Chapter 7

In chemical engineering, chemical reactors are vessels designed to

contain chemical reactions. The design of a chemical reactor deals with
multiple aspects of chemical engineering. There are some important type
that need to emphasize during the selection or the reactor. Firstly, the
selection of the type of reactor, volume calculation based on reaction
kinetic, geometrical arrangement of internal in a convenient manner for
the hyrdronomic of flow and lastly hyraluic calculation such to match the
allowable pressure rop with the velocity if residence time. Chemical
engineers design reactors to maximize net present value for the given
reaction. Designers ensure that the reaction proceeds with the highest
efficiency towards the desired output product, producing the highest yield
of product while requiring the least amount of money to purchase and
operate. Normal operating expenses include energy input, energy
removal, raw material costs, labor, and others. Energy changes can come
in the form of heating or cooling, pumping to increase pressure, frictional
pressure loss and agitation.

The recommended value for the good selection and design are

Gas-phase

reaction:20-50

m/s

(low

pressure),10-20

m/s(high

pressure)

Gas over catalytic bed: 0.10-0.30 depending on catalyst size for

allowable pressure resistance of catalyst pellet

Fluid bed: usually twice the minimum fluidisation velocity

Gas absorption column: 1 m/s in sieve

Gas in trickle bed reactor: 0.10-0.20cm/s

Liquid or supercritical fluids in tubular reactor: 0.5-3 m/s

4.0 Preliminary design of equipment

4.1 Heuristics
4.1.1 Reactor R-100
Reactor Sizing

Chemical Equation: CO + 2H2 CH3OH

Calculation of Initial Concentration, CA0
y Ao=0.052

= -2

= y Ao
=2(0.052) = -0.104
CA0 = yA0 PT / RT

CA0 = 0.052 (72) / (0.08314) (528)

3

CA0 = 0.0853 mol /m

Stoichiometric
Species

Feed rate to
reactor
(kmol/h)

CO2

FAo

Concentration of spesies
within reactor (kmol/ m

Pressure of species within the

reactor
)

CA = CA0 (1- x) / (1 + x)

PA = CA0 RT(1- x) / (1 + x)

H2

FBo

CH3OH

CB = CA0 ( B - 3x) / (1 +

PB = CA0RT( B - 3x) / (1

x)

+ x)

CC = CA0 (x) / (1 + x)

Pc = CA0 RT (x) / (1 + x)

Calculation of Initial Molar Flowrate

FA0

= 74.747 (0.032)
= 2.392 kmol/hr

FB0

= 74.747 (0.794)
= 59.372 kmol/hr

Calculation of catalyst mass

The design equation for Packed Bed Reactor (PBR):Assumption :

-rA = k

k =

PCO2m PH2 n , where m = 0.94 and n = 1.71 (Ledakowicz,S. 2013)

kg . hr . 2.65
kmol ( Koba, O. 2013)
0.004119

W = FA0

dx
rA
0

W = FA0

dx
k P A 0.94
P B1.71
0

RT (1 x )/(1+ x)

C A 0 RT ( B3 x )
0.94
( 1+ x )
k
dx

W = FA0

1.71

0.66

(1x )/(10.176 x )

1.71
0.94( 3.744(24.823 x )/(10.176 x ))
3.744

dx

0.66
2.392

0.004119 0
W = 7333.33 Kg

Calculation of Catalyst Volume

W

Weight of catalyst,kg
Density of bulk catalyst, kg/m

Volume of catalyst, m

Vcat = W/
Vcat =

7333.33 kg
1100 kg/m

Vcat = 6.67 m
Calculation of Reactor Volume
Assumptions:

Diameter to length ratio (D : L) is 1:3. Hence L = 3D

The catalyst bed occupies 1/3 of reactor volume.
Shell and Tube packed bed reactor.
1000 tubes with 28mm internal diameter.

Vreactor = 3 Vcatalyst
= 3(6.67m)
= 20 m

For cylindrical vessel, V =

D L
4

D 3 D
=
4
D = 2.04 m
Thus L = 3(2.04)
= 6.12m

4.1.2 Heat Exchanger

a) E-100
Rule 1: set F =0.9, q=UA

T lm

Rule 8:U= 30W/m2oC

From the energy balance calculated for the E-100, the q value is 98.1236kJ/s
Condition
Tin
Tout
Hot
350
150
Cold
41.369
196.85
The stream for the hot condition is obtained by assuming the temperature in and
temperature out.
[ ( 350196.85 ) (15041.369 ) ] =129.6188
T lm =
ln [( 350196.85 ) / ( 15041.369 ) ]

