PRELIMINARY DESIGN OF EQUIPMENT (HEURISTIC)

-All of the heuristic is taking from reference-

R-601

Shell and Tube vertical design

Stainless steel

L=7.0 m

D=3.8 m

12,100 1-in diameter, 6.4m length catalyst filled tubes

Design pressure=300 kPa

P average=2.14 barg

𝜋𝐷 2 𝐿
Volume of tube = 4

𝜋(0.0254)2 (6.4)
= 𝑋 12,100
4

= 39.24

= 39 tubes

𝜋𝐷 2 𝐿
Volume of shell = 4

𝜋(3.8)2 (7.0)
=
4

= 79.39

= 79 tubes

Volume of reactor = 79-39

= 40 m³

We choose L/D = 10 (Based on plug flow consideration)

𝜋𝐷 2 (10𝐷)
40 m³ = 4
, 𝐷 = 1.7205 𝑚
 𝑘1
𝐶6 𝐻6 (𝑏𝑒𝑛𝑧𝑒𝑛𝑒) + 4.5𝑂2 → 𝐶4 𝐻2 𝑂3 (𝑚𝑎𝑙𝑒𝑖𝑐 𝑎𝑛ℎ𝑦𝑑𝑟𝑖𝑑𝑒) + 2𝐶𝑂2 + 2𝐻2 𝑂

𝑘2
𝐶6 𝐻6 (𝑏𝑒𝑛𝑧𝑒𝑛𝑒) + 7.5𝑂2 → 6𝐶𝑂2 + 3𝐻2 𝑂

𝑘3
𝐶4 𝐻2 𝑂3 (𝑚𝑎𝑙𝑒𝑖𝑐 𝑎𝑛ℎ𝑦𝑑𝑟𝑖𝑑𝑒) + 3𝑂2 → 4𝐶𝑂2 + 𝐻2 𝑂

𝑘4
𝐶6 𝐻6 (𝑏𝑒𝑛𝑧𝑒𝑛𝑒) + 1.5𝑂2 → 𝐶6 𝐻4 𝑂2 (𝑞𝑢𝑖𝑛𝑜𝑛𝑒) + 2𝐻2 𝑂

-ri = kiCbenzene or –r3 = k3Cmaleicanhydride

K1 = 7.7 x 106 exp (-25143/RT)

K2 = 6.31 x 107 exp (-29850/RT)

K3 = 2.33 x 104 exp (-21429/RT)

K4 = 7.20 X 105 exp (-27149/RT)

For 1st reaction

-r1 = k1Cbenzene

From the first chemical reaction and according to the stream table, the benzene enter the
reactor at stream 6 and produce the maleic anhydride , carbon dioxide and water at stream 7.

(Stream 6):

T = 733.15 K, R = 8.314L.kPa/mol.K x 1m3/1000L x (1x106cm3)/1m3= 8314 cm3.kPa/mol.K

Cbenzene = 0.4422 kmol/m3

K1 = 7.7 x 106 exp [-25143/(8314)(733.15)] = 7.67 x 106 cm3/m3.s

-r1 = (7.67 x 106 cm3/m3.s)(0.4422 kmol/m3) x 1m3/(1x106) cm3 = 3.39 Kmol/m3.s

For 2nd reaction

-r2 = k2Cbenzene

(Stream 6):

T = 733.15 K,

Cbenzene = 0.4422 kmol/m3

K2 = 6.31 x 107 exp [-29850/(8314)(733.15)] = 62791746.6 m3/m3.s

-r2 = (62791746.6 m3/m3.s)(0.4422 kmol/m3) x 1m3/(1x106) cm3 = 27.77 Kmol/m3.s

For 3rd reaction

-r3 = k3Cmaleic anhydride

(Stream 7):

T = 881.15 K,

Cmaleic anhydride = 50.465 kmol/m3

K3 = 2.33 x 104 exp [-21429/(8314)(881.15)] = 23231.945 cm3/m3.s

-r3 = (23231.945 cm3/m3.s)(50.465 kmol/m3) x 1m3/(1x106) cm3 = 1.172 Kmol/m3.s

For 4th reaction

-r4 = k4Cbenzene

(Stream 6):

