4.

0 PRELIMINARY DESIGN OF EQUIPMENT

HEURISTICS
All the rules are based on the table of heuristic in Chapter 11 of Analysis, Synthesis and
Design of Chemical Process. (Richard Turton, 2014)

a) Heat Exchanger E-401

Carbon steel
A = 260 m2
Boiling in shell, condensing in tubes
1 shell-2 tube passes
Q = 13 530 Mj/h
From Table 11.11 of Analysis, Synthesis and Design of Chemical Process, 3rd Edition.
Rule 1: For conservative estimate, set F=0.9 for shell and tube exchangers with no phase
changes and Q=UAF T lm . When

at exchanger ends differ greatly, then check

F, and reconfigure if F is less than 0.85.

Rule 6: Minimum temperature approach is 10oC (20oF) for fluids
Rule 7: Cooling water inlet is 30 (90 ), maximum outlet 45 (115 )
2
Rule 8: Heat transfer coefficient, U= 280 W/ m . C for liquid to liquid

Given at stream 2 Thin=116.0OC, at stream 3 Thout=240.0OC

H ,T cw ,out
T

cw ,
H ,out T

H ,T cw ,out

T lm=
T lm=

(116.0 40 )(240.0 30 )
(116.0 40 )
ln
(240.0 30 )

131.84

Q = 3758.33kW
Therefore,
A = Q/UT lm F
=( 3758.33 x 103 )/(280)(131.84)(0.9)
= 213.08 m2
Area heuristic = 213.08 m2
Area from stream table = 260 m2

b) Heat Exchanger E-402

316 stainless steel
A = 226 m2

Boiling in shell, process fluid in tubes

1 shell-2 tube passes
Q = 8322 Mj/h
From Table 11.11 of Analysis, Synthesis and Design of Chemical Process, 3rd Edition.
Rule 1: For conservative estimate, set F=0.9 for shell and tube exchangers with no phase
changes and Q=UAF T lm . When

at exchanger ends differ greatly, then check

F, and reconfigure if F is less than 0.85.

Rule 6: Minimum temperature approach is 10oC (20oF) for fluids
Rule 7: Cooling water inlet is 30 (90 ), maximum outlet 45 (115 )
2
Rule 8: Heat transfer coefficient, U= 280 W/ m . C for liquid to liquid

Given at stream 8 Thin=504.3oC, at stream 9 Thout=550.0oC

T

H ,T cw ,out
T

cw ,
H ,out T

H ,T cw ,out

T lm=
T lm =

(504.3 40 )(550.0 30 )
(504.3 40 )
ln
(550.030 )

491.62

Q = 2311.67 kW
Therefore,
A = Q/UT lm F
=( 2311.67 x 103 )/(280)(491.62)(0.9)
= 18.66 m2
Area heuristic = 18.66 m2
Area from stream table = 226 m2

c) Heat Exchanger E-405

316 stainless steel
A = 1446 m2
Cw, cooling water in shell, process fluid in tubes
1 shell-2 tube passes
Q = 136609 Mj/h
Rule 1: For conservative estimate, set F=0.9 for shell and tube exchangers with no
phase changes and Q=UAF T lm . When

at exchanger ends differ greatly,

then check F, and reconfigure if F is less than 0.85.

Rule 6: Minimum temperature approach is 10oC (20oF) for fluids
Rule 7: Cooling water inlet is 30 (90 ), maximum outlet 45
)
2

Rule 8: Heat transfer coefficient, U= 280 W/ m . C for liquid to liquid

Given at stream 12 Thin=180.0oC, at stream 13 Thout=65.0oC
T lm = 75.74oC
Q = 37946.95 kW
Therefore,
A = Q/UT lm F
=( 37946.95 x 103 )/(280)(75.74)(0.9)

