
baffle cut (reference: bundle), Bb= Hb/Db, hence;

Bb =
0.21
144

According to Figure 12.41 in Chemical Engineering, Volume 6
(page 645), at Bb = 0.2,
Ra'=
0.15
Where, Ra' = The ratio of the bundle cross-sectional area in the window zone to
the total bundle cross sectional area.
Nw =
Nt x Ra'
225
225
tubes in a window zone
Nw = Number of tubes in a window zone

Nt = Total number of tubes or pipes
Given that, tubes in cross flow zone, Nc = Nt 2Nw

Nc =
1050
tubes in a cross flow zone
Rw = The ratio of the number of tubes in the windows zones to the total number in
the bundle
RW =
2N w
Nt
Rw =
0.3
Refer to Fig. 12.33, Chemical Engineering, Volume 6 (page 636), at

Rw = 0.3, window effect correction factor, Fw = 1.075
Ab
= lB(Ds-Db)
Ab
Ab/As =
0.0263 m2
0.0579
145

Since no sealing strips are used, Fb can be directly obtained from
Fig. 12.34 in Chemical Engineering, Vol 6 (page 637), by referring to appropriate
Ab/As. At Ab/As
Fb =
0875
Before evaluate the value of FL, the diametrical tube-to-bundle clearance

(ct) and the baffle-to-shell clearance (cs) need to be determined from Table 12.5
in Chemical Engineering, Vol. 6 (page 595),
Use
ct =
1/32 in
=
cs =
3/16 in
=
0.0008 m and
0.00476 m
Where, ct = the diametrical tube-to-bundle clearance

cs = the baffle-to-shell clearance
From Figure 12.41 in Chemical Engineering, Vol. 6, page 645), at

Bc = 0.2, angle subtended by the baffle chord,
Asb =
0.0357
1.83
m2
Asb = Shell-to-baffle clearance area per baffle

Asb =
c s Ds
2 b
2
Atb =
0.0341
m2
Atb = The tube to baffle clearance area per baffle
Refers to Fig. 12.35 in Chemical Engineering, Vol. 6 (page 638),
146

at (Atb+Asb)/As
0.154
0.17
L
A 2 Asb
FL = 1 L tb
Atb Asb
FL
0.743
ho
= hocFnFwFbFL
ho
415.557
W/m2.K
let hod
=
6000
Step 10
Fouling factor,
and hid
= 5000
W/m2.K (Cooling water),
W/m2.K (air and industrial

gas)
kw (stainless steel) = 16W/m.K
The overall coefficient based on the outside area of the tube,
d
d o ln o
1
1
1
di
=
Uo
h o h od
2k w
Uo
do do
d i h id d i h i
48.7668 m2.K/W
0.0205 W/m2.K
Step 11
147

The overall heat transfer area, A, can be determined by using the
following equation,
A = Q / Uo( Tm)
Where,
Q = Total heat transfer or heat duty

Tm = The mean temperature difference
A = 48133.19
m2
Step 12
It has been stated that the material of construction is stainless steel, 18 Cr/ 8 Ni, unstabilised (304) for
tube side and carbon steel for shell side. The reason for using stainless steel for tube side is very clear
that it has to withstand the corrosive effects of produced product in the reactor. Besides it has to
withstand the sudden changes (reaction) that take place in it.
Step 13
Reactor costing
The Bare module cost, BC is calculated using the formula and table 4.11. (Biegler, 1997)
From table 4.11
Co
700 $
Lo
4 ft
148

L
36.854 ft
Do
3 ft
11.044 ft
= 0.81
= 1.05
Take module factor, MF = 4.23
Bare Module Cost, BC = Co(L/Lo)a(D/Do)b
= $16519
MF2
4.23
UF
3.43
Fm
2.25
Fp
1.45
MPF = (Fm)(Fp) = 3.2625
Uninstalled cost =
(BC)(MPF)
$16519 X 3.2625
$53893
Installation =
BC(MF-1)
$16519 (4.23-1)
$53356
149
Total installed cost =
BC(MPF+MF-1)
$16519(3.2625+4.23-1)
$107248.9
Updated bare module cost =
UF(BC)(MPF+MF-1)
3.43($16519)(3.265+4.23-1)
$ 367,863.62
RM 1,397,881.74
150

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PRODUCTION OF

JASMIN A/P TRAMARAJH

MOHD HAFIZS BIN FIRDAUS

NURUL ATIKA BINTI MOHD YATIM

NURAMIRA FATEHA BT SUKOR

AIIZAT IKHWAN BIN ABDUL JALIL

Pinch Technology .......................................................................................... 4

Stream Identification ..................................................................................... 4

Concept of Composite Curve ........................................................................ 5

Original Composite Curve ..................................................................... 7

Selection of Minimum Approach Temperature ..................................... 8

Shifted Composite Curve ....................................................................... 8

Construction of Temperature Interval Diagram ......................................... 10

Construction of Cascade Diagram ............................................................... 11

Grand Composite Curve .............................................................................. 13

Heat Exchanger Network (HEN) Analysis and Design .............................. 14

Equipment Sizing and Costing .................................................................... 17

Distillation Column .............................................................................. 17

Storage Tank and Intermediate Tank ................................................... 23

Heat Exchanger .................................................................................... 26

Membrane Separator ............................................................................ 36

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Ethylene Oxide Absorber ..................................................................... 40

Carbon Dioxide Absorber .................................................................... 45

Carbon Dioxide Stripper ...................................................................... 48

LIST OF FIGURES AND TABLES

Table 1 Summary of the hot and cold streams ............................................................. 5

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

PROCESS FLOW DIAGRAM

Figure 1 Process Flow Diagram

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

HEAT EXCHANGER NETWORK

Heat integration is designed to conserve energy by re-using available waste

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Pinch technology method is applied to determine the heat integration of the

Targeting maximum energy recovery which influents the best possible

Design of heat exchanger network to fulfill the set target.

Below are the steps in using pinch technology:

The utility consumption and heat exchanger area are calculated.

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Concept of Composite Curve

Within each temperature range the stream is combined to produce a composite

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Original Composite Curve

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Figure 3 Original composite curve

Selection of Minimum Approach Temperature

Minimum temperature represents the smallest temperature difference that two

The shifted temperature of a hot stream, Tmin = - 5C

The shifted temperature of a cold stream, Tmin = + 10C

Shifted Composite Curve

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Table 3 Summary of the shifted hot and cold streams

Equipment Temperature Temperature

Shifted Composite Curve

Heat Duty (kW)

Figure 4 Shifted composite curve

PRODUCTION OF 21,000 MTPA OF ETHYLENE OXIDE

Construction of Temperature Interval Diagram

24.82808 -24.8281 SURPLUS

36.37329 14.90537 21.46792 DEFICIT

186.6856 275.2027 -88.5171 SURPLUS

223.8213 -223.821 SURPLUS