A=

q
98.1236
=
=28.03767 m2
U T lm F ( 0.03 )( 129.6188 ) (0.9)

b) E-101
Stream inlet = stream 7
Stream outlet = stream 8
Q = 88.4kW
Q=UAFTlm

From table 11.11

Rule 1 : F = 0.9 for shell and tube exchanger with no phase change
Rule 8 : Heat transfer coefficient, U = 30 w/m2 = 0.03kW/m2 for gas to gas

lm

T1

T 1 T 2
T1
ln
T2

= Thot in Tcold out

= 500 oC 255oC
= 245 oC

T2

= Thot out Tcold in

= 300.00oC 146.4875 oC
= 108.5125 oC

 T lm

245108.5125
245
ln
108.5125

= 167.5942

Q
UF T lm

88.4
(0.03)(0.9)(167.5942)

= 19.5402 m2

Assume cylindrical vessel

2D = H
A

D2
4

19.5402 =

V=

D
4

= 4.988m

= 9.9758m

D2
4

(4.988)2
4

(9.975)

=194.92m3
c)E-102
Stream inlet = stream 8
Stream outlet = stream 9
Q = 61.2 kW
Q=UAFTlm
From table 11.11
Rule 1 : F = 0.9 for shell and tube exchanger with no phase change
Rule 8 : Heat transfer coefficient, U = 30 w/m2 = 0.03kW/m2 for gas to gas
T 1 T 2
T1
T
lm =
ln
T2
T1

= Thot in Tcold out

= 305.0 oC 200.00oC
= 105.00 oC
T2

= Thot out Tcold in

= 136.754 oC 35.122 oC
= 101.632 oC
T lm

105.00101.632
105.00
ln
101.632

= 103.3068
A

=
=

Q
UF T lm
61.2
(0.03)(0.9)(103.3068)

= 21.9380 m2

Assume cylindrical vessel

2D = H
2
D
A =
4

21.9380 =
D
H
V=

D2
4

D
4

= 5.285m
= 10.570 m
H

(5.285)2
4

(10.570)

= 231.875 m3

d)E-103
Stream inlet = stream 9
Stream outlet = stream 10
Q

= 1.85 X 104 W

=UAFTlm

From table 11.11

Rule 1 : F = 0.9 for shell and tube exchanger with no phase change
Rule 8 : Heat transfer coefficient, U = 30 w/m2 for gas to gas
Rule 7 : cooling water inlet is 300C maximum outlet 450C

lm

T1

T 1 T 2
T1
ln
T2

= Thot in Tcold out

= 136.754 oC 45 oC
= 91.754 oC

T2

= Thot out Tcold in

= 35 - 30 oC
= 5 oC

T lm

91.7545
91.754
ln
5

= 29.8157

Q
UF T lm

1.854 X 10 4
(30)(0.9)(29.8157)

= 22.9343 m2
Assume cylindrical vessel
2D = H
A

D2
4

22.9343 =

V=

D2
4

= 4.706178 m

= 9. 4124 m

D
4

( 4.706178 )
4

(9. 4124)

= 163.7499 m3
e)E104
Stream inlet = stream 12
Stream outlet = stream 13
Q = UAF T

lm

Q = 2.08 X 104 W
From table 11.11
Rule 1 : F = 0.9 for shell and tube exchanger with no phase change
Rule 8 : Heat transfer coefficient, U = 30 w/m2 for gas to gas
Rule 7 : cooling water inlet is 300C maximum outlet 450C

lm

T 1 T 2
T1
ln
T2

T1 = T T
hot in
cold out
= 206.850 oC 45 oC
= 161.85 oC
T2 = T
hot out Tcold in
= 53oC - 30 oC
= 23 oC

 T lm

161.8523
161.85
ln
23

= 71.1622 oC
A=

Q
UF T lm

2.08 X 104
(30)(0.9)(71.1622)

= 10.8063 m2
Assume cylindrical vessel
2D = H
A

D
4

10.8063 =

V=

D
4

= 3.2044 m

= 6.4609 m

D2
4

(3.2044 )
4

= 52.9620 m3

(6.4609)

f)E-105
Rule 1: 0.9 for shell and tube exchangers
Rule 8: U = 30 W/m2 C
The value of Q is 205.0635 kJ/s. The value of temperature at cold stream was
assumed as following:
THot, in = 255 C

TCold, out = 254C

THot,out = 40 C
T1 = THot,in - TCold,out
= 255 C - 254C
= 1 C
T2 = THot,out - TCold,in
= 40 C - 37C
= 3 C