(115

= 1988.16 m2
Area heuristic = 1988.16 m2
Area from stream table = 1446 m2

d) Pump P-401 A/B

Centrifugal/electric drive
Stainless steel
W = 2.59 kW (actual)
80 % efficiency
Rule 1: Power of pumping liquids: kW = (1.67) [Flow (m3/min)][ P (bar)]/
Rule 4: Centrifugal pumps: Single stage for 0.057-18.9 m3
Given the total flow at stream 15 is 255.6 kg/h, density= 870 kg/m3
Stream 15, P=65kPa=0.65 bar (1 bar=100kPa). Stream 22, P=200kPa=2 bar
255.6

Flowrate (stream 15)

kg
1h
m3

=0.0049 m3 /min
h 60 min 870 kg

P=20.65
1.35

1.35

( 1.67 ) 0.0049

m3 ( ]

min

Fluid Pumping Power=

e) Pump P-405 A/B

Centrifugal/ electric drive
Carbon steel
W=0.825kW
80% efficiency
Rule 1: Power of pumping liquids: kW = (1.67) [Flow (m3/min)][ P (bar)]/
Rule 4: Centrifugal pumps: Single stage for 0.057-18.9 m3
Given the total flow at stream 24 is 10912.9kg/h, density= 870 kg/m3
Stream 24, P=200kPa=2 bar (1 bar=100kPa). Stream 19, P=25kPa=0.25 bar
Flowrate (stream 15)
1.75
P=20.25

10912.9

kg
1h
m3

=0.2091 m3 /min
h 60 min 870 kg

1.75

( 1.67 ) 0.2091

m3 ( ]

min

Fluid Pumping Power=

f) Pump P404 A/B
Centrifugal/electric drive
Carbon steel
W = 0.775 kW (actual)
80% efficiency
Rule 1: power for pumping liquids: kW = (1.67) [flow (m3 / min)][ P(bar)]/
Rule 4: centrifugal pumps: single stage for 0.057-18.9 m3
Given the total flow at stream 21 is 12507.1kg/h, density= 890kg/m3
Stream 20, P = 200kPa = 2 bar. Stream 20 55kPa =0.55bar
kg
1h
m3
12507.1

=0.2342 m3 /min
Flowrate (stream 21) =
h 60 min 890 kg
P = 2bar 0.55bar = 1.45bar

1.45
m3
(1.67) 0.2342

min

fluid pumping power=

g) Pump P-406 A/B

Centrifugal/electric drive
Carbon steel
W = 0.019 kW (actual)
80% efficiency
Rule 1: power for pumping liquids: kW = (1.67) [flow (m3 / min)][ P(bar)]/
Rule 4: centrifugal pumps: single stage for 0.057-18.9 m3
Given the total flow at stream 26 is 289.5kg/h, density= 890kg/m3
Stream 26, P = 200 kPa = 2 bar. Stream17 P= 45kPa =0.45bar
kg
1h
m3
289.5

=0.00542 m3 /min
Flowrate (stream 26) =
h 60 min 890 kg
P = 2bar 0.45bar = 1.55bar

1.55

(1.67) 0.00542

m3

min

fluid pumping power=

h) Fired Heater H-401

Fired heater-refractory-lined, stainless-steel tubes
Design Q = 23.63 MW
Maximum Q = 25.00 MW
Rule 13: Fired heaters: Radiant rate, 37.6 kW/m 2 (12,000 Btu/hrft2); convection rate,
12.5 kW/m2 (4000 Btu/hr.ft2); cold oil tube velocity=1.8m/s (6ft/sec) approximately
equal transfer in the two sections; thermal efficiency 70-90% based on lower heating
value; flue gas temperature 140-195C (250-250F) above feed inlet; stack gas
temperature 345-510C (650-950F)
Area radiant section= (0.5)(23630)/(37.6)= 314.22m2
Area convective section= (0.5)(23630)/(12.5)= 945.2m2
i) Reactor, R-401.
Rule 1: Rate of reaction in very intense must be established in the laboratory and the
time residence and the product distribution eventually must be found from the pilot
plant.
Rule 2: Dimension of catalyst particle are 2 5 mm in fixed bed reactor.
Rule 13: The value of catalyst maybe improve the selectivity more than to improve
the

overall rate of reaction.

