PRODUCTION OF

ACROLEIN
MAKHATHINI S. F
KHUMALO S. M
MANQELE K. B

OUTLINE
REACTOR DESIGN
HEAT EXCHANGER DESIGN (E-108)
ACROLEIN DISTILLATION COLUMN DESIGN (T-103)
CONDENSER DESIGN (E-102)
REBOILER DESIGN (E-103)
REFLUX DRUM DESIGN (V-102)
COST ESTIMATION

INTRODUCTION
OBJECTIVE(S)
The goal of this project is to design a grass roots facility
that will safely and
efficiently produce 50,000 metric tons per year of
acrolein from propylene, air, and
steam.

REACTOR DESIGN (R-101)

Method of calculation
Step 1.In order to design the reactor firstly type of
reactor is decided. Since the reaction is a catalytic
reaction, packed bed reactor is chosen.
Step 2. Material balance around reactor:
Step 3. In order to find reactor outlet temperature and
catalyst weight, design equation for PBR is applied
Step 4. Using catalyst weight, volume of reactor is
calculated using bulk density of catalyst

REACTOR DESIGN
Step 5. Using rule of thumb for reactor design, crosssectional area, length and diameter is determined.
Step 6. Carbon steel (double-welded butt joints with
spot examined) is chosen as a construction material of
the reactor.
Step 7. Thickness of reactor shell is calculated.

REACTOR DESIGN
VOLUME OF REACTOR = 3.44 m3
HEIGHT OF THE REACTOR = 3.97 m
DIAMETER OF THE REACTOR (PRACTICAL USAGE) = 1.05
m2
CATALYST WEIGHT = 4177.20 Kg
THICKNESS OF THE REACTOR = 0.0155m

HEAT EXCHANGER DESIGN (E108)

The prime objective in the design of an exchanger is to
determine the surface area required for the specified
duty (rate of heat transfer) using the temperature
differences available.
The overall coefficient is the reciprocal of the overall
resistance to heat transfer.
The main purpose of this Heat exchanger is to cool the
cooling water of the reactor due to high temperatures
sustained during the reaction
DUTY = 289.38 KW
LOG MEAN TEMPERATURE = 50.88 oC

HEAT EXCHANGER DESIGN (E108)

Overall coefficient = 1065 W/m2.oC
Trial Area = 9.48 m2
Tubes-side
Number of Tubes = 40
Tube Layout = Square pitch
Pressure Drop = 9.6 kPa
Mass flow rate = 6.89 kg/s

HEAT EXCHANGER DESIGN (E108)

Shell-side
Shell diameter = 254 mm
Baffle arrangement = 45% cut
Shell layout = pull-through floating head
Shell-side pressure drop = 34.11 kPa

DISTILLATION COLUMN
DESIGN(T-103)
There are two types of columns: tray or packed column
Column chosen: Tray column
Diameter of holes: 5mm
Spacing: 0.6 m tray spacing.
Method of Calculation: Underwood method was used for finding
the number of trays and the minimum and reflux ratio
Bubble point and dew point calculation were done.
Tray efficiency was determined: 50.11%
Material of construction: Carbon Steel

CONDENSER DESIGN (E-103)

The prime objective in the design of an exchanger is to
determine the surface area required for the specified
duty (rate of heat transfer) using the temperature
differences available.
The overall coefficient is the reciprocal of the overall
resistance to heat transfer.
The main purpose of this Heat exchanger is to cool the
cooling water of the reactor due to high temperatures
sustained during the reaction
DUTY = 396.4 KW

REBOILER DESIGN (E-104)

REBOILER TYPE: THERMOSIPHON
Thermosiphon reboilers can suffer from flow instabilities
if too high a heat flux is used.
DUTY = 9113.9 KW

COST ESTIMATION
Equipment cost is used to determine the fixed capital investment.
Equipment sizing was done using graphical method (Sinnort,1999)

Where type factor and pressure factor depend on the material of

construction
1$ = R 13.47 mid August 2016

Figure 1: graph used for costing a distillation column

COST ESTIMATION
Equipment

Cost estimated (ZAR)

Agitator (propeller)

Condenser

Distillation column

Pump (Centrifugal)

Reboiler (Thermosiphon, vertical)

Reflux drum (horizontal)

Reactor (agitated, Packed Bed)

Total

3866266.40

HAZOP STUDY
Ahazard and operability study(HAZOP) is a
structured and systematic examination of a complex
planned or existing process or operation in order to
identify and evaluate problems that may represent risks
to personnel or equipment.
The intention of performing a HAZOP is to review the
design to pick up design and engineering issues that
may otherwise not have been found.