Tlm =

T 1 T 2
T 1
ln(
)
T 2

= -2/ -1.09861229
= 1.820478 C
Q = UAF Tlm
A= Q/ UF Tlm
= 205.0635/(30 x 0.9x 1.820478)
= 4.172 m2

TCold,in = 37C

g)E-106
Rule 1: F = 0.9 for shell-and-tube exchangers
Rule 8: U = 30 W/m2
Since, the value of Q is too small which is 1.63 kJ/s, the value of temperature
at hot stream was assumed as following:
Hot ,=79
T

T Hot , out =47

T cold ,out =70

cold ,=40
T

Within counter-current flow, the formula used for

following:
Hot ,T cold ,out
T 1=T
= 7970
= 9
cold ,
T 2=T Hot , out T
= 4740
= 7

T1

and

T2

is as

 T 1 T 2
T lm

ln

T1
T2

( )

397
39
ln ( )
7

= 7.958158
Q=UAF T lm

A=

Q
UF T lm

1.448690698
( 0.03 )( 0.9 )(7.958158)

= 6.7422 m2

4.1.3 Methanol Distillation Column, (T-100)

Stream 28 (Light ends)

Tower
Stream 27

Stream

(T-100)

Stream 26 (Water)

For distillation column, these following heuristic are used, based on table11.13:
Rmin

Rule 5: Optimum reflux range of 1.2-1.5

Rule 6: Optimum number of stages approximately 2Nmin

x
x
]/[
]
1x 1x }/ln

Rule 7:

N min =ln {[

Rule 8:

Rmin =

Rule9: Used= a safety factor of 10% on number of trays

Rule 14: Lmax=53m and L/D

{ DF }/( 1)

For sieve tray, these following heuristic are used based on table 11.14

kg 0.5

3
m
Rule 2:
F s=u p0.5
v =1.2 1.5m/ s

Rule 3

: Ptray =0.007

Rule 4:

Etray =6090

Calculation
X ovhd =0.9655

X bottom =2.198E-0 .6
sat

sat

ovrhead =P1 / P2
sat

sat

bottom=P1 / P2

Sat

sat

ln P1 ln P 2

is given by the Antoine equation yield

Psat (kPa)= A[

B
]
T ( K ) +C

ln
1. Methanol
sat

P1 (kPa)=16.5785[

3638.27
]
T ( K )33.650

ln
2. Water
sat

P2 (kPa)=16.3872[

3885.70
]
T ( K )42.980

ln
At overhead
Methanol :

Water:

Psat
1 =

100.377kPa

sat

P2 =24.503 kPa

At Bottom
Methanol :

Water :

Psat
1 =

929.711kPa

Psat
2 =303.157 kPa

Thus :
ovhd=100.377 /24.503=4.1
bottom=929.711/303.157=

3.1

geom ave =( ovhd bottom )0.5=3.565

Number of tray

For minimum number of tray

N min =ln {[

x
x
] /[
]
1x ovhd 1x bottom }/ln

N min =ln {[

0.9655
2.198E-0 .6
] /[
]
3.565
10.9655 ovhd 12.198E-0 .6 bottom }/ln

N min = 12.87 13 tray

For Theoretical number of tray

N theoritical= 2(13) = 26 tray

For Actual number of tray

N theoritical=26 tray

Etray=0.6

N actual =

26
1.1=47.7 48 tray
0.6

Reflux Ratio

For reflux ratio minimum

Optimum reflux range of (1.2 to 1.5)

Rmin =

{ DF }/( 1)

Rmin =

/(3.5651)
{38313.90
31210.99 }

Rmin

Rmin =3.148

Range of R (1.2 to 1.5)

Rmin

Diameter of tower

For diameter
U=0.6 (moderate pressure)
F s=u p0.5
v
Pv= 2.81kg/ m3

D tray =

0.5

[ ]
4v
u

= 3.778 to 4.722

4 2.81
D tray =
0.6

0.5

= 2.44m

Volume of Tower

For volume
V=

D2 L
4

L= 53m (Rule 14)

V=

2.442 53
4

V = 247.83 m3
4.1.3 Compressor
a) C-100
Make-up compressor

Using rule 2, theoretical reversible adiabatic power,

Where;
T1 is the inlet temperature,
R= gas constant,
z1= compressibility,
m= molar flow rate,
Values of R=8.314 J/mol.K

W rev adiab

p2
p1

m z1 R T 1

T 1 = 308K
P1= 9.565 bar
P2= 33.599 bar
Z =1
mol
m=4.503 s

From rule 3, T = T

T P2
=
T P1

P2
P1

( )

so we can calculate the value of a

( )

log 10

a=

T
P2
=a log10 ( 1 )
T
P
206.85
35

log 10

log 10

33.6
)
9.56

= 1.41

W rev adiab

33.599
9.565

4.503(1)(8.314)(308)

Using compressor efficiency 75 %

W act = (40.034)/ (0.75)
=53.379 kW

= 40.034 kW

b) C-101
Rule 3: Outlet temperature for reversible adiabatic process, T2 = T1 (P2/P1)a
Tin = 53 C

Tout = 187.445 C

Pin = 3023.896 kPa = 30.23896 bar

Pout = 8010 kPa = 80.10 bar

T2
T1
P
log 2
P1
log

Rearrange the equation, a =

187.445
53
8010
log
3023.896
log

= 1.296721

Rule 2: Theoretical reversible adiabatic power = mz1RT1[{P2/P1}a 1)]/a,

where T1 is inlet temperature, R = gas constant, z1 = compressibility, m = molar
flow rate,
Values of R = 8.314 J/mol K, z1 = 1

[{ } ]
a

Wrev adiab =

m z1 R T 1

P2
1
P1

4.5031975

[{

mol
J
80.10
( 1 ) 8.314
( 53+273.15 ) K
s
mol . K
30.23896
1.296721

) (

1.296721

= 23 887.5076 J/s
= 23.8875 kW

Rule 6: Efficiencies of reciprocating compressors: 65% at compression ratios of

1.5, 75% at 2.0 an 80-85% at 3-6.
Using compressor effieciency of 75%

Wactual = (23.8875)/(0.75)
= 31.85 Kw

c) C-102
Rule 3: Outlet temperature for reversible adiabatic process, T2 = T1 (P2/P1)a
Tin = 40 C

Tout = 105.53 C

Pin = 4729.825 kPa = 47.29825 bar

Pout = 8010 kPa = 80.10 bar

T2
T1
P2
log
P1
log

Rearrange the equation, a =

105.53
40
8010
log
4729.825
log

= 1.841517

Rule 2: Theoretical reversible adiabatic power = mz1RT1[{P2/P1}a 1)]/a,

where T1 is inlet temperature, R = gas constant, z1 = compressibility, m = molar
flow rate,
Values of R = 8.314 J/mol K, z1 = 1

[{ } ]
a

Wrev adiab =

m z1 R T 1

P2
1
P1

16.25987688

[{

mol
J
80.10
( 1 ) 8.314
( 40+273.15 ) K
s
mol . K
47.29825
1.841517

) (

1.841517

= 37 660.3338 J/s
= 37.6603 kW

Rule 6: Efficiencies of reciprocating compressors: 65% at compression ratios of

1.5, 75% at 2.0 an 80-85% at 3-6.
Using compressor effieciency of 75%
Wactual = (37.6603)/(0.75)
= 50.2137 kW

d) C-103
Rule 3: Outlet temperature for reversible adiabatic process, T2 = T1 (P2/P1)a
Tin = 76.831 C

Tout = 11.995 C

Pin = 6750 kPa = 67.50 bar

Pout = 2222 kPa = 22.22 bar

T2
T1
P2
log
P1
log

Rearrange the equation, a =

11.995
76.831
2222
log
6750

log
=

= 1.671371

Rule 2: Theoretical reversible adiabatic power = mz1RT1[{P2/P1}a 1)]/a,

where T1 is inlet temperature, R = gas constant, z1 = compressibility, m = molar
flow rate,
Values of R = 8.314 J/mol K, z1 = 1

[{ } ]
a

Wrev adiab =

m z1 R T 1

P2
1
P1

a
=

[{ }

mol
J
22.22
1.11057601
( 1 ) 8.314
( 76.831+273.15 ) K
s
mol . K
67.50
1.671371

) (

1.671371

= -2 726.9836 J/s
= 2.7270 kW (ignore the negative sign)

Rule 6: Efficiencies of reciprocating compressors: 65% at compression ratios of

1.5, 75% at 2.0 an 80-85% at 3-6.
Using compressor effieciency of 75%
Wactual = (2.7270)/(0.75)
= 3.6360 kW

4.1.4 Pump
a) P-101

From table 11.9, the following heuristics are used:

Rule 1: power for pumping liquid(kW) = (1.67)[flow(m3/min)]P/(bar)/
From stream table and PFD,
Flowrate (stream 16) =797.2546tonne/year
tonne 1000 kg 1 year
1h
=1.517 kg/min
( 797.2546
)(
)(
)(
year
1 tonne 8760 h 60 min )

Flowrate ( stream16 )=

Density of mixture = (3.739E-9)(0.656)+(2.37E-15)(1280)+(9.998E-6)(1000)+

(1.007E-5)(0.0899)+(3.086E-6)(1.14)+(2.003E-4)(1.98)
= 999.8kg/m3

P=2282kPa956.498 kPa

101.325 kPa

1325.502 kPa

1.01325

Volumetric flowrate = (1.517kg/min) / (999.8kg/m3) = 1.517 X 10-3 m3/min

Fluid pumping power = (1.67)( 1.517 X 10-3)(13.255) = 0.0336kW

By applying rule 4-7

=0.75

Power = 0.0336/0.75 = 44760.04kW =0.047kW

b) P-100
From table 11.9, the following heuristics are used:
Rule 1: power for pumping liquid(kW) = (1.67)[flow(m3/min)]P/(bar)/
From stream table and PFD,
Flowrate (stream 16) =797.2546tonne/year
kg 1 year
1h
=1.903 kg /min
( 1000yeartonne )( 1000
1 tonne )( 8760h )( 60 min )

Flowrate ( stream16 )=

Density of mixture = (4.175E-5)(0.656)+(5.156E-10)(1280)+(3.421E-2)(1000)+

(2.901E-5)(0.0899)+(226E-6)(1.14)+(2.138E-4)(1.98)+(9.655E-1)(786.5)
= 786.5kg/m3

P= pressure suction pressure discharge

Pressure suction entering the distillation column (T-100) is 4729.825kPa
By assuming that the pressures drop before entering the pump is half of the
pressure at T-100. Thus, the pressure suction at the pump is,
=4729.825kPa/2 = 2364.9125kPa

P=2364.9125 Pa101.325 kPa

101.325 kPa

2263.5875 kPa

1.01325

Volumetric flowrate = (1.903kg/min) / (786.5kg/m3) = 2.420 X 10-3 m3/min

Fluid pumping power = (1.67)( 2.420 X10-3 )(22.63) = 0.0914kW
By applying rule 4-7
=0.75
Power =0.0914/0.75 = 0.122kW
4.1.5 Vessel
a)Methanol column reflux drum(V-102)
For stream 27
kg
day

Mass flow rate= 2739.73

kg
Average density = 754.85 m3
Volumetric flow rate is found by dividing its mass flow rate to its average
density.
kg
day
m3
kg =3.63 day
754.85 3
m

2739.73

m3
Volumetric flowrate=3.63 day
Stream 28
Mass flow rate= 49.73

kg
day

Average density = 294.73

kg
m3

Volumetric flow rate is found by dividing its mass flow rate to its average
density.
kg
3
day
m
kg =0.169 day
294.73 3
m
49.73

Volumetric flowrate=0.169

m3
day

m3
Total volumetric flowrate= 3.63 day

+ 0.169

m3
m3
day =3.799 day

Since it is the daily flow rate, it is equal to the capacity of the vessel.
V= 3.8 m

From heuristics table, the following rules are used; -Liquid drum are usually
horizontal.
-Horizontal vessels are used for volumes larger than 3.8m.

From the heuristic,

L
D =3
3

3 D
=3.8 m3
4

D= 1.17m
L=D x 3= 3.51m

b)Water Let-down Vessel (V-100)

Excess steam is condensed and removed from the reformer products, in a
knock-out vessel to ensure dryness for the compression train.
Stream 10
kg
Mass flow rate= 4.142 min

Average density = 239.8

kg
m3

Volumetric flow rate is found by dividing its mass flow rate to its average
density.

Volumetric flowrate=0.0173

m3
min

Given resident time=7.5min (jurnal)

=

V =7.5 X 0.0173

= 0.1295 m

m3
day

From heuristics table, the following rules are used;

-Vertical vessels are used for volumes less than 3.8m.
-Knockout should hold no less than 10 times the liquid volume passing per
minute:
It is selected 15 times the liquid volume passing per minute which is 0.1295
m3 in our system, so volume of our vessel is

15 x 0.1295 m = 1.9425 m

From the heuristic,

L
D =3
3 D3
=1.9425 m3
4
D= 0.938m
L= D x 3= 2.813 m

c)Crude Methanol Let down vessel (V-101)

8.232

kg
min

Average density = 57.46

kg
m3

Mass flow rate=

Volumetric flow rate is found by dividing its mass flow rate to its average
density.
3

Volumetric flowrate=0.143

resident time=7.5min (jurnal)

=

m3
V =7.5 X 0. 143
day
= 1,0725 m

m
day

From heuristics table, the following rules are used;

-Vertical vessels are used for volumes less than 3.8m.
From the heuristic,
L
D =3
3 D3
=1.0725 m3
4
D= 0.769 m
L= D x 3= 2.307 m