Академический Документы
Профессиональный Документы
Культура Документы
A PROJECT REPORT
Submitted by
YESWIN RAJA.R
212712203086
RASHESH GUPTA.D.V
212712203501
REMO PRATHAP
212712203502
BONAFIDE CERTIFICATE
SIGNATURE
SIGNATURE
Dr.N.Meyyappan, M.E.,Ph.D ,
PROFESSOR &
HEAD OF THE DEPARTMENT
INTERNAL EXAMINER
EXTERNAL EXAMINER
Date:
Date:
express
our
sincere
thanks
to
Professor
S.
GANESH
With profound respect, we express our deep sense of gratitude and sincere
thanks to our supervisor, Ms. G. HIMA BINDU, Assistant Professor,
Department of Chemical Engineering for her valuable guidance and
suggestions throughout this project.
and
the
management
of
CHENNAI
PETROLEUM
Finally, we thank the faculty and staff of the Chemical Engineering Department,
Sri Venkateswara College of Engineering for their support.
i
ABSTRACT
ii
TABLE OF CONTENTS
CHAPTER No.
TITLE
PAGE No.
ABSTRACT
ii
LIST OF FIGURES
vii
LIST OF TABLES
viii
ix
INTRODUCTION
MATERIAL BALANCE
10
reactor
4.2 Material balance around hot separator
14
16
18
19
21
22
iii
ENERGY BALANCE
23
23
24
31
33
36
37
39
40
43
44
46
47
47
50
50
51
51
51
51
51
52
54
55
57
iv
59
60
60
60
61
61
61
62
7.3 DISPLAY
63
7.4 ALARM
64
64
65
COST ESTIMATION
65
66
67
68
69
70
8.7 Depreciation
70
71
8.8 Sales
71
72
72
73
73
73
74
74
v
78
79
10
11
PROCESS SAFETY
80
80
10.2 Hazard
81
82
82
82
83
12
84
84
REFERENCES
86
vi
LIST OF FIGURES
FIGURE No.
TITLE
PAGE No.
3.1
4.1
10
4.2
14
4.3
16
4.4
18
4.5
19
4.6
21
4.7
22
5.1
23
5.2
24
5.3
32
5.4
33
5.5
36
5.6
37
5.7
39
5.8
40
5.9
43
5.10
44
5.11
46
6.1
47
9.1
Plant layout
vii
LIST OF TABLES
TABLE No.
4.1
TITLE
PAGE No.
15
5.1
25
5.2
26
5.3
26
5.4
29
5.5
30
5.6
30
6.1
50
8.1
Equipment cost
65
8.2
Fixed cost
66
8.3
67
8.4
68
8.5
Employees salary
69
8.6
70
vii
Absolute Temperature
Cp
Difference in Temperature
Heat Energy
ni
Hf0
DHDS -
Diesel Hydrodesulphurisation
DHDT -
Diesel Hydrotreating
GHG -
FFA
FAME -
R&D -
JO
Jatropha Oil
HSD
MEA -
Mono-ethanolamine
PIC
ix
1. INTRODUCTION
The need for the technologies to produce alternative, sustainable energy sources,
preferably renewable energy sources has been increasing across the world due to the
concern over limited fossil fuel sources, increasing petroleum prices, governments
directives and commitment to reduce GREEN HOUSE GASES emissions. Immediate
opportunities to fill the gap in the transportation fuels sector lie in finding the suitable
technologies using renewable resources such as Sugars, Starches, Lignocelluloses, Algal
Oil, Bio-mass, Garbage etc. to produce corresponding compatible fuels. All or many of
these routes have difficulties of cost of production, effect on food chain or demand of a
new infrastructure, which doesnt attract the present refineries.
Renewable energy sources will fascinate better if the similar fuels to the existing
hydrocarbons are produced to meet the conventional engine technology and compatible to
the existing distribution of infrastructure. Biodiesel [Fatty Acid Methyl Ester, FAME], Di
Methyl Ether [DME] and Synthetic diesel are few alternatives, projected recently in this
direction.
catalyst. Water deactivates both basic and acidic catalyst, necessitating the drying up of oil.
The soaps formed with basic catalyst from emulsion and soap, which are difficult to
remove. Acids and alkali-based processes produce waste stream and side products resulting
in loss of biodiesel yields.
Enzymatic Transesterification overcomes some of these disadvantages, but the
process is significantly costlier. Super critical transesterification is much simpler among all
transesterification processes. But very high temperature and pressure [3500C and 45MPa]
makes the process less attractive on a commercial scale. Heterogeneous catalysts in this
process have yet to prove their viability. Thus the process though simple suffers from
several disadvantages. The removal of free fatty acids for avoiding saponification in
subsequent steps, removal of product raw glycerin & recovery of excess alcohol used in the
process for complete conversion pose problem during the process.
requires blending with lighter diesel to meet the diesel specifications, which will
affect the refiners profitability adversely.
The presence of oxygen in biodiesel also results in higher emission of NOx. Also,
FAME is not well accepted by the auto industry in all proportions as these are
responsible for injector choking.
The waste plant mass after oil extraction can be used as a fertilizer.
The plant itself recycles 100% of the CO2 emissions produced by burning the
biodiesel; two mature plants can absorb 1 metric ton of carbon every year.
In view of the problems associated with use and production of biodiesel, the refiners
are exploring hydro-processing route as an alternative option. Co-processing results in
improvement in quality of diesel particularly with respect to cetane number and density.
This will enable integrated refining and marketing companies to meet stipulation of
blending bio-fuels in diesel that may be mandated by the government in near future. The
process is capable of handling different vegetable oils & conversions are quantitative.