Formula of packed bed reactor:

W=

F Ao
dx
r

Based on the reference:

Density of the catalyst : 5750 kg / m3 (Wikipedia,2010)

Rate of reaction: 6.2713 x 10-4 mole / kg.h ( Gade P. Rangaiah, 2003)
FAo = 0.06 mole / h (Richard Turton, June 2014)
F = 91.06 mole / h (Richard Turton, June 2014)

Conversion,

X=

F A F Ao
FA
91.060.06
91.06

= 0.9993
Therefore,
W=

91,06
( 0.99 )
6.2713 x 104

= 143 750 kg
So volume of reactor is,
V=

W
=

143 570
3
5759 = 25 m

j) Reactor, R-402.
Rule 1: Rate of reaction in very intense must be established in the laboratory and the time
residence and the product distribution eventually must be found from the pilot plant.
Rule 2: Dimension of catalyst particle are 2 5 mm in fixed bed reactor.
Rule 13: The value of catalyst maybe improve the selectivity more than to improve the
overall rate of reaction.
Formula of packed bed reactor:

W=

F Ao
dx
r

Based on the reference:

Density of the catalyst : 5750 kg / m3 (Wikipedia,2010)

Rate of reaction: 1.5586 x 10-4 mole / kg.h ( M.E. Zeynalli, 2010)
FAo = 91.06 mole / h (Richard Turton, June 2014)
F = 120.09 mole / h (Richard Turton, June 2014)

Conversion,

X=

F A F Ao
FA
120.0991.06
120.9

= 0.25
Therefore,
W=

91.06
( 0.25 )
1.5586 x 104

= 146061 kg
So volume of reactor is,

V=

146061
3
5750 = 25 m

k) Heat Exchanger, E-403

Rule 1: Set F = 0.90
Rule 6: minimum T

= 10oC

Rule 8: U = 280.0 W/m2oC

However, it is observed that rule 6 has been violated because T

is more than 10oC.

T lm=32.25
Q = 11834.52kW
A=

l)

Q
11834.52
=
=1456.20 m2
U T lm F 0.280(32.25)(0.9)

Heat Exchanger, E-404

Carbon steel
Boiling in shell, process fluid in tubes
1 shell-2 tube passes

From Table 11.11 of Analysis, Synthesis and Design of Chemical Process, 3rd Edition
Rule 1: For conservative estimate, set F=0.9 for shell and tube exchangers with no phase
changes and Q=UAF T lm . When

at exchanger ends differ greatly, then check

F, and reconfigure if F is less than 0.85

Rule 6: Minimum temperature approach is 10C for fluids
2
Rule 8: U= 280 W/ m . C for liquid to liquid

T lm = 20.04 C
Q = 3545.39 kW
Therefore,
A=

Q
F T lm U

3545.39 kW

2
= 0.9 20.04 280 = 702.05 m

m) Three phase separator, V-401

Carbon steel
V = 26.8 m2
Rule 1: Drums are relatively small vessels that provide surge capacity or separation of
entrained phase.
Rule 3: Gas liquid phase separators are usually vertical.
Rule 4: The optimum ratio of length to diameter is 3, but the range is about 2.5 to 5 in
common.
Rule 5: Liquid holdup time based on volume of vessel.
Rule 9: Gas velocity u given by

u =k

l
1
m/s
v

Where k = 0.0305 for vessel without mesh entrainer

Rule 12: Good performance obtained at 30%-100% for u for typical value is 75%
Vapor flow = Stream 14 = 255.6 kg/h, P = 65 kPa, T = 65
Liquid flow = Stream 15 + 16 = 77 754 kg/h, P = 65 kPa, T= 65
v