T = 733.15 K,

Cbenzene = 0.4422 kmol/m3

K4 = 7.20 x 105 exp [-27149/(8314)(733.15)] = 716800.25 cm3/m3.s

-r4 = (716800.25 cm3/m3.s)(0.4422 kmol/m3) x 1m3/(1x106) cm3 = 0.317 Kmol/m3.s

TOWER, T-601

From table 11.13, the following heuristic was

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)overhead/[x(1-x)bottom]}/ ln α

Rule 8: Rmin = {F/D} / (α-1)

Rule 9: Use safety factor of 10% on number of trays

Rule 14: Lmax = 53 m and L/D < 30

From table 11.14, the following heuristic was

Rule 2: Fs = μρv0.5 = 1.2 to 1.5 m/s (kg/m3)0.5

Rule 3: ΔPtray = 0.007 bar

Rule 4: Єtray = 10-20%

Xoverhead = 0.79

Xbottom = 0.0001976

αoverhead = 2738.68

αbottom = 6.21 x 10-3

αaverage = (αoverhead x αbottom)0.5 = 4.12

Nmin = ln{0.79(1-0.79)overhead / [0.0001976(1-0.0001976)bottom]} / ln4.2 = 6.9597

From the heuristic, when the feed is enter at the bubble point, the following equation was
used,
Rmin = (F/D) / (α-1)

F = 5650.6 + 1000.2 = 6650.4

Rmin = (6650.4/5598.4) / (4.12-1)

= 0.3808

Range R = (1.2 to 1.5) Rmin

= 0.456 to 0.57

Ntheoretical = 2(Nmin) = 2(6.9597) = 13.9194

Nactual = Ntheoretical / Є

= (13.9194 / 0.5) x 1.1 = 31 stage

Density, ρv = 0.7454 kg/m3

Viscosity, μ = [1.2 to 1.5] / (0.7454)0.5 = 1.3899 to 1.737

(Stream top)

V = 106443.725 m3/h = 29.568 m3/s

D = [4V / μ]0.5 = [4(29.568) / (1.3899 to 1.737)]0.5 = 5.2044 to 4.655 m

L/D = 10/4.2 = 2.38 < 30

From Table B.5.3 From Heuristic

Tower Diameter 4.2 m 5.2044 to 4.655 m
Reflux 0.189 0.456 to 0.57
No of tray 42 31
Efficiency 50% 10 to 20%

 Assume cylindrical vessel

 From the calculation above:
D = 5.2 m

H = 10 m

𝜋𝐷 2 𝐿
Volume = 4

𝜋(5.2)2 (10)
= = 212.37 𝑚3
4

> It is suggested that the dimension is 10% higher from the operating dimension.

Design D = 1.1 x 5.2 = 5.72 m ~ 6 m

Design H = 1.1 x 10 = 11 m

Suggested design and dimension:

H = 11 m

D=6m

𝜋𝐷 2 𝐿
The maximum capable capacity = 4

𝜋(6)2 (11)
= = 311.02 𝑚3
4
TOWER T-602

Based on the Table 11.13 of the Analysis, Synthesis and Design of Chemical Processes, there
are some rules that need to take account in order to do the heuristic for a tower. These rules
are as follow:

Rule 5: Optimum reflux in the range of 1.2 to 1.5Rmin

Rule 6: Optimum number of stages approximately 2Nmin

Rule 7: Nmin = ln{x/(1-x)overhead / [x(1-x)bottom]} / ln α

Rule 8: Rmin = {F/D} / (α-1)

Rule 9: Use safety factor of 10% on number of trays

Rule 14: Lmax = 53 m and L/D < 30

On the other hand, there are also rules that must we obey in doing the heuristics for trays. The
rules taken from Table 11.14 of the same book are as follow:

1. αav = (αoverhead x αbottom)0.5

𝑃 𝑠𝑎𝑡
αoverhead = 𝑃1𝑠𝑎𝑡 @ 𝑇𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑 ; 1 = light key component (MA)
2

2 = heavy key component (DP)