The reactions also remove the Sulphur and Nitrogen content in the oil and hence produce a
more quality diesel.
3.3
Vegetable oil contains Free Fatty Acids (FFAs) typically varying from 0.5-10.0 wt %.
Hence storage & handling of these oils require specific metallurgy to avoid the
corrosion.
Exothermicity of reactions:
The high degree of exothermicity is expected due to high content of oxygen (~10 wt%)
in vegetable oils and high heat of reactions. Co-processing of vegetable oil results
about 30C increase in reactor temperature per % of vegetable oil co-processed. This
problem was handled by decreasing inlet temperature to reactor resulting in reduced
fuel consumption.
Chemical H2 consumption:
The vegetable oils contain typically about 10% oxygen which is converted into water,
CO & CO2 respectively by hydrodeoxygenation, hydrodecarbonylation and
hydrodecarboxylation routes. The typical hydrogen consumption is about 2.0 wt% of
vegetable oil processed. For the process, additional H2 requirement was met by
increasing make up H2.
.
CO/CO2 Inhibition:
The CO inhibits the activity of the catalyst by adsorption on active sites, although
inhibition is temporary & less pronounced with NiMo catalyst & higher pressure.
During processing of vegetable oils, water (6.0-8.0% of vegetable processed), CO2
(4.0-6.0% of vegetable processed) and CO (0.5-1.0% of vegetable processed) are
generated depending on the operating conditions and catalyst system. The water can be
separated via boot provided in the separator vessel. The buildup of CO and CO2 in the
recycle gas is therefore required to be controlled. The proper system need to be
installed to reduce CO & CO2 content in recycle gas. Water gas shift & CO methanator
systems may be required. In this process, CO2 was removed by Amine scrubbing and
concentration of CO was controlled by purging of gas from separator.
4. MATERIAL BALANCE
For either total material balance or component material balance we use a simple basic
formula which may be stated as:
Input mass flow rate Output mass flow rate = Rate of Accumulation
Product
28763 Kg/hr
Feed ( JO + HSD)
28433 Kg/hr
Fig. 4.1: Material balance around hydrogenator reactor
Basis:
30m3/h of Diesel
3m3/h of Jatropha oil
Density of feed
= 861.6 kg/m3
Density of product
= 836.9 kg/m3
84.4
10
13.2
0.6
0.1
1.7
23997
3753
170.598
28.433
483.361
H2S
32
34
H2
0.5 O2
H2O
16
18
3H2
N2
---
2NH3
28
34
11
(1)
(2)
(3)
10.662 Kg/h of H2
10.13 Kg/h of H2
60.42 Kg/h of H2
57.4 Kg/h of H2
6.09 Kg/h of H2
73.314 Kg/h of H2
Total H2 supplied
H2 Unreacted
5.785 Kg/h of H2
172.20 Kg/h
32.80 Kg/h
516.6 Kg/h
1.42 Kg/h
Sulphur
8.53 Kg/h
Oxygen
24.17 Kg/h
Carbon =
23997 Kg/h
Hydrogen
3753 Kg/h
Hydrocarbons
Hydrogen + Carbon
At Inlet:
Feed:
28433 Kg/h
H2:
330 Kg/h
Total Inlet:
28763 Kg/h
13
At Outlet:
H2S:
172.2 Kg/h
H2O:
516.6 Kg/h
NH3:
32.8 Kg/h
Nitrogen:
1.42 Kg/h
Sulphur:
8.53 Kg/h
Oxygen:
24.17 Kg/h
Excess H2:
256.7 Kg/h
Hydrocarbons:
27750 Kg/h
Total Outlet:
28763 Kg/h
Rate of Mass in
Feed from
Reactor
Hydrocarbons
28763 Kg/h
277
50Kg/h
28763 Kg/h
Vapour from Hot separator to cold separator:Table 4.2: Flow rates of components of stream from hot separator to cold separator
H2S
172.20 Kg/h
NH3
32.8 Kg/h
Nitrogen
1.42 Kg/h
Oxygen
24.17 Kg/h
Excess Hydrogen
256.70 Kg/h
Total
487.30 Kg/h
At Outlet:
Vapour from hot separator to cold separator: 487.29 Kg/h
Hydrocarbons to Stripper:
27750 Kg/h
516.6+8.53 =
525.73 Kg/h
Total Outlet:
28763 Kg/h
15
Water spray
H2O + NH4OH
82.8 Kg/h
H2O
---
NH4OH
17
18
35
18/17 32.8
Water supplied
0.05 m3/hr
Density
1000 Kg/m3
0.05 1000
50 - 34.73
16
50 Kg/h
15.27 Kg/h
At Inlet:
Feed:
487.3 Kg/h
Water supplied:
50 Kg/h
Total Inlet:
537.3 Kg/h
H2O
---
NH4OH
17
18
35
