Equipment: Ethanol heater

Equipment Code: EH-01

Type: Screw Plug Immersion Heater

Data and Assumptions:

1. Heat requirement is 4790193.921 kJ (From Energy Balance)

2. Heat efficiency is 75%
Design Requirements:

1. Power rating
2. Watt Density
3. Number of Elements
4. Sheath Material
5. Screw Plug Material
6. Immersed length
Design Calculation:

Solving for Total Power Rating:

4790193.921 kJ 1 hour 1
Power rating= × ×
8 hour 3600 sec 0.75
Power rating= 221.76 kW

Solving for Number of Elements:

Using 100 KW Power rating per heater:

221.76 kW
Elements =
100 kW/Heater
Elements = 2.2 or 3 Elements

To compute for the design of the electric heater’s cubic vessel with 10% volumetric allowance,

Mass of Feed: 6212.064197 kg

Density of Feed: 785.7193513 kg/m3

6212.064197
Theorical Volume: = 7.91 𝑚3
785.7193513

Actual Volume: 7.91 𝑚3 × 1.25 = 9.85 𝑚3

 𝑉 = 𝑆3

9.85 = 𝑆 3

𝑆 = 3.138 𝑚 ≅ 3.2 𝑚

Specification Summary:

Equipment EH-01
Total Power Rating 221.76 kW
Number of Elements 3
Voltage 600 V
Screw Plug Size 3 in
Pressure rating 300 psig
Screw Plug Material Carbon Steel
Immersed Length 130 in
Sheath Material Incoloy Steel
Watt Density 75 watts per square inch
Cubic Vessel’s Edge 3.2 m
Equipment: Air heater

Equipment Code: EH-02

Type: Screw Plug Immersion Heater

Data and Assumptions:

1. Heat duty is 5193027.619 kJ (From Energy Balance)

2. Heat Efficiency 75%
Design Requirements:

1. Power rating
2. Watt Density
3. Number of Elements
4. Sheath Material
5. Screw Plug Material
6. Immersed length

Design Calculation:

Solving for Total Power Rating:

5193027.619 kJ 1 hour 1
Power rating= × ×
8 hour 3600 sec 0.75
Power rating= 240.42 kW

Solving for Number of Heaters in Series:

Using 100 KW Power rating per heater:

240.42 kW
Number of Elements=
100 KW/Heater
Elements= 2.4042 or 3 heaters in series

To compute for the Air duct design:

Air velocity (𝜐) = 1.5 m/s

Mass of air = 24200.04139 kg/shift

Volume of air:

P= 4 atm

T= 513 K
19118.0327 5082.008692
( 28
+ 32
)×0.08205×513 𝐾
V=
4

V= 8856.079 m3

8856.079 m3
Q=
8×3600 𝑠

Q = 0.3075 m3/s

Solving for Duct Cross-sectional Area:

𝑄
A=
𝜐

0.3075 m3/s
A=
1.5 𝑚/𝑠

Solving for Duct Width:

A= 0.205 𝑚2 W

𝑊2 = 𝐴

𝑊 2 = 0.205 𝑚2

𝑾 = 0.452 m

Solving for Duct Length:

For 5 minutes residence time,

𝑚 60 𝑠
L = 1.5 × × 5 𝑚𝑖𝑛𝑠
𝑠 1 𝑚𝑖𝑛
𝑳 = 450 m
Specification Summary:

Equipment EH-02
Total Power Rating 240.42 kW
Number of Elements 3
Voltage 600 V
Screw Plug Size 3 in
Pressure rating 300 psig
Screw Plug Material Carbon Steel
Immersed Length 130 in
Sheath Material Incoloy Steel
Watt Density 75 watts per square inch
Air velocity in duct 1.5 m/s
Duct Width 0.45 m
Duct Length 450 m
Equipment: Oxidation Reactor

Equipment Code: OR-01

Type: Vertical tubular reactor

Data and Assumptions:

1. Adiabatic operation
2. Flat velocity profile
3. No axial dispersion
4. No radial dispersion
5. Pseudo-homogeneous assumption
6. Bed void fraction (ε) is 0.375
7. Space time is 8 hours

Design Requirements:

1. Bed Diameter
2. Bed Length
3. Reactor Length
4. Shell Thickness
5. Head Thickness

Reactor composition:

Components Input Output

Ethanol 6087.822913 60.87822913
Water 124.2412839 2482.610943
Nitrogen 19118.0327 19118.0327
Oxygen 5082.008692 1146.361406
Acetaldehyde - 706.7771826
Acetic Acid - 6897.445129
Total 30412.10559 30412.10559