= 0.082 kg/m3

l=3521 kg / m3

From rule 9

(estimated from stream table at stream 15 and 16)

u= 0.0305

3521
0.082

0.5

u = 6.32 m/s
Use the uact

= (0.75) (6.32) = 4.74 m/s

Now mass flow rate of vapor =

u v D
4

= 0.071 kg /s

Solving for D, D = 0.4177 m

Rule 5: 5 min of liquid flow
The volume of liquid =

(5 min) (60 s) (

0.5 LD 2
4

77754 kg
h

0.06851 Lm3
3

)(

m
3521 kg

)(

1h
3600 s

) (L)(m2)

Solving for L = 1.84 m

Calculating L/D = 1.84/0.4177 = 4.4
The ratio of length to diameter L/D is 4.4 is in the range from rule 4 which is from 2.5 to 5.
From the heuristic that we have calculated, V-401 is a vertical vessel with D = 0.4177 m and
L = 1.84 m

n) Compressors and drives, C-401.

a

{ }

P2
Rule 2: Theoretical reversible adiabatic power m z 1 R T 1 [( P 1)]/a
1

Where

T 1 is inlet temperature, R=gas constant,

=molar flow rate, a=( k1)/k

z 1 =compressibility,

and k =C p /C v

3
Values of R:=8.314 J /molK=1.987 Btu /lbmolR=0.7302 atm ft /lbmol R

Rule 4: Exit temperatures should not exceed

167204

( 350400 ) ;

for

diatomic gases ( C p C v =1.4 . This corresponds to a compression ratio of about 4.

Rule 6: Efficiencies of reciprocating compressors: 65% at compression ratios of 1.5,
75% at 2.0, and 80-85% at 3-6.
Based on the rule above, we can conclude that,

1.

Tout=202.2 =475.2 K

2. Was in range 167204

3. Reciprocating compressor
4. Given in equipment summary 65% efficiencies
Based on the information,

Mass flowrate= 35
a=

kmol
streamtable
s

k1 1.41
=
k
1.4

0.2857

z 1=1

P2=140 ; P1=65
a

{ }

P2
Power m z 1 R T 1 [( P 1)]/a
1

35 ( 1 ) ( 8.314 ) ( 338 )

[({

140
65

0.2857

)]

0.2857

134 kW

o) Tower, T-401
Carbon steel
D=3.0 m
61 sieve trays
54% efficient
Feed on tray 31
12-in tray spacing
1 in weirs
Column height = 61ft =18.6m
Rules 1: Distillation is usually the most economical method for separating liquids,
superior to extraction, adsorption crystallization or others.
Rule 5: Optimum reflux in the range of 1.2-1.5Rmin
Rule 6: Optimum number of stages approximately 2Nmin

Rule 7: Nmin=ln ( [x/(1-x)]ovhd / [x/(1-x)]bot ) / ln

Rule 8: Rmin=(F/D) / ( 1
Rule 9: Use a safety factor of 10% on number of trays
Rule 14: Limit the tower height to about 5.3 m maximum and L/D should be less than
30. The column height is 18.6 m and the diameter is 3.0 m. it is based on the reference
that we have.
Therefore,
L/D =

18.6
3

= 6.2 which is < 30

So, we can conclude that sizing design specification for T-401 with its diameter and
height of column are satisfied the rule.

p) Tower, T-402
Carbon steel
D = 6.9 m
158 sieve trays
55% efficient
Feed on tray 78
6-in tray spacing
1-in weirs
Column height = 79 ft. =24.1m
Rules 1: Distillation is usually the most economical method for separating liquids,
superior to extraction, adsorption crystallization or others.
Rule 14: Limit the tower height to about 53m (175ft) maximum because of wind load and
foundation consideration. An additional criterion is that L/D be less than 30
(20<L/D<30), often will require special design
As our project to produce styrene, the separation of styrene and ethyl benzene was happen
at the distillation column (T-402). The ethyl benzene will recycle back to feed while
styrene will become the main product.
Length, L = 24.1 m= 79 ft

Diameter, D = 6.9 m
L 24.1
=
=3.493
D 6.9