15.27 Kg/h
At outlet:
Vapour from cold separator to Scrubber:
H2S:
172.20 Kg/h
Nitrogen:
1.42 Kg/h
Oxygen:
24.17 Kg/h
Excess Hydrogen:
256.70 Kg/h
Stream to NH4OH:
82.8 Kg/h
Total Outlet:
537.3 Kg/h
Vapour
454.5 Kg/h
Rich amine with H2S
1424.19 Kg/h
172.20 Kg/h
Nitrogen:
1.42 Kg/h
Oxygen:
24.17 Kg/h
Excess Hydrogen:
256.70 Kg/h
Vapour as Feed:
454.50 Kg/h
MEA:
1226.4 Kg/h
Total Inlet:
1681 Kg/h
18
At outlet:
Hydrogen:
256.7 Kg/h
172.2 Kg/h
Oxygen:
24.17 Kg/h
Nitrogen:
1.42 Kg/h
Total Outlet:
1681 Kg/h
Hydrocarbons
27750Kg/h
Stripping steam
3567.2 Kg/h
=560 6.37
=3567.2 (Kg/h)
At Inlet:
Feed (hydrocarbons): 27750 Kg/h
Steam:
3567.2 Kg/h
Total Inlet:
31317.2 Kg/h
At outlet:
Diesel Outlet:
27750 0.96
= 26640 Kg/h
= 3567.2 Kg/h
Total Outlet:
31317.2 Kg/h
20
Naphtha ( 18.5%)
205.35 Kg/h
3567.2 Kg/h
Total inlet:
4677.2 Kg/h
0.815 1110
Naphtha at Outlet:
0.185 1110
904.65 Kg/h
=
Steam:
205.35 Kg/h
=
Total Outlet:
3567.2 Kg/h
4677.2 Kg/h
21
22
5. ENERGY BALANCE
5.1 ENERGY BALANCE AROUND FEED PRE-HEATER
HSD (2800C) + JO (250C) + H2 (400C)
9689910.581 kJ/h
Reactor
Outlet, 3700C
T H.E.-1 (3050C)
11201347.67 kJ/h
90
90948.832 kJ/h
Cold fluid in
mCpT
So,
Qoil
First let us find out the value of Cp of the mixture of Jatropha and diesel feed
Cp JO
Cp HSD =
So average heat capacity
0.962 kJ/kg K
1.3672 kJ/kg K
Cpi xi
1.3267 kJ/kg K
23
Hence,
Qoil
QH2
9619125.581 kJ/h
mCpT
330 14.3 ( 40 - 25 )
70785 kJ/h
70785 + 9619125.581
9689910.581 kJ/h
Heat energy with hot fluid in =Q associated with products from the reactor
Qh
mCpT
11201347.67 kJ/h
(Qin-Qout)cold
( 11201347.67 9090948.832 )
( 9689910.581 - Qout )
7579511.672 kJ/h
Qout
Feed, 3530C
7579511.672 kJ/h
H2S
(1)
H2
0.5 O2
H2O
(2)
3H2
N2
2NH3
(3)
---
=[ H f o] products [ H f o] reactants
H2S
O2
N2
H2
NH3
H2O
- 20.63
- 46.2
- 285.8
Standard Heat
of formation
(KJ / mol)
Where
-H1 + HRo + H2
H2
HR0
For reaction 1:
H2
S H2S
To calculate H1:
H1 for H2 : =
Where ni
ni cpi dT
moles of H2
=
25
73.314 kmol/h
14.663 kmol/h
Here
626 298
328 K
73253.90 kJ
ni cpi dT
dT
H1 for S :
Total
H1 for reactants
14.663 kmol/h
=
5295.2198 kJ/h
73253.90 + 5295.2198
78549.1198 kJ/h
a + b T + c T2 + d T3
34.5234
-17.638110-3
67.6664 10-6
-53.245410-9
26
H1 for H2S
ni (a + b T2 + CT3 d T3) dT
172312.3677 KJ/hr
-20.63 34
-701.42 kJ
-H1 + HR0 + H2
93061.8279 kJ/h
For reaction 2:
H2
+ 0.5 O2
For H1 of H2 =
H1 for
O2
H2O
5295.2198 kJ/h
ni (a + b T + c T2 + d T3) dT
27.0257
11.7551 10-3
-2.3426 10-6
-0.5623 10-9
Total H1
H2 for H2O
76646.273 kJ/h
73253.90 + 76646.273
149900.173 kJ/h
ni (a + bT +c T2 +d T3) dT
28
32.4921
.0796 10-3
13.210710-6
-4.54710-9
(6262-2982)+ 13.210710-6 /3
(6263-2983) 4.54710-9 /4
(6264-2984)
=
HR0
So, heat of reaction 2 =
168149.3099 kJ/h
HR2 =
-H1 + HR0 + H2
148014.7369 kJ/h
For reaction 3:
3H2 +
H1 for H2
H1 for N2
N2
2NH3
---
3 73253.90
219761.7 kJ/h
ni (a + bT +c T2 +d T3) dT
29
33.1216
10.1923 10-3
-4.262110-6
0.231610-9
H2 for NH3
132214.7065 kJ/h
219761.7 + 132214.7065
351976.4065 kJ/h
Cp =
a + b T + c T2 + d T3
25.9796
-3.970310-3
24.4989 10-6
24.260410-9
30
H2 for NH3
ni (a + b T + c T2 + d T3 ) dT
14.633[25.9796(626-298) (3.970310-3) / 2
(6262-2982) + (24.498910-6)/3
(6263-2983) + (24.260410-9 /4)
(6264-2984) ]
14.663[8521.3088 - 601.6434 +
1787.2012+883.5677]
HR0
HR3
14.663 10590.4343
155287.5381 kJ/h
-46.2 34
-1570.8 kJ
-H1 + HR0 + H2
-198259.6684 kJ
Thus the total heat energy evolved due to endothermicity of the reactions is:
HR1 + HR2
+ HR3
42816.8964 kJ/h
31
3050C
9090948.832 kJ/h
Hydrocarbons, 610C
17 00C,
5802649.88kJ/h
1195803 kJ/h
Or,
Qh in
mCpT
Cp
Q/ mT
1.1288kJ/kg K
Also,
mCpT
Qc in =
=
27750 1.197 ( 61 25 )
1195803 kJ/h
Qc out =
Difference in heat
mCpT
5802649.875 kJ/h
Qc out - Qc in
32
5802649.875 1195803
4606846.875 kJ/h
Thus,
Heat lost by the reactor product
= 4606846.875kJ/h
So the heat along with the hot fluid out = 9090948.832 4606846.875
= 4484101.957 kJ/h
Now,
Q/ mT
0.9280 kJ/kg K
To Cooler, 590C
To H.E. 1
211426.8 kJ/h
1195803 kJ/h
Sour Water, 400C
32527.865 kJ/h
Fig. 5.4: Energy Balance around Hot Separator
33
Outlet 1:
Amount of sulphur
8.53 kg/h
Amount of water
516.6 kg/h
= 4.186 kJ/kg K
Cp avg = xiCpi
So,
= mCpT
= 525.13 4.1295 ( 40 25 )
= 32527.865 kJ/h
Outlet 2:
Heat out
= mCpT
= 487.3 12.761 ( 59 25 )
= 211426.8 kJ/h
Outlet 3:
So,
Amount of C5H12
= 904.65
mass fraction
= 904.65 / 27750
= 0.0326
Cp of C5H12 at 610C
= 1.214 kJ/kg K
Amount of Naphtha
= 205.35
= 205.35 / 27750
34
= 7.4 10-3
Cp of Naphtha at 610C
Amount of Diesel
So, mass fraction
= 1.983 kJ/kg K
= 904.65
= 26640 / 27750
= 0.96
Cp of Diesel at 610C
Cp avg
= 1.19 kJ/kg K
= xiCpi
= 1.214 0.0326 + 1.983 7.4 10-3 + 1.19 0.96
= 1.1967 kJ/kg K
Heat out
= mCpT
= 27750 1.197 ( 61 25 )
= 1195803 kJ/h
Heat in =
Heat out
35
= 4484101.957 kJ/h
Qh out
= 1439757.665 kJ/h
= 3044344.292 kJ/h
= Q /CpT
= 3044344.292 / 4.186 ( 86 25 )
= 11922.428 kg/h
36
OffGases,1310C
Water, 250C
1774439.52
kJ/h
Naphtha, 420C
10767.8 kJ/h
8022.203 kJ/h
Fig. 5.6: Energy Balance around Condenser-2
mCpT
mCpT
mCpT
= 205.35 2.298 ( 42 25 )
= 8022.203 kJ/h
37
Total
Qout
Qsteam
mCpT
QLC
mCpT
Qin - Qout
= ( 2443888.72 + 375275.46 )
( 159853.46 + 1614586.06 + 8022.203)
= 2819164.18 1782461.72
= 1036702.46 kJ/h
= 1036702.46 kJ/h
m=
Q /CpT
= 1036702.46 / 4.186 ( 48 25 )
= 10767.8kg/h
38
LH, 1800C,
Hydrocarbons, 1700C
2819164.18KJ/hr
6487761.7 kJ/h
Steam, 1900C
2625102.48 kJ/h
6293700.00 kJ/h
mCpT
6293700.00 kJ/h
2819164.18 kJ/h
Total
Qout
6293700.00 + 2819164.18
9112864.18 kJ/h
mCpT
3567.2 4.46 ( 190 25 )
39
2625102.48 kJ/h
Qout
Qin
9112864.18
QHC + 2625102.48
QHC
9112864.18 2625102.48
6487761.7 kJ/h
Inlet 2: Hydrocarbons
We have,
So,
Thus,
The heat energy associated with this stream is same as that coming out from heat
exchanger 1.
Hydrogen, 400C
55062.15 kJ/h
44306.1528 kJ/h
68632.7972 kJ/h
mCpT
1226.4 2.779 ( 38 25 )
40
44306.1528 kJ/h
mCpT
256.7 14.3 ( 40 25 )
55062.15 kJ/h
Outlet 1: Hydrogen
Q
= 1226.4 kg/h
= 1226.4 / 1424.19
= 0.861
Cp of MEA at 410C
= 2.779 kJ/ kg K
Amount of H2S
= 172.2 kg/h
= 172.2 / 1424.19
= 0.1209
Cp of H2S at 410C
= 1.003 kJ/ kg K
Amount of O2
= 24.17 kg/h
Mass fraction of O2
= 24.17/ 1424.19
= 0.01697
Cp of O2 at 410C
Amount of N2
Mass fraction of N2
= 0.920 kJ/ kg K
= 1.42kg/h
= 1.42/ 1424.19
41
= 9.9705 10-4
Cp of N2 at 410C
= 10.4 kJ/ kg K
Cp avg
xi Cpi
= mCpT
= 1424.19 2.5399 ( 41 25 )
= 57876.8 kJ/h
We have,
Qout
Qin
112938.95 44306.1528
=
68632.7972 kJ/h
42
71809.337 kJ/h
627.9 kJ/h
68632.7972 kJ/h
15.27 4.186 ( 36 25 )
703.12 kJ/hr
QNH4OH =
Total
mCpT
mCpT
67.53 4.175 ( 36 25 )
3101.32 kJ/hr
703.12 + 3101.32
3804.44 kJ/hr
43
mCpT
50 4.186 ( 28 25 )
627.9 kJ/hr
Qout
Qin
Qcooler + 627.9
QH2O
We have,
3804.44 + 68632.7972
Qcooler =
71809.337 kJ/hr
Water , 250C
44
= 71809.337 kJ/hr
Qin
mCpT
= 487.3 12.761 ( 59 25 )
= 211426.8 kJ/hr
Difference in heat
= 211426.8 71809.337
= 139617.463 kJ/hr
This heat must be carried away by the cooling water used for cooling
Amount of water required m =
Qdiff / CpT
= 139617.463 / 4.186 ( 49 25 )
= 1389.72 kg/hr
45
46
Derive the relationship for volume of the reactor and space time
Calculate the diameter and height of the reactor using thumb rule
Available data:
1.feed (diesel+oil) flow rate rate:33 m3/hr
2.mafke up H2 floiw rate : 330 kg/hr
3.Initial sulfur content present in diesel: 33000ppm(3.3%)
4. final sulfur content present in diesel: 12500ppm(1.25%)
HC-S+H2 H2S+HC
Components
No of moles at t=0
No of moles at t=t
1.
HC-S
a(1-x)
2.
H2
b(1-x)
3.
H2S
Ax
4.
HC
Bx
47
-rs =K (HC-S)n
-rs =K (a(1-x))n
= K (an(1-x))n
Cso = 0.033 kg of sulfur/kg of diesel
-rs= k*0.943*(1-x)^0.5
= 28432.8 kg/hr
= 938.28 kg/hr
Fso= 938.28/32
= 29.321 kmol/ hr
6
10 kg
We know that for the plug flow reactor the design equation = = 0
V=Fso0
V=0.943 0
(1)1/2
(1)1/2
Take X=cos
=-sin
sin d
(1)1/2
=2sin22
Sin=2sin2 cos2
sin d
2sin2 cos2
0 (1)1/2=0
1
2 sin2
2
=-21/20 cos 2
= -2^1/2 *2(sin 8.1096
90
= -2* 2^ ( 0.071-0.707)
49
= 1.799
(1)1/2
V=0.943 1.799
V= 29.321* 1.799/ k* 0.943
= 55.937/ k
We know that
= Cso 0
= 0.9127 hr ^-1
(1)1/2
* 1.799
K = 1.8572
Substitute k value in equation (5)
V = 55.937/ 1.8572
= 30.119 m3
* d2h/4 = 30.119 m3
According to Thumb rule
h/ d =4
so, h=4d
substitute in equation (6)
* d2 (4d) /4 = 30.119
d3 = 9.5872
d = 2.1244 m
h = 4d
= 4 * 2.1244
50
= 8.497
H = 8.50 m
= 24.0952
DESIGN SUMMARY:
1. Volume of the plug flow reactor = 30.119m3
2.
= 24.0952m3
3.
= 8.5 m
4.
= 2.1244m
5.
= 6.8m
6.
Catlyst used
7.
Operating temperature
8.
Operating pressure
= Ni-Mo
= 353
= 69.4 kg/ cm2
51
UNIT
SHELL SIDE
TUBE SIDE
Fluid circulated
Hydrocarbon
Reactor effluent
kg/s
7.74
7.799
Fluid temperature
Inlet/outlet C
61/170
305/193
Specific heat
kJ/kg C
1.197
1.1288
Viscosity
Cp
0.451
0.39
Density
kg/m3
959
861
kPa
70
70
Thermal conductivity
W/m C
0.66
0.081
m2 C/W
Heat Duty
Heat load on shell side fluid, Q = mh * Cph * Th
where,
Q
= Heat transferred, kW
= 1010.1 kW
= mc * Cpc * Tc = mh * Cph * Th
1010.1 = mc (1.197)(170-61)
mc
= 7.74kg/s
52
7.9 * 10-4
170
LMTD =
1 2
1
135 132
135
132
= 0.0225 = 133
Temperature Efficiency, P =
Heat capacity rate ratio , R =
(17061)
= (30561) = 0.447
(305193)
(17061)
= 1.03
= Uo Ao Tm
Where,
Q
Uo
Ao
1010.1 10^3
500126.4
= 15.98 m2
25 mm triangular pitch
=
DoLe
2010-3(4880-225) 10-3
53
193
0.303m2
=
No of tubes NT
=
=
= 52.7 53 tubes
From the tube count table the heat exchanger unit selected will have 254 mm (10) shell
ID with 53 tubes, 1 shell & 4 tube passes.
hiDi
0.023 (Re)0.8(Pr)0.33()0.14
where
hi
Di
Cp =
Prandtl number = Cp / k
Specific heat capacity, kJ/kg C
Gt
mc
At
At
Gt
( /4) (15.810-3)2(
) = 0.0030 m2
7.74
25800.0158
0.390.001
= 104523
54
1.128810000.390.001
Pr = (Cp / k) =
0.081
= 5.435
= (416.590.081) / (0.0158)
hi
= 2135.68 W/m2 C
hio =
hio =
1687.19 W/m2 C
hoDe
0.36 (Re)0.55(Pr)0.33()0.14
k
where
ho
De
= Effective diameter, m
As
Pr
DO 2) } / DO
4{(0.860.0250.025) ( )0.020.02}
0.02
= 0.0142 m
where
Ds = shell ID
C
= clearance = PT OD
= 0.5 Ds , Ds = 0.254m
= GsDe / =
= (Cp / k)
12000.0142
0.4510.001
1.19710000.4510.001
0.66
= 37782.71
= 0.818
5155.6W/m2 C
DO ln (DO/Di)
2KW
= 0.02 ln (0.02/0.0158)
( KW = 50 W/m2 C)
250
=
4.7110-5 m2 C/ W
UO = 515.85W/m2 C
56
1010.1 10^3
515.85126.4
= 15.5 m2
% EXCESS AREA
PT = 2106
where,
f
Gt
()0.14
specific gravity
0.72 * (104523)-0.33
Gt / = (258/861) = 0.30m/s
= 1
= 0.861
= 0.016
0.0162582 4.84
57
PS = 210 6
, kPa
where,
f
DS = Shell ID = 0.254m
Nb = No. of baffles
4.83
= 0.50.254 = 38 baffles
0.22712002 0.254(38+1)
2106 0.014210.957
, kPa
19.62 kPa
DESIGN SUMMARY
Heat duty of the heat exchanger = 1010.1 kW
Area required for heat transfer = 15.5 m2
Area available for heat transfer = 16.08 m2
% Excess area =3.74 %
Number of tubes = 53
Number of passes on tube side = 4
Number of passes on shell side = 1
Shell ID = 254mm
Film heat transfer coefficient tube side , hio = 1687.19 W/m2 C
Film heat transfer coefficient shell side , ho = 5155.6 W/m2 C
Pressure drop tube side PT = 8.27 kPa
Pressure drop tube side PS =19.62 kPa
58
Instrumentation and process control engineering plays vital role in controlling the
process for desired output from the plant. All instruments should be installed from standard
manufacturers by selecting based on the previous process experience.
Instrumentation is provided to monitor the vital process parameters during plant
operations. They may be incorporated in automatic control loops or used for the manual
monitoring of process parameters. They may also be a part of automatic computer data
acquisition. Instruments monitoring critical process parameters will be fitted with
automatic pop-ups and enunciations to alert the operator at critical and hazardous situations
in prior. The main objective of the designer when specifying instrumentation and control
schemes are, to keep process parameters within the operating limit, so as to detect
dangerous situations that may develop due to process deviations and to provide
alarms/buzzer and automatic fail safe systems. And also to maintain the product
composition within the specified quality standards and to operate the plant at the lowest
production cost. Variables in a process must be measured and then controlled and
integrated for optimum processing conditions. Mechanical and electrical components and
systems have been designed by instrumentation and process control engineers to reduce
labor and improve feasibility of plant operation, and to allow extensive outdoor plant
construction.
The economic advantage of automatic process control has been well established
throughout the industry, thus accounting for the rapid growth in this area of the chemical
process industry.
The main objectives of designer when specifying instrumentation and process
control are:
Monitor and control the process parameters within the operable range on real time
basis.
Maintaining the product quality within the specifications.
Ensure optimum production cost with integrated fail safe mechanisms.
59
Eliminating all the pit-falls that may rise due to manual intervention and properly
taken care of such situations and alert by prior signaling and controlling
catastrophic failures automatically before-hand.
7.1
60
In the hydrogenator, raw materials react to produce the diesel associated with water.
The conversion in the reactor is very much dependent on the molar proportion of
the reactants. The online molar feeds are measured and the controlled for the
specified mole ratio of diesel feed : Jatropha oil feed to get the desired output from
the reactor. The required pressure drop through the reactor for consistent plug
conditions is supplied by the compressor discharge pressure and is maintained by
the reactor outlet damper.
61
In the flow control loop the dynamic elements consist of the controller, the flow
measuring element and the control valve. The control action for a flow control system is
generally PI. The integral control is needed to eliminate offset and thereby establish a
precise ratio of the mixed streams. Derivative action is usually avoided in flow control
because the signal from a flow measuring element is inherently noisy. The presence of
derivative action would amplify the noise and give poor control.
some material into the reactor, which will reduce the rate of the reaction; or venting the
reactor to reduce the pressure. The emergency shutdown system must be highly reliable.
In almost all industries Computer based Distribution control systems and
Programmable logic controllers with human interface systems are installed for easy control
through computers, in this system the hardware requirements for pneumatic, electronic,
and microprocessor-based controllers are working, all pneumatic signals in the range of 3
to 15 psig , the energy needed to operate these pneumatic components is a source of clean,
dry air at a pressure of about 20 psig. The pressure can vary from 20 psig by about +-10 %
without adversely affecting the operation of the instruments.
The electronic system required both electrical and pneumatic power to operate the
components. A transducer or converter is needed between the controller and the valve to
convert current (4-20 mA) to pressure (3- 15 psig)
The components for a microprocessor based system contains the control algorithm
reside as a computer program in the memory of the computer. The operator communicates
with the control system with a keyboard, a monitor, and a printer. The computer can
perform many more functions than implementation of the control algorithm; the recorder
of the pneumatic or electronic system is replaced by a monitor screen on which transients
are shown.
In a modern controller both analog and digital signals are processed. The analog
signal is the type that represents a continuous variable with varies over a range of values.
The digital signal is a binary signal that can be represented by two states.
7.3 DISPLAY
The software in a modern controller has made the strip chart recorder almost
unnecessary. Through the use of skilled programming, the transients produced in a control
system can be displayed on a monitor screen dynamically. As time progresses, the values
of selected variables are displayed as a function of time. The segment time shown on the
screen can be selected to be a few minutes to a few hours to show dynamic detail or long
term trends. Transients that occurred in the past can be stored and displayed again.
63
7.4 ALARM
An extensive amount of the software in modern controllers is devoted to detecting
and reporting a problem in the form of an alarm. The alarm takes the form of a visual
signal, an audible signal (beeping horn), or the auction of a switch.
64
8. COST ESTIMATION
8.1
Equipment
Quantity
Cost( Rs in Lakh)
3.4
Hydrogenator
112.5
Separators
42
Stripper
34
Scrubber
43.6
Condenser
37.4
65
Descriptions
278.9
97.62
97.62
167.34
125.51
6.
1600.00
Lakhs / acre)
7.
139.45
139.45 Lakhs
83.69 Lakhs
2729.61 Lakhs
=
223.17 Lakhs
272.96 Lakhs
272.96 Lakhs
818.88 Lakhs
66
3275.53 Lakhs
8.3
3275.53 + 818.88
4094.41 Lakhs
Raw Material
Cost ( Rs)
136 per m3
28648.224
38.96
Jatropha oil
80 per kg
22518936 Kg
18015.15
Diesel feed
47 per kg
202670424 Kg
95255.10
67
Utility
Cost ( Rs)
Electricity
Rs 10 /KWh
555.55KWh24hr
(555.55KWh)
(Power taken
330days
from Refinery)
=4399956KWh
L.P Steam
35640 Ton
(-) 655.40
M.P Steam
43560 Ton
(-) 838.96
Water
65 per m3
565488
367.56
68
8.5
OPERATING COST
Table 8.5: Employees Salary
S. No
Designation
Nos
Executive Director
15.00
General Manager
12.00
9.00
Production Manager
6.00
Engineer
19.20
Production Operator
12
36.00
Chemist
36.00
Clerical Staff
3.60
Medical Staff
18.00
10
Worker
20
14.40
11
Accounting Staff
7.20
12
Sales officer
4.00
13
Security
4.80
= Rs 185.20 Lakhs
69
8.6
Rs 113309.21 Lakhs
Utilities Cost
Maintenance Cost
Rs 100 Lakhs
Rs 185.20 Lakhs
Rs 55.00 Lakhs
Rs 112962.59 Lakhs
8.7
DEPRECIATION
Depreciation Rate
Equipment
278.9
55.78
41.84
55.78
55.78
Total = Rs 488.08 Lakhs
70
0.0525 488.08
Rs 25.62 Lakhs
Depreciation Amount
Total Depreciation
0.025 227.9
=
Rs 5.69 Lakhs
Rs 31.31 Lakhs
8.8. SALES
Diesel production in One day
639.36 MT
330 Days
Selling Price
Sales Revenue in One year
639.36 330
210988.8 MT
Rs 116043.84 Lakhs
Less Depreciation
Rs 116012.53 Lakhs
Sales Revenue
Total Production Cost
Rs 116012.53 Lakhs
Rs 112962.59 Lakhs
Rs 3049.94 Lakhs
Rs 1006.48 Lakhs
Rs 2043.46Lakhs
71
Cash accruals
Rs 2043.46 Lakhs
+ Rs 31.31 Lakhs
=
8.9
Rs 2074.77 Lakhs
1.97 Years
(2043.46/4094.41) 100
49.9 %
72
9.1
9.2
9.3
9.4
shop etc., should be located in the building. For this purpose product analysis should be made
which contains what is to be produced, how much is to be produced, what will be the sequence
of operations and how the machines can be best grouped.
The various production departments should be located in such a way that the traffic or
movement of workers should be easy. Flow of materials with in the department and also
between one department and another department should be economically and neatly managed.
74
Service department means canteen, stores, water etc., should be properly positioned
and should be suitably allotted. These should be located from factory as well as workers point
of view.
The various sections of departments of the factory can be arranged in to three main
groups, viz. Administrative, Services and Production departments. As far as possible,
administrative departments should be located in a separate wing, where there should be no
noise and disturbances due to movement and vibrations of machines. General Service
departments such as finished part store, tool rooms should be located as central as possible.
Storage facilities for raw materials and intermediate and finished products may be
located in isolated areas or in adjoining areas. Hazardous material becomes a decided menace
to life and property when stored in large quantities and should consequently be isolated.
Storage in adjoining areas to reduce materials handling may introduce an obstacle toward
future expansion of the plant. Arranging storage of materials so as to facilitate or simplify
handling is also a point to be considered in design. Where it is possible to pump a single
material to an elevation so that subsequent handling can be accomplished by gravity into
intermediate reaction and storage units, costs may be reduced. Liquids can be stored in small
containers, barrels, horizontal or vertical tanks and vats, either indoors or out of doors.
A great deal of planning is governed by local and national safety and fire code
requirements. Fire protection consisting of reservoirs, mains, hydrants, hoe houses, fire pumps,
reservoirs, sprinklers in buildings, explosion barriers and directional routing of explosion
forces to clear areas, and dikes for combustible-product storage tanks must be incorporated to
protect costly plant investment and reduce insurance rates.
Expansion must always be kept in mind. The question of multiplying the number of
units or increasing the size of the prevailing unit or units merits more study than it can be
given here. Suffice it to say that one must exercise engineering judgment; that has a penalty
for bad judgment, scrapping of present serviceable equipment constitutes but one phase, for
shutdown due to remodeling may involve a greater loss of money than that due to rejected
equipment. Nevertheless, the cost of change must sometimes be borne, for the economies of
larger units may, in the end, make replacement imperative.
75
This word Utilities is now generally used for the ancillary services needed in the
operation of any production process. These services will normally be supplied from a central
site facility; and will include Electricity, Steam for process heating, Cooling water for general
use etc
The power required for electrochemical processes; motor drives, lighting, and general
uses, may be generated on site, but will more usually be purchased from the local supply
company. The voltage at which the supply is taken or generated will depend on demand. For a
large site the supply will be taken at a very high voltage, typically 11,000 or 33,000 V.
Transformers will be used to step down the supply voltage to the voltages used on the site. In
the United Kingdom a three-phase 415-V system is used for general industrial purposes, and
240-V single-phase for lighting and other low-power requirements. If a number of large
motors is used, a supply at an intermediate high voltage will also be provided, typically 6,000
or 11,000 V.
The steam for process heating is usually generated in water tube boilers; using the most
economical fuel available. The process temperatures required can usually be obtained with
low-pressure steam, typically 2.5 bar, and steam is distributed at a relatively low mains
pressure, typically around 8 bar. Higher steam pressures, or proprietary heat-transfer fluids,
such Dowtherm needed for high process temperatures. The generation, distribution and
utilization of steam for process heating in the manufacturing industries is properly planned.
The energy costs on a large site can be reduced if the electrical power required is
generated on site and the exhaust steam from the turbines used for process heating. The overall
thermal efficiency of such systems can be in the range of 70 to 80 % ; compared with the 30 to
40 % obtained from a conventional power station, where the heat in the exhaust steam is
wasted in the condenser. Whether a combined heat and power system scheme is worth
considering for a particular site will depend on the size of the site, the cost of fuel, the balance
between the power and heating demands; and particularly on the availability of, and cost of,
standby supplies and the price paid for any surplus power electricity generated.
Natural and forced-draft cooling towers are generally used to provide the cooling water
required on a site; unless water can be drawn from a convenient river or lake in sufficient
76
quantity. Sea water, or brackish water, can be used at coastal sites, but if used directly will
necessitate the use of more expensive materials of construction for heat exchangers.
The water required for general purposes on a site will usually be taken from the local
mains supply, unless a cheaper source of suitable quality water is available from a river, lake
or well.
Demineralised water, from which all the minerals have been removed by ion exchange,
is used where pure water is needed for process use, and a boiler feed water. Mixed and
multiple bed ion-exchange units are used; one resin converting the cations to hydrogen and the
other removing the acid radicals.
The distribution of gas, air, water, steam, power, and electricity is not always a major
item, inasmuch as the flexibility of distribution of these services permits designing to meet
almost any condition. But a little regard for the proper placement of each of these services,
practicing good design, aids in ease of operation, orderliness, and reduction in costs of
maintenance. No pipes should be laid on the floor or between the floor and the 7 feet level,
where the operator must pass or work. Chaotic arrangement of piping invites chaotic operation
of the plant. The flexibility of standard pipe fittings and power-transmission mechanisms
renders this problem one of minor difficult.
Existing or possible future railroads and highways adjacent to the plant must be known
in order to plan rail sidings and access roads within the plant. Railroad spurs and roadways of
the correct capacity and at the right location should be provided for in a traffic study and
overall master track and road plan of the plant area.
77
9.5
plant layouts. Following steps are generally considered in designing a plant layout.
The
type of data and information required depends upon the nature of the layout problems. In case
planning a new plant layout, the data required will be very elaborate and will cover the
manufacturing particulars along with growth rate required. If the layout problem is for making
minor alterations in the layout, the data required will be limited to manufacturing methods,
sequence of operations, equipment involved etc. Product analysis consists of breaking down
the product into sub assemblies and the sub-assemblies into their individual parts. Product
analysis determines the operations necessary for the production of each part. Production
process is then analyzed.
Inter relationship between the work areas is also planned while designing the
individual operations or work areas. Similarly, the inter relationship between related groups of
operations should be worked out. At this stage, flow diagram also should be co coordinated
with the material flow pattern.
After installing the layout there may be possibility that it may not work as planned,
people may not follow the method they are supposed to, material does not arrive as planned. It
may result in delays. In such circumstances management should try to find out the reasons for
such delays, the activities which have to be taken care off and evaluate the consequences.
Action should be taken to rectify the mistakes, to minimize their effect on the execution of the
plan.
78
9.6
PLANT LAYOUT
79
Pump seals
Fittings
Flanges
Drains
80
Sample valves
10.2 HAZARD
H2S is generally recognized by a characteristic foul odor. Prolonged exposure to low
concentrations will dull the sense of smell. This can be fatal to those who think they can detect
a dangerous concentration by its offensive odor.
In low concentrations, H2S irritates the eyes, throat and respiratory system. When high
concentrations are present, death due to lung paralysis may occur before odor is detected.
Toxicity of H2S
1ppm can smell
10 ppm allowable for 8 hour exposure
100 ppm kills smell in 3-5 min. May burn eyes and throat.
200 ppm kills smell rapidly, burn eyes and throat. Will cause headache and nausea
300 ppm Respiratory disturbances in 2-15 min. Artificial resuscitation needed.
Immediately dangerous to life and health.
500 ppm to 700 ppm quick unconsciousness, breathing stops, immediate artificial
resuscitation needed.
1000 ppm Unconsciousness at once, permanent brain damage unless rescued
promptly.
81
10.4
HAZARDS OF DIESEL
82
83
84
REFERENCES
1. Bhatt. B.I and Vora S.M., Stoichiometry, 4th Edition, Tata McGraw Hill
Publication, New Delhi, 2011.
2.
Coulson and Richardsons, Chemical Engineering Design, 4th Edition, ButterworthHeinemann Publication, Singapore, 2005.
3.
Donald QKern, Process Heat Transfer, 10th Reprint, McGraw Hill Publication, New
York, 1997.
4.
McCabe
L.Warren, Julian
Peter,Unit
Operation in
Chemical Engineering, 6th edition, McGraw Hill Publication, New York, 2007.
5.
Octave Levenspiel, Chemical Reaction Engineering, 3rd Edition, John Wiley & Sons
Publication, New York, 1999.
6.
SpecificHeatofJatropha
Oil,www.endmemo.com/physics/specificheat.php,
last
9.
10.
Design
of
oil-water
separator,www.engineeringtools.com/separatordesign,
last
12.
Heat
of
Formation
of
Ammonia,
Hydrogen
sulfide,
www.chemistry.about.com/od/thermodynamics/a/Heat-Of-Formation.html,
accessed on 14th February, 2014.
85
water,
last