Operating temperature = 513 K

Operating Pressure = 4 atm

Activity= 200 g ethanol/l-catalyst-hr

Thermal Properties of Feed:

Density (ρ) = 3.101336866 kg/m3

Viscosity (μ) = 0.00002455293 Pa-s

Bed void fraction (ε) = 0.375 for close random packing, monodispersed, (Dullien, 1992)

Solving for Actual Bed Diameter( Db) by Ergun Equation:

μν (1-ε)2 ρν2 (1-ε)

∆P=150 { × [ ]} +175 { × [ 3 ]}
D2 ε3 D ε

Initially assume ∆P’ and D,

Pressure drop (∆P’) = 3480 Pa/m (average pressure drop in Packed-bed)

Bed Diameter (D) = 4.11 m (Maximum diameter of Packed-bed reactors)

0.00002455293 ν (1-0.375 )2 3.101336866 ν2 (1-0.375 )

3480=150 { × [ ]} +175 { ×[ ]}
4.112 0.375 3 4.11 0.375 3

3480 = 1.615 × 10−3 ν + 1565.0614 ν2

v= 1.49117 m/s

Solving for Reactor Diameter:

Volumetric flowrate, Vv;

Average molecular wt. = 32.63

30412.10559
( ) × 0.08205 × 513 K
32.63
Volume =
4 atm
Volume = 9807.659 m3

9807.659 m3 1 hour
Vv = × =0.340504 m3/sec
8 hour 3600 sec
Bed Area, A

0.340504 m3/sec
A= = 0.22837 m2
1.49117 m/s
Bed Diameter, D

4×0.22837 m2
D=√ = 0.5392 m (1.769 ft.)
3.1416

Use Step 8 on Table 7.1 Chemical Process Engineering Design and Economics by Silla, D is less
than 30 in (0.762 m), round off the diameter to 2.2748 ft (0.693374 m).

Solving for Actual Bed Area, Ab;

2
3.1416 × 0.6933742 m
Ab= = 0.377595 m2
4
Solving for Actual Superficial Velocity, νs;

0.340504 m3/sec
νs = = 0.90177 m/s
0.377595 m2

Solving for Bed length (Lb);

Vc
Lb=
Ab
Where:

Vc = Volume of Catalyst

Ab = Actual Bed Area

Solving for the volume of the catalyst;

6026.944 kg EtOH 1 L Catalyst 1m3

Vc = × ×
8 hours 0.200 kg/h HAc 1000L

Vc = 3.76684 m3
 3.76684 m3
Lb= = 9.975 m
0.377595 m2

Solving for internal pressure;

PAbs =ρgh+Patm

PAbs =(3.101336866 × 9.81× 10.0403) + 405300 Pa

PAbs =405605.4340 Pa = 58.84 psi

For allowable working stress:

S=Su×Fm×Fa×Fr×Fs

Where:

S= allowable working stress

Su= Ultimate tensile strength
Fm= Material Factor
Fa= Radiograph factor
Fr= Stress relieving factor
Fs= Allowable factor for safety

Su = 55000 psi

S=55000×1.0×1.0×0.25

S=13750 psi

Solving for Shell thickness:

PD
ts = +C
2Se-P

Where:

ts = shell thickness
P = working pressure
D = diameter
S = allowable stress
e = efficiency
C = corrosion allowance; (min C = 1/16)

(58.84)(21.228) 1
ts = +
2(13750)(1.0)-58.84 16

ts =0.108 in

Head is Toroispherical since operating pressure is less than 150 psig.

Solving for Toroispherical Head thickness:

1.104PD
th = + C
2eS-0.2P
1.104 × 58.84×21.228 1
th = +
2(13750)(1.0)-0.2× 58.84 16

th = 0.11266 in

For depth of toroispherical head

d = .25D

d=.25(21.228) = 5.307 in

d= 0.1348 m

Solving for Reactor Length (Lr);

Lr = Lb + d

Lr = 9.975 m + 0.1348 m

Lr = 10.1098 m
Specification Summary:

Equipment Oxidation Reactor

Materials of Construction Carbon steel (S42; Graded A)
Temperature 513 K
Mass 30608.74947 kg/shift
Pressure: 4.5 atm
Bed Length: 10 m
Bed Diameter: 0.7 m
Nominal Shell Thickness: 3/16 in.
Nominal Head Thickness: 3/16 in.
Corrosion Allowance: 1/16
Depth of Head 0.17333976 m