𝑃 𝑠𝑎𝑡
αbottom = 𝑃1𝑠𝑎𝑡 @ 𝑇𝑏𝑜𝑡𝑡𝑜𝑚 ; 1 = light key component (MA)
2

2 = heavy key component (DP)

 The table below contain the parameters for Antoinne equation

𝐵
log10 𝑃 = 𝐴 − ; 𝑃 (𝑚𝑚ℎ𝑔); 𝑇(𝐾)
𝑇+𝐶
Component A B C Temperature
Range
Maleic 16.2747 3765.65 -82.15 79ºC - 243ºC
Anhydride
Dibutyl 16.9539 4852.47 -138.10 196ºC - 384ºC
Phthalate

At Toverhead At Tbottom
3765.65 3765.65
𝐿𝑜𝑔10 𝑃𝑀𝐴 = 16.2747 − 𝐿𝑜𝑔10 𝑃𝑀𝐴 = 16. 2747 −
(195 + 273) − 82.15 (330 + 273) − 82.15
PMA = 26.03 mmHg x 133.32 PMA = 23.50 mmHg x 133.32
= 3.47 kPa = 3.13 kPa

4852.47 4852.47
𝐿𝑜𝑔10 𝑃𝐷𝑃 = 16.9539 − 𝐿𝑜𝑔10 𝑃𝐷𝑃 = 16.9539 −
(195 + 273) − 138.10 (330 + 273) − 138.10
PDP = 9.44 mmHg x 133.32 PDP = 6.52 mmHg x 133.32
= 1.26 kPa = 0.87 kPa

𝑠𝑎𝑡 𝑠𝑎𝑡
𝑃𝑀𝐴 3.47 𝑘𝑃𝑎 𝑃𝑀𝐴 3.13 𝑘𝑃𝑎
𝛼𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑 = 𝑠𝑎𝑡 = = 2.754 𝛼𝑏𝑜𝑡𝑡𝑜𝑚 = 𝑠𝑎𝑡 = = 3.598
𝑃𝐷𝑃 1.26 𝑘𝑃𝑎 𝑃𝐷𝑃 0.87 𝑘𝑃𝑎

> αaverage = (2.754 x 3.598)0.5 = 3.148

 𝑓𝑒𝑒𝑑
𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒
2. 𝑅𝑚𝑖𝑛 = ;
𝛼𝑎𝑣 −1

Feed at stream 11 (inlet of tower)

distillate at stream 13 (overhead product)

𝑘𝑚𝑜𝑙𝑒
1012.4
ℎ
𝑘𝑚𝑜𝑙𝑒
52.4
𝑅𝑚𝑖𝑛 = ℎ = 8.995
3.148 − 1

3. R = (1.2 to 1.5)Rmin = (1.2 to 1.5)(8.995) = 10.794 to 13.493

𝑥
( )𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑
ln 1−𝑥
𝑥 𝑘𝑚𝑜𝑙𝑒
(
1−𝑥
)𝑏𝑜𝑡𝑡𝑜𝑚 49.5
ℎ
4. 𝑁𝑚𝑖𝑛 = ; 𝑥𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑 = 𝑘𝑚𝑜𝑙𝑒 = 0.945
ln 𝛼𝑎𝑣𝑒𝑟𝑎𝑔𝑒 52.4
ℎ

𝑘𝑚𝑜𝑙𝑒
0.1
𝑥𝑏𝑜𝑡𝑡𝑜𝑚 = ℎ = 0.10 𝑥 10−3
𝑘𝑚𝑜𝑙𝑒
1000.01
ℎ

0.945
)(
1 − 0.945 𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑
𝑙𝑛 [ ]
0.10 𝑥 10−3
( )
1 − 0.10 𝑥 10−3 𝑏𝑜𝑡𝑡𝑜𝑚
𝑁𝑚𝑖𝑛 = = 10.48
ln 3.148

5. Ntheoretical = 2Nmin = 2(10.48) = 20.96

𝑁𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙
6. 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑋 (1 + 0.1) ; 𝜀𝑡𝑟𝑎𝑦 = 60% = 0.6 (𝑓𝑜𝑟 𝑎𝑞𝑢𝑒𝑜𝑢𝑠 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛)
𝜀𝑡𝑟𝑎𝑦

20.96
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑋 (1.1) = 38.427 ~ 39 𝑠𝑖𝑒𝑣𝑒 𝑡𝑟𝑎𝑦𝑠
0.6

7. H = (Tray spacing x Nactual) + 3 m = (0.6 m x 38.427) + 3 m = 26. 056 m

8. Fs = uρv0.5 = 1.2 to 1.5; where,

ρv0.5 = 3.38 kg/m3 (MA)

 1.2 𝑡𝑜 1.5 1.2 𝑡𝑜 1.5 𝑚 𝑚
𝑢= 0.5 = 0.5
= 0.653 𝑡𝑜 0.816
𝜌𝑣 3.38 𝑠 𝑠

ὺ 𝑘𝑔
9. 𝑣 = ; 𝑤ℎ𝑒𝑟𝑒 ὺ = 5194 (𝑜𝑣𝑒𝑟ℎ𝑒𝑎𝑑 𝑣𝑎𝑝𝑜𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒)
𝜌 ℎ

𝑘𝑔
5194 𝑚3
𝑣= ℎ = 0.4269
𝑘𝑔 𝑠 𝑠
3.38 3 𝑋 3600
𝑚 1ℎ
4𝑣
10. 𝐷 = 𝜋𝑢

𝑚3
4 (0.4269 𝑠 )
= 𝑚 𝑚 = 0.832 𝑚 𝑡𝑜 0.666𝑚
𝜋 (0.653 𝑠 𝑡𝑜 0.816 𝑠 )

0.832 𝑚 + 0.666 𝑚
𝐷𝑎𝑣𝑒𝑟𝑎𝑔𝑒 = = 0.749 𝑚
2

The value of Daverage and height is then being used to calculate the cost of this tower.

𝐿 26.056 𝑚
11. 𝐷 = = 34.79
0.749 𝑚

The value of L/D obtained from heuristics is slightly higher than the desired value which is 30.
This may be due to some errors during calculation that had done.

The differences of the actual number of tray, height and diameter of the tower are as follow:

Table B.5.3 Heuristics

Number of tray 42 39
Tray efficiency 65% 60%
Reflux ratio 1.24 10.794 to 13.493
Height 18 m 26.056 m
Diameter 1.05 m 0.832 m to 0.666 m
HEAT EXCHANGER E-601

-Heuristic for heater by using table 11.11-

Rule 1: Assume conservative estimate set F = 0.9 for shell and tube exchanger with no phase
change. Q = UAFΔTlm

Data from pfd: Q = 151 000 W

T1 (Fluid in) = 32ºC

T2 (Fluid out) = 116ºC

Rule 6: Minimum temperature approach, ΔT = 10ºC

Rule 7: Neglect because heater using low pressurized steam (LPS)

Rule 8: U = 280 W/m2.ºC because liquid to liquid

Hence to find ΔTlm:

T1 = 32ºC t1 (LPS in) = 130ºC

T2 = 116ºC t2 (LPS out) = 120ºC

[(130−116)−(120−32)]
𝛥𝑇𝑙𝑚 = (130−116) = 40.26°𝐶
ln[ (120−32) ]

Find A from Q formula,

𝑄 151 000 𝑊
𝐴= = = 14.88 𝑚2
𝑈𝐹𝛥𝑇𝑙𝑚 𝑊
(280 2 . °𝐶) (0.9)(40.26°𝐶)
𝑚

Thus, our area in pfd is 14.60 m2 and it is almost similar with the heuristic area and use floating
head, stainless steel heater.

For sizing, area of E-1 must be used in order to get diameter, D, length, L and volume, V

A = 2πrL, where radius, r = D/2 and L=2D

𝐷
A = 2𝜋 ( 2 ) (2𝐷)

= 2𝜋𝐷2

14.6 𝑚2 = 2𝜋𝐷2 , 𝐷 = 1.52 𝑚 𝑎𝑛𝑑 𝐿 = 2(1.52 𝑚 ) = 3.04 𝑚

 𝜋𝐷 2 𝐿
Thus, volume V = 4

𝜋(1.52)2 (3.04)
= = 5.52 𝑚3
4

HEAT EXCHANGER E-602

-Heuristic for heater using Table 11.11-

Rule 1: Assume conservative estimate set F = 0.9 for shell and tube heat exchanger with no
phase change. Q = UAFΔTlm

Data from pfd: Q = 405,300 W

T1 (Fluid in) = 153.4°C

T2 (Fluid out) = 170°C

Rule 6: Minimum temperature approach, ΔT = 10°C

Rule 7: Neglect because heater is using high pressurized steam (HPS)

Rule 8: U = 30 W/m2.°C because gas to gas

Hence to find ΔTlm,

T1 = 153.4°C t1 (HPS in) = 400°C

T2 = 170°C t2 (HPS out) = 390°C

[(400 − 170) − (390 − 153.4)

𝛥𝑇𝑙𝑚 = = 233.28°𝐶
(400 − 170)
ln [ ]
(390 − 153.4)

Find A from Q formula,

𝑄 405,300 𝑊
𝐴= = = 64.35 𝑚2
𝑈𝐹𝛥𝑇𝑙𝑚 𝑊
(30 2 ) (0.9)(233.28°𝐶)
𝑚

Thus our area in pfd is 61.6 m2 and it is almost similar with the heuristic area and install floating
head, stainless steel heater.

Area must be used in order to determine diameter, D, length, L and volume, V

 𝐷
𝐴 = 2𝜋𝑟𝐿, 𝑤ℎ𝑒𝑟𝑒 𝑟 = 𝑎𝑛𝑑 𝐿 = 2𝐷
2

𝐷
= 2𝜋( )(2𝐷)
2

= 2𝜋𝐷2

64.35 𝑚2 = 2𝜋𝐷2 , 𝐷 = 3.2 𝑚 𝑎𝑛𝑑 𝐿 = 2(3.2) = 6.4 𝑚

𝜋𝐷2 𝐿 𝜋(3.2)2 (6.4)

𝑉𝑜𝑙𝑢𝑚𝑒, 𝑉 = = = 51.47 𝑚3
4 4

HEAT EXCHANGER E-603

-Heuristic for using Table 11.11-

Rule 1: Assume conservative estimate F = 0.9 for shell and tube heat exchanger with no phase
change. Q = UAFΔTlm

Data from pfd: Q = 21,516,000 W

T1 (Fluid in) = 924.1°C

T2 (Fluid out) = 130°C

Rule 6: Neglect due to minimum temperature approach, ΔT = 100°C not equal to 10°C

Rule 7: Neglect because heater using high pressurized steam (HPS)

Rule 8: U = 30 W/m2.°C because gas to gas

Hence to find ΔTlm,

T1 = 924.1°C t1 (HPS in) = 1000°C

T2 = 130°C t2 (HPS out) = 1100°C

[(1000 − 130) − (1100 − 924.1)

𝛥𝑇𝑙𝑚 = = 434.25°𝐶
(1000 − 130)
ln [ ]
(1100 − 924.1)
Find A from Q formula,

𝑄 21, 516,000 𝑊
𝐴= = = 1835.09 𝑚2
𝑈𝐹𝛥𝑇𝑙𝑚 𝑊
(30 2 ) (0.9)(434.25°𝐶)
𝑚

Thus, our area in pfd is 1760 m2 and it is almost similar with the heuristic area and use floating
head, stainless steel.

Area must be used in order to determine diameter, D, length, L and volume, V

𝐷
𝐴 = 2𝜋𝑟𝐿, 𝑤ℎ𝑒𝑟𝑒 𝑟 = 𝑎𝑛𝑑 𝐿 = 2𝐷
2

𝐷
= 2𝜋 ( ) (2𝐷)
2

= 2𝜋𝐷2

1835.09 𝑚2 = 2𝜋𝐷2 , 𝐷 = 17.09 𝑚 𝑎𝑛𝑑 𝐿 = 2(17.09) = 34.18 𝑚

𝜋𝐷2 𝐿 𝜋(17.09)2 (34.18)

𝑉𝑜𝑙𝑢𝑚𝑒, 𝑉 = = = 7840.54 𝑚3
4 4

PUMP 601

Pressure: 101 kPa (1.01 bar)

Flowrate: 6608 kg/hr

Component (kmol/hr): Benzene 84 kmol/hr

Density of Benzene: 876 kg/m3

Rule 1: Power (kW) = 1.67 (flow) (ΔP)

𝑘𝑔 1ℎ 𝑚3 𝑚3
𝐹𝑙𝑜𝑤 = 6608 𝑋 60 𝑚𝑖𝑛 𝑋 876𝑘𝑔 𝑋 = 0.126 𝑚𝑖𝑛
ℎ

Fluid pumping power = 1.67 x 0.126 x (3-1.01) = 0.4187 kW

0.4187 𝑘𝑊
Power Shaft = = 0.64 𝑘𝑊
0.65

0.64 kW compared to the actual power shaft of 0.6 kW from equipment summary.
PUMP 605

(Stream 13)

Pressure: 80 kPa (0.8 bar)

Flowrate: 5194 kg/hr

Component in kmol/hr ;

Maleic Anhydride, A: 49.6 kmol/hr

Quinone, B: 0.8 kmol/hr

Maleic Acid, C: 2.0 kmol/hr

Density of mixture = 𝜌𝐴 𝑥𝐴 + 𝜌𝐵 𝑥𝐵 + 𝜌𝐶 𝑥𝐶

49.6
𝑥𝐴 = = 0.9466 , 𝜌𝐴 = 1480
52.4

0.8
𝑥𝐵 = = 0.0153 , 𝜌𝐵 = 1320
52.4

2.0
𝑥𝐶 = = 0.038 , 𝜌𝐶 = 1590
52.4

Density of mixture = (1480)(0.9466) + (1320)(0.0153) + (1590)(0.038) = 1481.584 kg/m3

Rule 1: Power (kW) = 1.67 (flow) (ΔP)

𝑘𝑔 1ℎ 𝑚3 𝑚3
𝐹𝑙𝑜𝑤 = 5194 𝑋 𝑋 𝑋 = 0.0584
ℎ 60 𝑚𝑖𝑛 1481.584𝑘𝑔 𝑚𝑖𝑛

Fluid pumping power = 1.67 x 0.0584 x (4-0.8) = 0.312 kW

0.312 𝑘𝑊
Power Shaft = = 0.48 𝑘𝑊
0.65

0.48 kW compared to the actual power shaft of 1.4 kW from equipment summary.
V-601

Stream 1 V-601 Stream 2

P = 1.01 bar
Temperature = 30°C
Mass Flowrate = 6608 kg/hr
Benzene = 84.6 kmol/hr
Density benzene = 876 kg/m3

Rule 2: Liquid drum are usually horizontal

Rule 4: Optimum ratio of length to diameter = 3 m, but the range 2.5 to 5 is common.

Rule 6: In drum feeding a furnace, 30 min for half-full reflux drum allowed.

Rule 8: Liquid-liquid separation are designed for settling velocity of 0.085-0.127 cm/s (2-
3in/min)

mass flowrate, m = uρA , where u = 0.106 cm/s

A = πD2/4

ρ = 876 kg/m3

𝑘𝑔
4𝑚 4(6608 )
ℎ
D = √𝑢𝜌𝑖𝑛𝜋 = √ 𝑐𝑚 1𝑚 876𝑘𝑔 3600𝑠 = 5.02 𝑚
(0.106 )( )( 3 )( )(𝜋)
𝑠 1000𝑐𝑚 𝑚 1ℎ𝑟

30 min liquid flow (Rule 6) = (30 min)(6608 kg/h)(1h/60min)(1m3/876kg) = 3.77169 m3

Volume of the liquid = 0.5LπD2/4 = 3.77169 m3

9.896 L = 3.77169 m3

= 0.38 m

Volume = [π(5.02)2(0.38)]/4 = 7.52 m3