Specification Illustration:
Equipment: Flash Drum

Equipment Code: FD-01

Type: Vertical Gas-Liquid separator with Mesh Eliminator and Vortex Breaker

Data and Assumptions:

1. 99.9999% separation for gas and liquid phase

2. 2 batch/shift
3. Surge time is 10 minutes
Design Requirements:

1. Separator Diameter
2. Separator Height
3. Liquid Height
4. Mist Eliminator Thickness
Operating Parameters:

Operating temperature = 313 K

Operating Pressure = 1.00 atm

Solving for superficial velocity (ν);

Physical properties:

Density of Vapor, ρv = 1.098519665 kg/m3

Density of Liquid, ρL= 1016.99552 kg/m3

From Table 6.9, Chemical Process Engineering Design and Economics by Silla;

ρL-ρv
ν =kv√
ρv

kv = 0.107 m/s (With mist eliminator)

1016.99552 − 1.098519665
ν = 0.107 m/s √
1.098519665

ν = 3.25 m/s
Solving for Cross-sectional Area (A);

Volumetric Flowrate, Vv
2481.369637 20264.39411
( 1016.99552 + 1.098519665) 1 hour
Vv= ×
2 3600 seconds
Vv= 2.5624 m3/s

Solving for Cross- sectional area of Separator (As)

2.5624 m3/s
As=
3.25 m/s
As= 0.78884 m2

Solving for Separator Diameter (Ds)

4 × 0.78884 m2
Ds= √ = 1.0019 m
3.1416

Use Step 8 on Table 7.1 Chemical Process Engineering Design and Economics by Silla, D is
greater than 30 in (0.762 m), round off the diameter to 4 ft (1.2192 m).

Liquid phase surge time (ts) = 5 min

3.1416 × 1.21922
Actual Cross-sectional Area= = 1.167 m2
4

Solving for Liquid height in Separator (Ls);

2481.369637 kg 1 m3
Liquid Volume (Lv) = ×
3600 sec 1016.99552 kg

Liquid Volume (Lv) = 0.000677 m3/s

m3 60 sec
0.000677 s
× 10 min × 1 min
Liquid Height (HL) =
1.167 m2
 Liquid Height (HL) = 0.34846 m

From Chemical Process Engineering Design and Economics by Silla

Settling Length (HS) = 1.5D

Settling Length (HS) = 1.5 × 1.005 m = 1.5075 m

Mist eliminator thickness (MT) = 0.152 mφ

Vapor Space (VS) = 0.305 m

For depth of toroispherical head

d = .25D

d=.25(1.005 m)

d= 0.25125 m

Solving for Total Separator Height (H):

H = HL + HS + MT + VS + d

H = 0.34846 m + 1.5075 m +0.152 m +0.305 m + 0.25125 m

H = 2.564 m

Solving for internal pressure;

PAbs =ρgh+Patm

PAbs =(560.71 × 9.81× 2.564) + 202650 Pa

PAbs =216753.47 Pa = 31.45 psi

φ Typical height for mist eliminator according to Silla is 6 in or 0.152 m

For allowable working stress:

S=Su×Fm×Fa×Fr×Fs

Where:

S= allowable working stress

Su= Ultimate tensile strength
Fm= Material Factor
Fa= Radiograph factor
Fr= Stress relieving factor
Fs= Allowable factor for safety

Su = 55000 psi

S=55000×1.0×1.0×0.25

S=13750 psi

Solving for Shell thickness:

PD
ts = +C
2Se-P

Where:

ts = shell thickness
P = working pressure
D = diameter
S = allowable stress
e = efficiency
C = corrosion allowance; (min C = 1/16)

(31.45 )(72) 1
ts = +
2(13750)(1.0)-31.45 16

ts =0.1449 in
Head is Toroispherical since operating pressure is less than 150 psig.

Solving for Toroispherical Head thickness:

1.104PD
th = + C
2eS-0.2P
1.104 × 31.45×72 1
th = +
2(13750)(1.0)-0.2× 31.45 16

th = 0.1534 in
Design Specification:

Equipment Code FD-01

Materials of Construction Carbon steel (S42; Graded A)
Temperature 313.15 K
Mass 30608.74947 kg/shift
Pressure: 1 atm
Height: 2.6 m
Diameter: 1.2192 m or 6 ft
Shell Thickness: 0.1449 in
Head Thickness: 0.1534 in
Nominal Shell Thickness: 3/16 in.
Nominal Head Thickness: 3/16 in.
Liquid Height 0.35 m
Mist eliminator Thickness 0.152 m or 6 in

Design Illustration: