INSTRUCTION MANUAL CONCEPTUAL PROCESS DESIGN ChE 201L University of San Carlos Chemical Engineering Department Cebu CityTable of Contents Chapter & Title 1 2, 3. 4. Overview, Ld 12 13 Design Approach. Essential Design Activities. Creativity & Consistency in Design. Review Meeting. ‘Technological Responsibility. Report Structure and Contents. 4d 42 43 44 45 46 47 48 49 4.10 4.10. 4.10. 4.10.3 an 412 4.12, 4.12 412. 412. Implementation. Reporting Techniques, Language and Size, Cover Final Report. Preface. ‘Summary. Table of Content, Introduction. Process Option and Selection. Basis of Design (BOD). 1 Purpose. Battery Limit. CPD Specific. ‘Thermodynamic Properties. Process Structure & Description. Criteria and Selections. Process Flow Scheme (PFS). 3 Batch Cycle diagram, Process Stream Summary. Utilities. 4.12.6 Process Yields. 413 44 415 4. 4. 415 4.16 417 4.18 419 4.20 4.21. 422 Process Control. Mass and Heat Balances. Process and Equipment Design. 4 Equipment Data Sheets. ‘Wastes. Process Safety. Economy Conclusions and Recommendations. List of Symbols. Literature, Appendices. Integration by Process Stimulation, 5.2 Equipment Selection and Design. 3 Special Issues. (CPD Final Report, cover page) (CPD Final Report, not a Chapter) (CPD Final Report, not a Chapter) (CPD Final Report, not a Chapter) (CPD Final Report, Chapter 1) (CPD Final Report, Chapter 2) (CPD Final Report, Chapter 3) (CPD Final Report, Chapter 4) (CPD Final Report, Chapter 5) (CPD Final Report, Chapter 6) (CPD Final Report, Chapter 7) (CPD Final Report, Chapter 8) (CPD Final Report, Chapter 9) (CPD Final Report, Chapter 10) (CPD Final Report, Chapter 11) (CPD Final Report, Chapter 12) (CPD Final Report, not a Chapter) (CPD Final Report, not a Chapter) (CPD Final Report, numbered) E Soocaeiwsasananauasvnn I i 12 12 13 B B 4 14 15 15 15 16 16 17 18 19 19 20 20Table of Contents (cont'd) Chapter & Title Page 3. Typical Problents, 21 Batch Operation. 21 Reactors. 21 Equilibrium Reactors. 21 8 Reactar Concepts. 21 3.3 Separation by Distillation. 2 5.4 Throttling of Fluid Flows. 2 6. Quality Control 23Tile Appendices Table of Contents Basis of Design (BOD) for CPD Final Report. Preliminary Basis of Desi Activity Planning, Basis of Design (BOD) ‘Thermodynamics ign (BOD) for CPD Review Meeting, ~ Utility Conditions and Costs, = Methods and Models. Drawing a Process Flow Scheme Process Flow Scheme “TAME” Example “TAME” Example P/P Separation Example PIP Separation Example P/P Separation Example PIP Separation Example PIP Separation Example P/P Separation Example P&P Separation Example Batch Process Example Bateh Process Example Batch Process Example Batch Process Example Text Symbols + Symbols and Coding. - Process Flow Scheme (PFS). = Block Scheme. = Process Flow Scheme (PFS). ~ Pure Component Properties. ~ Process Stream Summary. + Mass and Heat Balance for Total Streams, + Utility Summary. = Process Yields. ~ Equipment Summary and Specification Sheets, ~ Batch Process Flow Scheme (PFS) ~ Batch Cycle Diagram + Batch Remarks and Calculations ~ Batch Process Stream Summary Si units in Process Systems Design Apperidix -ii- Sean 4 16 7 Is 19 21 22 34 35 36 9 4i1. Overview, Mi Design Approach ‘The execution of a design is best served with a stepwise approach, which eventually lads {o the four most important documents of a design, ie: Block Schemes. ‘These provide a simple design approach and a good process overview. Process Flow Schemes (PFS). ‘These are developed from a Block Scheme(s) and provide the “process logic”. Batch Cyele Diagrams. {These provide the additional definition for “state transition” ofa batch process. Process Stream Summary. This provides stream data (e.g., mass and heat flows) for all streams, consistent with the stream numbers in the PFS. Summaries for batch processes also include batch quantities and batch cycle times. Mass & Heat Balance. These must be consistent with the Process Stream Summary and prove design consistency. These five documents (4 for continuous processes and 5 for batch processes) form the “back bone” of the design and should be a consistent unity. They will be discussed in ‘more detail below. Block Schemes. From literature research data are retrieved of various and/or process conditions. From these data, processes (options) are represented in a Block Scheme. Per Block rough design specifications are given, c.g., at least process conditions (emperature & pressure). For a reactor the required conversion and/or selectivity can be specified whereas for a separation the required purities and/or yields of outgoing streams, With these data and with the derived block schemes for the various process options a first impression can be obtained of the ‘component balances over the whole process system. A “best” option is selected. For an example of a block scheme see Appendix 7-2. Process Flow Scheme (PFS), Batch Cycle Diagram, Process Stream Summary and Mass & Heat Balances, For the “best” option a start is made with selection, integration and performance ‘calculations for the various Unit Operations, e.g. reactors, columns, vessels, heatexchangers, pumps, etc. Also, a more detailed quantitative assessment of all process streams (mass flows) is done. At this stage, for the selected process a first PFS is prepared and if it concerns a batch process, the batch Cycle Diagram is added, The PFS, the Process Stream Summary (mass flows on first instance, heat flows later) and the Batch Cycle Diagram (additional for Batch Processes) should be made as early as possible, ie., already during or directly after the Block Scheme phase. These documents provide the designer with the necessary ‘overview from the start, ie., temperatures, pressure drops and the possibly required equipment. This information enables the designer to assess a first approximation of process conditions and to monitor future development of the process design into the final stage. For examples of the discussed documents see Appendices 8 and 9. Heat Flows, Heat Flow Balances. PFS and Flow Summary (mass flows) will develop in time towards more detailed and refined versions. Eventually the heat flows are ineluded and with these data I approach to the design must be as simple as possible. Pencil, paper and a simple spreadsheet are excellent tools, especially during the first phase of the project, eg, for Block Schemes and first PFS. The amount of detailed (equipment) calculations will be the result of a balance between degree of completeness and available time. Within this context, critical equipment, e.g., reactors, and separation equipment deserve priority. Required equipment details are normally determined by data required for cost assessment. For an example of required equipment information, see equipment data sheets, Appendix 87. 1.2 Essential Design Activities Literature Study. ‘A literature search for information from which the “best” process has to be selected is required. This selection is based on a suitable combination of feedstocks, produced products and wastes, including relevant reactions and kinetics. reactor choice and ‘manufacturing methods. The market situation for feedstocks and products is taken into account as well, Block Schemes and Process Flow Scheme. Development of logical combinations (integration) of selections required for feed purification, reaction, product recovery, and product purification. Order of magnitude assessment for relevant process streams and’ process conditions. Evaluation of the various process options resulting in a choice based on sound considerations. Drawing. of a Process Flow Scheme, which demonstrates the preferred option in a clear and logical way. Unit Operations, Mass & Heat Balances. Selection and integration of the required Unit Operations and calculations of their required performances. Quantification of the resulting process flows (mass and heat per unit time), including Heat Integration and Mass & Heat balances.Equipment Sizing. Calculation of the required main dimensions of the equipment installed, based on the required performance of the selected Unit Operations. Process Design Evaluation. Evaluation of safety (¢g., Fire Explosion Index), environment (e.g., wastes) and ‘economy (income and expenditure). Reporting. Preparation of a clear and consistent Design Report, which must comply with standards laid down in Chapter 2 of this report. Assessment of the Design. Discussion of the Design Report with the complete team and teacher(s), ie., Engr. Evelyn B. Taboada, Engr. May V. Tampus and panelists. 1.3 Creativity & Consistency in Design, Creativity is largely based on intuition, whereas consistency is largely based on numbers and clear concepts. As a consequence, creativity is often seen as an unstructured, visionary property, whereas consistency is often perceived as bureaucratic; both properties seem to be in competition, This is of course not true. Both properties are essential for the delivery of e.g., a good design. although a design without consistency is like a ship without a rudder. Moreover, lack of creativit will at best only result in “run of the mill” solutions, without any technological progress being achieved. An effective merger between consistency and creativity is required and takes creativity. 4. Intuition. The extent to which we are able to exploit our capacity of intuition depends on the extent to which we are willing and capable to digest our experiences. In this respect the following aspects are important: ~ To be open to and to be willing to reflect about our experiences - Coherence, i¢., the notion about possible coherence between experiences, the notion about differences and contradictions between them ~ Tobe alert for these aspects, i.e., spend time on study and evaluation +. Creative work. Our creative abilities have connection to certain functions, residing in the right part of our brain, i.e. associative abilities, notion connectivity and patterns, imagination and non-linear thinking. ‘These abilities are to be stimulated by attention to be paid to our ideas and to let them be tested on their value.a a a a a a 1 1 1 i 1 ’ l l | | | 2.0 Review Meeting Approximately three weeks afler issuing the CPD assignment the preliminary Basis of Psign (BOD) is reviewed during 2 Review Meeting. This document of approximately 12 pages maximum is prepared by the team during the three weeks mentioned above. It includes the following elements (Chapters) 1. Description of the Design. Process background, what will be done, what not. 2. Process Definition Process Concepts, block scheme, thermodynamics, pure components, streams, 3. Basic Assumptions, Plant capacity and location, battery limit, definiti 4. Financial Margin of the Design. Maximum financial margin available for the design. 5. Planning ‘Work allocation between team members, Design milestones, e.g., dates for start, BOD- review. issuing of the CPD Final Report, final assessment of the design. In general terms for the team members: When should what be ready and who will do what? of INOUT-streams. ‘Taking into account the relatively short period of three weeks, of course the document (not more than ~ 12 pages) must be seen as a slart for the CPD only. After the review meeting, the document will be further developed, i.., it will be systematically updated by the team az the design proveeds. However, the preliminary BOD will provide a cleat basis forthe design at an carly stags, and consequently, it will minimize room for misinterpretation between prine'pal and team. Moreover, several (updated) sections of the “Preliminary BOD” will be included in the BOD of the CPD Final Report, Chapter 3. For more information see Section 4.7 and Appendix 2 of this manual.Technological ‘The team members will write the CPD Final Report. Therefore, they are considered to have shared authorship. However, because allocation of design tasks exists between the team members, some differentiation in responsibilities is justified. Therefore, team members should be able to defend the various chapters or sections of their CPD Final Report as follows: er chapter or section, in principle + Two (2) team members Per important section or chapter (see [*] below) + All team members (4 max.) In detail biect ‘Team Members Report Structure 41) Summary 4p] Preface (optional) 40] |. Introduction 2 2. Process, Options and Selection ary 3. Basis of Design 4c] 4. Thermodynamic Properties 40 5. Process Structure & Description 2 6. Process Control 2 7. Mass and Heat Balances 404 8. Equipment Design 2 9. Wastes 4 oy 10, Health, Safety & Environment 2 11. Economy 40] 12. Conclusions and Recommendation 4 ft] List of Symbols Relevant Team Member Literature Relevant Team Member Appendices Relevant Team Member4, 42, 43. 44. Report Structu Contents A design report is primarily intended to fix knowledge about the design on paper and thus transfer it to others. These “others” may be, eg. the engineering contractor, the future Glam owner or the design team for a next plant of this type! They in tum have to carry formance for the designed installation. It i, therefore, rot surprising {esign book structure is strictly adhered to. ‘With all this in mind, this Wiee on the C’PD Final Report structure, ie, which chapters should be included and what should be their contents, Administrative Guidance on administrative issues is given. It deals with report structure, reporting techniques, language, and report size, EPrinciple, students are expected to implement the structure and contents of their CED Final Report as described inthe following sections. This will fae designers to Frure and explain certain key topics, which otherwise might have been forgotten. Tis spproach may seem somewhat inflexible, but practice has prover thee S pays Off.” In ease students nevertheless think they have reasons not te be in compliance, they are expected to provide a convincing explanation, Rey Techni OF course freedom remains to arrange chapters and sections, eg., never have more than “3 layer subs” (including chapter, ie. 1.2.3). ‘This ean Practically always be achieved by just adding another 2" or 3" level section. Please note that distracting, bulky items, such as drawings, sketches, tables, detailed calculations, equipment data sheets, etc. should be made available a2 appendices, 10 which will be referred in the main text, Language and Size ‘The English language is to be used, The size ofthe report should not exoced 60 pages of text, excluding appendices. ‘The font size should not be less than 10 points. Cover Final Report (CPD Final Report, cover page) {The cover layout is standardized and students are requested mot to change it. This is because this cover will be copied on a standardized cover page for Feports, issued by the department of Chemical Engineering. A changed layout may not ot thie standard cover page.45 46 47 48 The following items have to be specified on the Final Report cover. + CPD Number As provided by instructor ~ Subject As agreed with instructor - Authors : Provide names + Keywords + For easy retrieval from database (still to be set up) + Dates 2 Dates for assignment received and Final Report issued For more details, see Appendix 1. Preface (CPD Final Report, not a Chapter) This is unnecessary text. By leaving it out a page is saved. fat all present, it should be the first numbered page of the report, ¢.g., Summa (CPD Final Report, not a Chapter) A Report summary must be considered as an “appetizer”. Based on its contents, most readers will determine whether ot not to continue with the rest, Especially management staff often will not read more than the summary. Therefore, the summary should nor sake more than one page (44) and should not contain lengthy descriptions of process technology, etc. However, it should contain information about the market, eg., the European production level (Va!) compared with the capacity of the designed plant, price levels and availability of feedstocks, ‘competition, ete, The status of the process also requires attention, i.c., docs the design apply to a new process that has never escaped the laboratory, or even worse, has it been derived from a patent and not even been tried out on pilot or bench scale. Moreover, the “on-stream” factor, i.e., the number of actual “on-stream” bours divided by the number of available “on-stream” hours on an annual (yearly) basis, must be provided and explained, Economic criteria should be mentioned, including sensitivities. Within this context, the total invesiment (the installation's total ‘construction costs) and the economical life of the installation should not be forgotten. Last but not the least, key conclusions and recommendations should be mentioned. In the absence of the Preface, the Summary should be preceding all relevant text of the report. ‘The Summary’s page should then be the first page of the report to be numbered, e.g., ir (-i- incase the “Preface” is present). The summary of this manual ean be taken as an example. Ke of Contents (CPD Final Report, not a Chapter) The table of contents contains chapter, title and starting page number for easy reference. The Summary should be listed in this table, because the Table of Contents should provide the complete contents of the Final Report, ie., including the Summary. Also include all the appendices with their number, title and page number. In case no Preface is present, the first page of the Table of Contents should have page number ~ii- the following pages ~ii-,-iv-, etc. (if a Preface is present —iii-, ete) The Table of Contents of this manual can be taken as an example. Introduction (CPD Final Report, Chapter 1) The introduction should be used to bring the reader on speed with the conceptual design aspects. The important properties of the product and its main applications should be reviewed. Reference can be made to the list of “Pure Component 8-2. Issues related to environment (¢.g., wastes), and safety should be included,49 4.10 The market situation for product(s) and feedstocks must be highlighted, eg, Competitors’ production and sales levels, prices and applied process(es), eg. in Europe and/or worldwide. Furthermore, a short review should be made of the Possible impact of the plant's envisaged production level on the current market situation. Also a short explanation about the available processes and the preferred selection should be given. Reference to a block scheme may be helpful. Other issues could be, eg. + Availability/non-availability of physical data (reaction stoichiometry/kinetics, equilibria), ~ How are issues solved (theoretical data, data from test runs, educated guesses, ete)? + Patent situation, ~ Competition’s developments, ~ Do similar plants already exist? Ifo, where and how many? Moreover, solutions for key design problems can already be mentioned here. After all, a design report is not a novel with the outcome at the end! Also explain why specific aspects are included or not included in the design. In this way, the reader is quickly introduced to the aspects that determine the design and obtains a good impression about what he/she might expect with respect 10 solutions and design quality. However, do not saturate the reader with complicated, unnecessary information but keep it short. Where necessary, make reference to relevant chapters, ‘The introduction should take about 2 pages (A4). Process Options & Selection (CPD Final Report, Chapter 2) From literature and/or provided documentation various process options are available, ail having pro's and con’s. From these options, one option must be selected as a basis for further process design. ‘The reasoning for selecting this specific option must be included in this chapter, e.g, why a continuous or a batch process has been chosen. Explicitly define what is taken as a design basis and what is not! Deliberations about process options often leave the reader in distress, because ‘nowhere it has been mentioned explicitly what actually has been taken “on board” Block schemes, cycle diagrams (for batch processes) graphical representation and tables are useful tools for effective process review. Use tables for balancing pro's and con's of the various options, e.g., by crediting with (+) signs for advantage and () signs for disadvantage per characterizing element, Transfer more lengthy details to relevant appendices; only keep Key items and results from appendices in the main text. Provide the block scheme and a batch cycle diagram (later for batch process) for the selected option and describe the essential details of the process. The block scheme and the cycle diagram (later if relevant) may be added as an appendix, which can be referred to in subsequent chapters as well. For an example of a block scheme and a batch cycle diagram see Appendices 7-2 and 9-2, respectively of, (CPD Final Report, Chapter 3) In this chapter all Key data for the design, as agreed by client and designers are tabulated and provided with background information. Items such as feedstocks,we ae Se Eee ese eT lel CG rr EOE CU EC lll EC lll re lll rel ell ele 4.10.1 4.102 4.103 Products, wastes, utilities, specific equipment to be used, plant location, costs, etc. are covered. These agreed key data are determining for the design result and should always be easily retrievable in case of questions. That is why for the CPD such data ‘must be covered in one chapter in a clear, unambiguous and logical way. Purpose. In practice, data from a BOD have contractual value and are meticulously and clearly described in a separate report (manual), ie., the Basis of Design (BOD). Contract refers to this BOD and designers (service organization or a contractor) have to adhere to these data. If not, a lawsuit can be the result, Please note that in practice, the BOD will be adapted during the design, of course with mutual consent between the client and designer, e.g., more suitable feedstocks could be introduced, utilities may be changed, other unit operations may be adopted, line-up may be changed. From all these changes record will be made, for which the original BOD serves as an excellent reference. Battery Limit. With the BOD the Battery Limit of the design is determined. This limit must be seen as an imaginary fence around the installation and can be nicely shown by means of the block scheme (see Section 6.9). Important issues are what are inside the fence, what is necessary for the design but will be outside and what is crossing the fence, ive., what is coming in and what is leaving. For instance, all materials, e.g., streams centering and leaving this limit, must be painstakingly specified one by one before the design starts, e.g., commercial specification, design specification, temperature (°C), pressure (Bara), phase (V/L/S), manner of transportation (pipe line, rail, road, ship, €tc.). Also utilities, catalysts, etc, should not be forgotten. Obviously, all unit ‘operations (equipment) inside the battery limit will have to be designed, with the exception of those that are mentioned to be specifically excluded. CPD Specific. |n view of the foregoing this chapter is important because it will provide the basis for the CPD, and consequently, it will be judged accordingly. Two topics will be dealt with in other chapters, “ie., Process Options and Selection (Chapter 2) and Thermodynamic Properties (Chapter 4). However, these topics must be summarized in this chapter (Chapter 3 of the final Report), while for more details reference should bbe made to the chapters mentioned. Just as in practice the BOD will most likely also change during the CPD. The BOD must contain THE LATEST, UP TO DATE INFORMATION! The content of the BOD has been described in more d Appendix 2-1. Major elements are briefly mentioned below. 1. Description of the design. A brief summary of previous chapters. What will be done, and what will not be done! 2. Process Definition, + Process concepts chosen. A summary of Chapter 2. Explicitly state what will be used and done. Include stoichiometry, kinetics, catalysts AS APPLIEI 9.All = Block Schemes A simple PFS, see Appendix 7-2. Show total mass streams (va) and tt (Vield) values with the product stream as reference stream, Im case of a batch process, it may be practical to add information of batch cycle diagrams. = Thermodynamic Properties. A summary of Chapter 4, Important issues only. Express relia = Pure Component Properties. Provide the list. See Appendix 8-2. Use component names consistently with this list throughout the CPD Final Report. 3. Basie Assumptions. - Plant capacity. Define plant capacity in Va (product or feed). Define all other in- and outgoing streams in name and quantity as a result, (All these data are known.) Define stream hours/a, economical plant life. Explain choices. + Location. Define. = Battery Limit The imaginary fence around the plant. Defines “INSIDE” and “OUTSIDE”, + Definition In- and Outgoing Streams. Includes feedstocks, process chemicals, products, wastes, utilities, catalysts, etc. Use a table for each stream and deal with the streams one by one, include costs and prices. Refer to relevant sources of information. Also sce the introduction of this chapter. In case utility data are not available, see Appendix 3 for information, 4. Beonomic Margin. This margin is expressed in terms of money and is calculated as the difference between income from sales minus costs for feedstock. With this margin the maximum allowable investment for the design must be calculated for a DCFROR (earning Power) of 10%, Provide background views, and conclusions. Include this margin in your economic evaluation (Chapter 11). ity. For this Review Meeting (see Section 2.0 of this manual), the above should be taken into account to the best of designers’ knowledge after 3 weeks from start. For this meeting a document of about 12 pages should be produced, CPD Activity Planning included. For the content of this document, also see Appendices 2-2 and 2-3. Th Pr Without reliable data on thermodynamic properties, a CPD cannot be performed. Such ti (CPD Final Report, Chapter 4) data are defined as equations and values for constants, parameters, etc, required for property estimation of component mixtures (C,"s, enthalpies, V/L- viscosities, densities, etc.) but also for reaction(s), e.g., reaction equilibria L ria, solubilities, Operating Window. ‘The data mentioned above should be valid for the ranges of operating conditions, as they occur in the design. These ranges are called “Operating Windows”, which may differ for the various unit operations, included in a design. Use of data that are not valid within an operating window (ie., outside their range of validity) must be prevented as it leads to extrapolation, resulting in unreliable results Data Validation,412 4121 Therefore, literature should be scrutinized for data that are valid within the various operating windows of the design. ‘These data should then be used to validate data generated by the so-called flow sheet calculation programs (flowsheeters, eg, CHEMCAD, SUPER PRO, ASPEN’, HYSIM) normally used for design calculations. It is the designers’ responsibility to demonstrate for the CPD the validity of applied thermodynamic data within the operating windows. This can be done by, e.g., graphical representation of flowsheeter generated data, where in the same graph also the data from literature are plotted. 3. Data Accuracy. The designer is expected to demonstrate applied data to be sufficiently accurate for his design (sensitivities!). Because the foregoing is a key issue for the design, this separate chapter has been allocated. ‘See Appendix 4 for more information on thermodynamic methods and models. Process Structure & Description (CPD Final Report, Chapter 5) In Chapter 2 of the CPD Final Report, a process has been selected and block schemes have been made available. However, because many details about the selected unit operations and equipment have not yet been revealed, this chapter will take care of this. Important elements are design criteria, unit operations/equipment selection, Process Flow Schemes (PFS), Batch Cycle Diagrams (in case of a batch process) and Process Stream Summaries. Criteria and Selections. Chapter 5 of the CPD Final Report (this chapter) will explain how all information from. the foregoing chapters is used to assess the various design criteria. Moreover, it is explained how these criteria have determined the choice of the following design elements: = Unit operations, ie. sequence, type, specific equipment, ete. = Final process conditions, - Process chemicals, e.,, hydroxides, acid, process water, extractants, etc., = Desiceants (for driers), = Ete, These choices have to be motivated with crisp and clear reasoning, based on “first principles” of process technology. Selected design criteria have to be explained not only for the equipment under consideration, nit also with respect to their influence on design and operation of up-stream and down-stream equipment. An example is the influence of reaction conversion and selectivity on down-stream separation of reactants and products and the influence of the purity of recycled reactant on reactor performance. Heat integration is another interesting topic. Preparation of simplified block schemes may help to bring the message across. Detailed calculations on equipment sizing are NOT expl , but in one of the following chapters. It must be clear that adequate design (sizing) cannot be done, unless the foregoing aspects have been fully assessed. “ue4122 412.3 4124 Process Flow Schemes (PES). During the design the basic block scheme of the selected process has developed into a fully equipped Process Flow Scheme (PFS). It represents the line-up of the various unit ‘operations (equipment) and their connection with process flows (streams) in a logical and clear way, It is an essential document, not only for “Process Administration”, but also for transfer of know-how about the process design to others. Therefore, the PFS must be explained in this chapter by providing a step-by-step process review. In doing so equipment must be referred to by name, followed by its equipment number between brackets, eg, Run Down Vessel (V113). The same is done for streams, eg, CO> absorber Feed <314>. Note that for stream numbers the <> signs are used for easy reading, Where necessary, important process- or equipment details have to be explained, Please note, that the Process Stream Summary is of vital importance for good understanding of the PFS (also see Section 6.12.4 below). See following appendices on drawing a PFS. = Drawing a PFS Appendix 5. = Symbols and Coding Appendix 6. - PFS (example) : Appendices 7-1, 8-1 and 9-1. Batch Cycle Diagram. For a batch process a Batch Cycle Diagram must be added because without it, the PFS, and therefore the process cannot be understood. This diagram shows the elapsed time required to perform a transition of state in a relevant equipment item for its relevant batch stage, ic., the “stage time”. It also represents the time elapsed between starts of the considered stage (or any other repetitive stage point), ie., the batch cycle time (also see Chapter 4 of this manual). Moreover, the diagram links the various stages (operational modes) of the various equipment items in a consistent and comprehensive way. For a good overview the various batch stages must be drawn up in the relevant PFS with thick lines. For more information, also see Chapter 7. See Appendices 9-1 and 9-2 for examples of a PFS of a batch process and a Batch Cycle Diagram. Process Stream Summary. ‘The PPS and in case of a batch process the PES and the Batch Cycle Diagram can not be studied without a Process Stream (Flow) Summary. These items form a “unity”. In this summary mass flows are tabulated for all the components separately and in total for each stream, Furthermore, temperature, pressure, phase (V, L, V/L) and enthalpy of the streams are specified. Needless to say, that with these mass flows, mass balances can be made which of course should balance (IN versus OUT) over each equipment item per component and per total stream. Process engineers (designers) will always combine the logic of the PFS with that of the Stream Summary for quickly understanding the process design. ‘This understanding is accelerated by using one of the few facts that are certain in life, i... mass (and also heat) can not be destroyed. In other words: “mass (and heat) balances should always check"! Please note that with this technique the consistency of a design, and therefore, its quality is largely determined. Moreover, by applying this technique a design is quickly understood. For an example of a Process Stream Summary see Appendix 8-3. -12-412.5 412.6 For a batch process, another Process Stream Summary is used. Apart from mass flows it also contains information on batch quantity (mass), work (in Joules) and batch times (tage and batch). See Appendix 9-4 for an example of a Process Stream Summary for batch processes. See Chapter 7 for more information. Utilities. Unilty requirements should be reviewed with respect to the following topics, eg., other ‘options, reasons for selection, major users and possibilities for future reduction. For this reason, it is necessary to produce a utility summary (as an appendix). Small tables may be prepared from it for use inthis chapter. ‘See Appendix 8-5 for an example for a Utility Summary. Process Yields. ‘A Process Yield represents a consumption per ton of main product, e.g. feed/t, by- products/t, process chemicals, utilities/t. Process yields are important parameters for monitoring a process and comparing it with others. They form the “finger print” of a process. This performance of the design should be compared with that of already existing installations. Conclusions should be drawn and recommendations given. A block scheme can best be used for review. It contains major flows “in” and “out” as well as the larger “internal” stroam, ¢.g., recycles. Total mass flows are specified for those streams in the block diagram, together with the yields. As an example of a block diagram, see Appendix 8-6. 4.13. Process Control (CPD Final Report, Chapter 6) ‘A good process should be controllable, This issue should be taken into account already during an early stage of the design, i.c., during process selection, and selection and arrangement of unit operations. The designer should realize that in many cases process control have impact on process equipment requirements, e.g., additional vessels, reactor design, etc. The purpose of this chapter is to clarify why certain combinations of control loops were chosen and positioned from a process point of view and how these choices have influenced the design. The starting point is that a controller unit works according to expectation, e.g, it controls ‘the most important process variables: + Pressure (PC), pressure difference (DPC), - Temperature (TC), temperature difference (DTC), = Flow (FC) + Quality (QC) = Level ac) ~ Ratio (RC, primarily for flows = RFC) There is no need for copying textbooks on control theory and/or explanations about time lags. PID, and other “control box stuff’. The question is whether the controllers are correctly positioned in the process. Only basic control is required for the CPD. Advanced control and other exotic machinery are not required. For example, “13.414 instrumentation safeguarding is excluded, because it requires a much more detailed design and much more expertise than could be expected from the student designers. For an example on how to introduce process controllers in a PES, sez Appendices 7-1 and 8-1, which also serve as examples for a PFS. For controller symbols, see Appendix 6, first page. Other reference: “Chemical Process Control: An Introduction to Theory and Practice” by , Stephanopoulos, Chapter 25 ~ “Design of Control Systems for Complete Plants” ‘Mass and Heat Balances (CPD Final Report, Chapter 7) AAs already mentioned in Section 6.9 of this manual, mass and heat balances are essential tools for process designers. Nature will not allow mass and heat to be converted into nothing or be created from nothing. Consequently, during design activities designer adheres to the law of mass and energy conservation. This chapter is intended to let the designer demonstrate the quality of the design by providing the mass and heat balances and where required to explain the sources of any imbalance and its effects on the final results. The following topics should be taken into account, - Practical Aspects. ‘As a check measure the designer will regularly perform mass and energy balances for his work. In principle, these balances (output-input) should not show deficits, neither Positive tor negative. However, nothing is perfect in life and therefore also imbalances still do occur. This is acceptable, as long as the designer is able to satisfactorily explain the sources, e.g., inaccuracies of data and/or algorithms and/or calculation (inaccuracies. Moreover, such inaccuracies should be demonstrated to ‘have no or only minor influence on the final results, It must be clear, for instance a mass balance around a reactor will never “balance” if reaction stoichiometry already does not yield a closed mass balance. Always let your computer program for reactor calculations check on mass and heat balances by the simple approach, i.c., overall IN should equal overall OUT! Also do this with output from flowsheeter calculation programs, ¢.g., SUPER PRO, ASPEN, CHEMCAD, etc. Program simple overall IN and OUT balances with “check streams” to check these calculation monsters, + Balance for Total Streams. ‘The CPD requires mass and heat balances for total streams to be made using spreadsheets (or other calculation devices) for individual equipment and, of course, for the complete installation (Battery Limit). These calculations require data from the Process Stream Summary, thus demonstrating data consistency. ‘See Appendix 8-4 for a Mass and Hear Balance (total streams). + Balance for Stream Components. The CPD also requires a mass balance or component around the Battery Limit. These calculations also require data from the Process Stream summary. A heat balance is performed as well. It provides the difference between enthalpies of IN- and OUT going streams. This difference is equal to the difference between heat “IN” and “OUT”, as introduced or removed by heat exchanger equipment (steam, cooling water, air cooling, etc.) This should check with the heat balance for the total streams, For an example, see Appendix 8-3, the last table, 14.als 4.15.1 Process and Equipment Design (CPD Final Report, Chapter 8) Process design normally develops from the block scheme phase eventually to the Process Flow Scheme phase. Calculations develop in parallel from simple spreadsheet calculations to complex calculations for which in most cases flowsheeter calculation programs are used. During these flowsheeter calculations, unit operations are integrated and their performance is tested on meeting design specifications, whilst keeping ‘equipment size (costs) within “reasonable” limits. Based on the final Process design configuration (flowsheeter configuration), the required equipment performance data are fixed, ¢.g., reflux ratios, tray numbers, reactor conversion and. selectivity. Bases on these data the process equipment is ultimately sized for its main geometry. In this chapter (Chapter 8 of the CPD Final Report) background information must be provided about the important decision points for process and equipment design using the following topic headers. Integration by Process Stimulation. Tools and their specific applications (e.g., CHEMCAD for process simulation, MATCAD for reactor modeling) should be mentioned and briefly explained. Major problems encountered with these tools as well as solutions should be described briefly Simulation of modeling approach, results and their interpretation, and anything else ‘that may be of key interest to subsequent users of the report must be reviewed. 4:15.2 Equipment Selection and Design. Only equipment as specified on a PFS is considered for detailed design, ic., reactors, columns, vessels, separators, pumps, compressors, heat exchanger equipment, ete. Consequently, only this equipment is eventually included in the total investment costs. Therefore, it is crucial to assess the necessity of equipment before any calculation is started, ‘ready in an carly stage of the design. Also, specifying a distillation column without its overhead system (no reflux accumulator, reflux pump, etc.) Would be the wrong thing to do. Another mistake is the absence of a pump where fluid transport is required by pressure drop is lacking, Use of common sense and technological insight may be a remedy. Once selected, the equipment is designed and sized, based on required performance, ile. based on design criteria. Calculations to this end should be provided as appendices, where equipment should be referenced using their equipment ID (equipment identification number). The main text of the report contains information on selection, calculation methods, and their validity. Design criteria and input data should always be provided, i.e., details in the calculations (appendices) and key information in the main text. Design criteria are, e.g., separation sharpness for key components, reaction conversion and selectivity, minimum temperature difference, flow and pressure drop, efficiency, available utility temperatures, etc. Input data are e.g,, flows (always provide reference streanvflow identification number!!), process conditions (temperature and pressure), ete 15.4153 4154 2 4.16 Calculations ean be done per group, e.g., report sections for pumps, reactors, distillation columns, ete. Special Issues. The following issues should be taken into account, ~ Always provide guidance to your calculation methods. Do not treat the reader with a forest of equations without providing a clue about their purpose. = ~ A simulation mode! of the process (e.g. CHEMCAD model) should at least have a clear and comprehensive description as an appendix to the report, ~ Specific mathematical models may have been prepared for equipment simulation. Specify the name of the software and how it has been applied. Furthermore, a description of such models is mandatory. It should also include all inputs, assumptions, constraints and range of validity, basis for applied equations, etc. ‘These issues must be clearly and comprehensively presented. A program listing ‘or a print of a result is not sufficient (sce also next item), ~ Program listings should not be included. Comprehensive calculation results and underlying details about calculation methods can be added as appendices. - Highlight material selection and corrosion aspects. Equipment Data Sheets, Equipment data sheets are important, because eventually the ordering of equipment is done using data as specified on the sheets. These data are specified by the designer, ‘who generates the data from his design calculations. Obviously, the designer is held fully responsible for these data. They must be flawless, because wrong data inevitably Produce wrong equipment. Please note that during the various design stages of a Droject multiple disciplines contribute to these data sheets within their own domain, £2, construction material experts, rotating equipment expetts, construction engineers, cic. However, the designer normally has the largest impact in determining the equipment’s main geometry. Two different types of equipment data sheets exist, ie. Equipment Summary Sheets and Equipment Specification Sheets. ~ Equipment Summary Sheets, ‘These sheets provide limited detail. They are used for providing quick reference for overall dimensions, process conditions and capital estimates, - Equipment Specification Sheets. These sheets provide design details, which are dependent on the type of equipment. They serve as a basis for equipment ordering, The sheets should be presented as appendices, to which can be referred where necessary, e.g, for equipment design calculations Name, Equipment Identification Number (ID Number), service, type, number and process conditions are provided for all sheets. ‘These data must be consistent with all ‘other project documentation, e.g. the PFS. ‘See Appendix 8-7 for examples of equipment data sheets. Wastes (CPD Final Report, Chapter 9) All processes produce wastes, directly or indirectly. This chapter will provide an ‘opportunity to let the designers demonstrate their “waste conscious” attitude, -16-4A7 Indirect Wastes These wastes include all pollution occurring during, e.g., manufacturing of feedstocks and plant equipment or as a result of product usage, e.g., fuels for heating or traction. This category should be taken into account for “Project Life Evaluations” but is not included in the CPD. Direct Wastes For the CPD only direct wastes must receive attention. These wastes can be in the form of gases, liquids, solids, or combinations and originate directly from the designed plant. Gaseous waste can be contaminated off-gas. It may or may not be combustible, and it may or may not be odorous. Liquid waste could be contaminated process- or surface water, contaminated cooling water (process leakage), heavy ends, ete. Solid waste can be, eg, spent catalyst from fluid-bed or fixed-bed reactors. Examples are fines in the effluent of a Catalytic Cracker's catalyst regenerator, oF pellets and crushed debris from a catalyst change. It can also be packaging material of imported process chemicals. Liquid or solid wastes can also be in the form of an unwanted by-product. Wastes often occur as combinations, e.g., solid particles in a vapor or liquid stream. An example of the latter is slurry oil from a Catalytic Cracker, which is a catalyst containing oil stream, In all these cases, the materials have to be disposed off in a responsible, but economical way. Aspects like “ Population Equivalents” of aqueous wastes should not be forgotten. This chapter is intended to let designers make an in-depth review of all direct wastes produced and how they are handled in the design. All wastes should be categorized in (a) tablo(s) and their effects tabulated and discussed. Obviously, prevention of wastes is the best remedy. Therefore, it must be reviewed 10 what extent process choice as well as choice of unit operations/equipment has influenced the design’s waste production. The impact of produced wastes on the design’s economics must be separately reviewed in Chapter 11, “Economy”, of the CPD Final Report Process Safety (CPD final Report, Chapter 10) The tendency exists among students to copy large parts of text about personal safety provisions like gas masks, fite extinguishers, wearing goggles and gloves, etc.. etc. Descriptions of gas warning systems, instrumental safeguarding, etc., are also very popular. However, this is NOT wanted! What should be taken into account are safety aspects vis a vis operating personnel from a process design point of view. In others ‘words, what can the designer do to reduce safety risks towards operating personnel. In quantifying those aspects, two tools can assist, ie, a Hazard and Operability study (HAZOP) and the Fire and Explosion Index (FEI) assessment, both carried out on the final CPD. ‘This chapter expects designers to carry out these assessments, draw conclusions from them and make recommendations accordingly. This activity will enhance the designer's awareness of critical safety aspects of the CPD. “174.18 HAZOP. A limited Hazard and Operability study (HAZOP) must be carried out, e.g., for an evidently critical piece of equipment such as a reaction section. Selection criteria may be flammable substances, reactivity, runaway, volume, pressure, and temperature. The result may be the recommendation to add valves, improve control, change construction, introduce fire protection of the equipment, etc. Where possible, these recommended actions must be implemented in the design and reported, FEL ‘Assessment of this index must be done for the complete CPD and is based on the nature of the process and the properties of process materials and products. The ‘outcome will be a potential “Degree of Hazard”, which will categorize the installation between “Mild” and “Extreme”. Although many times processes cannot easily be changed, measures reducing the risks should be recommended. Where possible, these recommended actions must be implemented in the design and reported. lease note that it is the task of the designer to design a safe plant in spite of the fact that hazards and/or risks are potentially present. Knowing the hazards and risks enables their effective reduction by adapted design for which the designer is responsible. Such reduction must lead to hazards and risks at “acceptable levels”, ‘eg., when compared with driving a car on a highway or with traveling by airplane, However, those who argue that reduction of hazards and risks to zero is impossible are lying or do not know their trade. For more information, see: = The course book from TUDelft “Chemical Risk Management”. > Coulson and Richardson, “Chemical Engineering”, Volume 6, Chapter 9, “Safety and Loss Prevention.” Economy (CPD Final Report, Chapter 11) Many reasons may exist to start designing a (petro)chemical processing installation. However, the bottom line will always be a high degree of certainty about the installation earning ‘back its investment, including required profit. For comparing economic ‘competitiveness of processes, in first instance local effects like taxes, subsidizing, grants, ‘ic. should never be included. These effects tell nothing about the process, but may only increase confusion, Therefore, they will be taken on board in a later stage, for instance ‘when a multi-national must select the plant location (¢.g., the country). Therefore, the economic evaluation of a CPD must exclude all fringes mentioned above. ‘At least the following economic information must be assessed and presented. Investment. (Once-Of. Using the “Lang Method” only. This requires reasonable accuracy with respect to required equipment. For instance, where pumps are required, they must be specified. Please notice that most pumps have installed spares! Operating Costs. (Annual) Operating Costs (Manufacturing Costs) are normally provided in amount of money (f, UK £, US §, etc.) per year (annum). However, these costs should also be expressed in amount of money per ton of product, or, e.g., for a waste treatment plant, in amount of money per ton of feed. If wastes and/or unwanted by-products cannot be sold (which is normally the case), their costs of disposal should be included in the operating costs. Costs of loan (Capital Charge) have to be included as well -18-a eee Se SS Ss 419 Income. (Annual). Sales of product and sellable by-products, Cash Flow. (Annual). ‘The difference between Income and Operating Costs. Economie Criteria. ‘These provide the link between “Once-Of?” investment and annual income and costs, ie, Rate On Return (ROR), Pay Out Time (POT), Discounted Cash Flow Rate On Return (DCFROR = Earning Power). Cost Review. Indication of main cost elements with handy table(s) and suggestions about where and how costs could still be further reduced, together with ‘impact on economical criteria, Sensitivities. Sensitivity of economic criteria with respect to investment, operating costs (select right variables, c.g., feedstock, utilities, wastes, ete,), product prices, ete. Variances of +/- 10% are used. Negative Cash Flows, In case of negative cash flows and/or economic criteria below targets, break-even costs/prices and/or investments required for meeting set economic eriteria, e.g, an Earning Power of 12% (dependent on business environment). Please note on the following: + Lengthy calculations must be presented in appendices. ~ In arriving at the final answers, a numerical, step-by-step approach should be followed. This will provide “in-between” results, making it easier to understand and check the approach and results. ~ Values are presented in the form of tables where possible, right adjusted, with equal decimal point positioning per column. ~ _ Instead of scientific notation (e.g. x.xxx E xx, this should not be used in financial documents) always use fixed-point format (¢.g., KXX.x). + The “dimension” of a variable (investment, cash flow, interest, ete. (should be adjusted to its magnitude, e.g. M$. 15.123 instead of $. 15,123,000.-. The choice of “dimension” (MS, $) is determined by the constituting clements providing sufficient magnitude for comparison, + Values should not have a ridiculously high accuracy but nevertheless the arithmetic (additions, subtractions) should always be consistent. For more information, see: Coulson and Richardson, “Chemical Engineering”, Volume 6, Chapter 6, “Costing and Project Evaluation”. ‘onclusions and Recor tions (CPD Final Report, Chapter 12) Based on the detailed knowledge gathered during the design, a review of strengths, and weaknesses of the design must be given, This review is normally composed of conclusions/recommendations that were made in the various chapters of the CPD Final Report and provides a good basis for final conclusions and recommendations. For instance, the reliability of the design and the measures to be taken for improvement could be addressed. In addition, suggestions may be done about alternative unit operations, ‘cquipment line-up or research for areas of uncertainty, e.g., reaction kinetics, Cost -19-421 4.22 reduction and SHE also are favorite topics. Do not forget to summarize the main topics in the Summary of the CPD Final Report List of Symbols (CPD Final Report, not a Chapter) Under this heading all symbols used in the report are tabulated. They can be provided alphabetically per chapter. Alternatively, one list could be provided, again in alphabetical order. A suggestion is to tabulate all symbols in a data bank (eg, spreadsheet) directly from the start, with the data bank filling up gradually with the design progressing. Ranking will be an easy job and the occurrence of errors will be minimal. Standard symbols can be found in Appendix 10. Appendix 11 provides SI Base Units as well as SI Derived Units. Literature (CPD Final Report, not a Chapter) References can be numbered and reference can be made to those numbers, Appendices (CPD Final Report, numbered) ‘Appendices must be numbered for referencing and should have numbered pages. They should be used for the following documentation: - Detailed, lengthy calculations. - Larger tables, e.g., Process Stream Summaries, Mass and Heat Balances, Utility ‘Summaries, etc. - Equipment Data Sheets, i., Equipment Summary Sheets, Equipment Specification Sheets, = Ete. Use your imagination! -20-5S. Typical Problems ‘This chapter covers a number of problems that appear to be encountered by less experienced designers, Sa 52 5.21 522 33 Bi ions As explained previously, for batch processes the availability of a Batch Cycle Diagram {also called “Gantt Chart”) is essential. This diagram provides a graphical representation of all the required activities (batch stages) as a function of time, e.g., reactor fill, reaction, cooling down, reactor discharge, etc. In this way a clear overview is provided of activity (Stage) categories, the time required for each activity, the time required for a complete “batch cycle”, ic, the Batch Cycle Time (t, h) and the pattern of repetition, Normally, a design starts with the assessment of the design determining process, c.g., the reactor that produces the product. For this process, the Batch Cycle Time ((t, h) is determined, keeping in mind, that the reaction time normally largely determines the Batch Cycle Time and is independent on the reactor volume. Once ‘,, the annual production, P, and the number of stream hours per year, hay are known, the tons of product per batch, Pry can be calculated, Le.: ‘Number of batches per annum = = " = hatte tl Tons of product per batch Peat Pin tt Average production rate 5 Pog Pig 7 Prat! fe {why ‘Once quantities per batch in {t) have been determined, all average streams (mass flows) can be determined by dividing these quantities by t,.. These average values are important as input for the continuous part of the process, because they can be treated as if they were continuous flows. Reactors, Although the curriculum on reactors leaves no room for misinterpretation, the following. issues seem to need clarification. Equilibrium Reactors. Only fast reactors operate close to equilibrium, e.g., with a temperature approach of about 5 to 10°C. For phase transitions and sequential reactions equilibrium can be surpassed, sometimes resulting in complete conversion. In certain cases, this can also bbe reached by removing one or more reaction products, eg. by absorption or adsorption. Reactor Concepts. ‘Always assess the reactor concept by designing the reactor “around” the reaction ‘mechanism, based on sound chemical engineering reasoning. In literature, underlying reasons for the choice of a reactor concept (if any) are often just not available or even Jet out on purpose. It should be realized that heat and mass transfer also could be determining factors for the assessment of the reactor concept. Separation by Distillation “The presence of azeotropes and/or de-mixing phenomena should always be considered. CHEMCAD shortcut modules continue to calculate separations even past the azeotropic 2point. This leads to ridiculously high numbers of equilibrium plates (trays), which under the circumstance, of course, is completely unrealistic. The existence of other separation methods, which for certain separation problems are much better suited, eg. crystallization or extractitn, should also be considered. ‘Throttling of Fluid Flows Transport of fluids is the result of available pressure drop (impulse!), not the other way around! If this pressure drop is created, e-g,, by means of a valve, this process is called throttling”. Throttling of fluid flows will normally result in a temperature change. In frst instance, this phenomenon is dependent on the fluid phase, ic, liquid or gaseous (vapor) and is not always fully understood. ‘Therefore, an explanation follows. + Liquid Fluids, Throttling of a liquid uid, eg., by @ valve, is considered under V/L equilibrium conditions at the valve inlet. At the vaive exit, the equilibrium temperature of the fluid will have to decrease to new equilibrium conditions at a lower pressure. IF adiabatic conditions are present, this temperature decrease will be obtained by vaporization, i.e, “flash off” of part of the liquid. In other words, a liquid fluid at adiabatic conditions will partly vaporize after being subjected 10 pressure drop. Consequently, if €g., & cooler (heat exchanger) is installed downstream of a valve, this equipment has to be designed for two-phase flow. The cooler will be larger (Surface and size), and therefore, more expensive, In these cases the obvious location of such a cooler is up-stream of the valve, where “flash-off” can be avoided, ~ Gaseous Fluids: “Throttling” of a gaseous fluid also inflicts temperature changes. These changes are a result of the Joule Thompson (Kelvin) effect. With this effect an “inversion point” is defined, This point represents a key temperature above which expanding (throttled) Bascous fluid experience a temperature increase. Below this “inversion point” temperatures decrease. For hydrogen this point exists at ~183 °C. This effect is important for, e.g. reftigeration installations, air splitters, or valves where large Pressure drops occur. Downstream equipment has to be designed to cope with this phenomenon,6 Quality Control the designer in making it more consistent and complete, Design Objectives. ~ Design objectives must be clearly described, ~The degree of achieving them must be clearly demonstrated, ~ Deviations must be mentioned and elucidated. Choices, Conclusions and. ‘Recommendations, + They must be defendable, - They must be complete. Prevent ‘omissions, + Clearly separate own ‘findings from those. developed by others. Comprehensiveness of the report. + The report must be comprehensive for the targeted readers, 7 Design work performed by the team must stand clearly from the report. = Use of results from work by “others” must be clearly reported as wel ~ Information about the design must be balanced, i.e, sufficient but not trivial Report Structure. 7 The guidance provided in this manual should be followed with respect to the structure = not, deviations must be made plausible (this may be @ hard job). {The Summary must be tight and tothe point, containing the essence of the design + Over-extensive deliberations must be excluded. Be “straight to the point”. + Text suitable for inclusion in an appendix should be excluded from the main text, ~The text should be readable. Avoid pompous language, lengthy lines and textbook material Bits and Pieces. ~ The report should have been painstakingly checked and corrected + The Table of Contents must be complete, also including all appendices. > Numbering of pages, figures, tables, cfc. must be consistent, 7 Appendices must be complete. No missing pages), figure(s), tables), et. ~ Figures, graphics, tables, etc. must be comprehensive on a standalone basis, by Providing readable and relevant. ‘text, information, definition of axes, Teferences, etc. -23-‘App. 2- BOD Appendix 2-1 Basis of Design (BOD) for CPD Final Report 1. Description of the design. Dackground ofthe design. briefly summarized, Refer to previous chapters if possible, What will be done and what will NOT be done! 2. Process definition. = Process Concept chosen. Summary of Chapter 2 Process options, option chosen. Explain. Continuous, batch, combination. Why? Stoichiometry, catalyst, tc. Reaction kinetics. experimental data, ete. What is used? = Block Schemes. ‘A simple “Process Flow Scheme” (Rectangles as simplest form) ‘Connecting Streams (Numbered) rocess Conditions (Pressure, temperature, vapor/tiquid/solidy ‘Total mass streams & vit values _(Values taken from final ass balance) = Thermodynamic Properties. ‘Summary of Chapter 4 ‘Made(s) foe vapocliquid equilibria, heat data, Explain choice(s)- ‘Comparison with data from literature. Provide plots: 2/9 or VF @ p = constant. «List of Pure Component Properties. ‘Name (Consistent naming throughout report) ‘Structural formula {Sketch for more complex components) Molecular weight tkgtkmol) Boiling point CC. Atmosphere, rank components according») ‘Melting point €C) Liguid Density (kglm’, Define reference temperature) MAC {Maximum Allowable Concentration) LDxs. (Lethal Dose) 3. Basic Assumptions. = Plant Capacity. ify describe Feedsiocks, Base Chemicals, Products, By-Products, Wastes, More details: see “definition of streams” Provide tons/a, stream hours/a, economical plant life. Explain choices. + Location. ‘Country, industrial ara, etc. + Battery Limit. ‘Define (briefly describe) the plant (important equipment) inside Battery Limit. Use block scheme, Define faciities, assumed available outside the Battery Limit = Definition of ALL in- and out-going streams / substances (passing the Battery Limit). Foedstocks, products, wastes, util 1 Provess conditions (7, p, V/US, pipe ral ete) Prices Catalysts ‘Composition, shape, bulk density, prices, ec Deal with each stream or substance (c.g. catalyst) separately! Present values per siream or substance in table und explain with text. Provide both commercial specifications and your chosen (explain) design values (2 columns i table)! 4, Margin in f, £, Sete. Margin = Tatal Value (Products, OUT) ~ Total Value (Feedstocks, Process Chemicals, 1N), Explain! Calculate maximum allowed investment at a Discount Cash Flow Rate of Return of 10%. Draw conclusions Appendix - 1 -Item No. of Pages (Approx) 1. Description ofthe design. 1xAd Background ofthe design, briely summarized. Refer to previous chapters if possible. ‘What wil be done and what will NOT be done! 2. Process definition. + Process Concept chosen, (Future CPD Final Report, Chapter 2) 24 Process options, option chosen. Explain, Continuous, tc, combination. Why? Stoichiometry, catalyst, ec Reaction kins, experimental data, et. What is used? Block Schemes. "As foe CPD Final Report, Chepter 3, “BOD” Laas (7 = Thermodyuamic Properties. (-Fucure CPD Final Repo, Chapier 4) 144 Model.) for vaprfiquid equilibria, best data, Explain choices). Comparison with data fom literature, Provide plots) or xT @ p ~ constant. ~ List of Pare Component Properties. ras o Appendix 2-2 Preliminary Basis of Design (BOD) for CPD Review Meeting ‘Total volume should be limited to approximately 12 pages ‘As for CPD Final Report. Chapter 3, “BOD™ = Process Stream Summary 4 Mass Bata MASS per UNIT OF TIME! (preliminary, moles are optional) Define the streams per component Stream numbers in rss, component names in column! Basic Assumptions. ‘As for CPD Final Report, Chapter 3, “BOD” Margin in f,4,5, ete. ‘As for CPD Final Report, Chapter 3, “BOD" 1! READ “MANUAL CONCEPTUAL PROCESS DESIGN” 11 READ “DOUGLAS, PART HI” !! Appendix - 2 - (Future CPD Pinal Report, Chapter 7) 2 M4 2xad eadAppendix 2-3 CPD - Activity Planning To be presented at the Review Meeting Approximately 1 page Definition of “Date”: DAY/ MONTH / YEAR (And sometimes time!) Date ‘Activity — Deliverable sededie — Kick-OfF CPD Program Assignment Review (~ three weeks after kick-off). CPD Review Document Issue CPD Final Report CPD Final Report Time in between is minimal 2x 3 working days sohen Discussion of CPD Final Report Quality Assessment of CPD Final Report Appendix - 3 - :Appendix 3 App.3—Utlities Basis of Design (BOD) — Utility Conditions and Costs Available Utilities a._Steam ‘Superbeated steam is considered to be available at the temperatures and absolute pressures given below. “Conditions Steam Class Wiigh Pressure] Medium Tow Pressure Pressure P [Bara] AED 10 i} Site “F (superheated) (oC) [= [410 220 190 ‘T (condensation) foCT_| | 250 180. [1333 Fouling coefficient: 10 kW/m?®C Fouling Factor: 0.1m? °C/kW b._EBlectricity Power Voltage V] Carrent eee Tow 220 aC Medium : 380 ‘Three ~ phase AC High 3000 — 10000 (3 - 10 kV) _| Three — phase AC Pressurised air is intended for instrumentation and other applications, with the exception of process air, Pressurized air is available atthe following conditions: Value 20 7 stessssesses ECL") : 4. Water Water TE PUBara] | H[RWinF °C] | Fouling Tacior a Lim caw] Potable: 15 4 | | Demineralized (Process) 1S. 7 } | Cooling: | 2040 | 3 20 los i ‘Remarks (1) Design Value (2) Maximum allowed 3) At ground level(Cetuey Coats ME P70 ‘App.3 — Utilities [ Value 28 40” a i i I l | | Air pressure 7 Bara UTILITY COSTS, EXCL. VAT’ Tay [LAV [Unit Casts, Nitin Energy | En. Per | Quant. Energy | Quant, | Min Max. _| Min. Max. NG™ Nav [MT 31.65 10.26 | 0.43 | 0.00821 | 0.013586 kg | Mo 37.68 | 031| 0.51 | 0.00821 | 0.013586 ton | MJ | 37678.57 | 309.52 | 511,90 | 0.00821 | 0.013586 | HFO* ton | MJ 41.45 | 280.00 | 300.00 | 6.75513 | 7.237636 Coal ton | MI 29.30 | 110.00 3.75427 0 Steam LP/HP | ton 30.00 | 35.00 Blectricity® kwh 0.13} 0.22 Cooling m 0.05} 0.10 | Water w | lo] 250 | BEW/Process | Nm? 0.05 7 Pressurized Air a a Remarks 1. Ref. “Cost Data, WEBCIDACE”, 18" Edition November 1995 2. Tton= 1000 ke 3. NG~= natural gas 4. Density 0.84 kyNm’, = MW= 18.60 5. HEO = heavy fuel oil 6. For quantities larger than 10° kWh/a Appendia. - 5 -‘App-4— Thermodynamics Appendix 4 ‘Thermodynamics - Methods and Models N.B.: See item 5 for abbreviations 1. Thermodynamic methods Literature: Lecture notes “Thermodynamic voor ontwerpers” Binary parameters: -from database from literature/experiment input: note units note form of correlation, e.g. A= AYRT -test for known situation e.., with PROCESS through the property generator: tables and graphs of L + G equilibrium, phase envelope: , x; P, x; T,x extra in ASPEN: -“own models” -fitting of experimental data fitting of results model 1 with mode! 2 -own properties (e.2., pH) 2, Selection of thermodynamic models PYTLandV ——: SRK, PR, (BWRS: time consuming) SRK, PR, virial equation, p<1/2 p.c (Chao-Seader) + Thomson et. al., Rackett, Lydersen/Gunn-Yamada 1a) correlation: Wilson/NRTL/UNIQUAC ‘1AGn) group cont, UNIQUAC, ASOG LeL2 equilibrium: NRTL 2/3 parameters (2 parameters: o = 0.2) S-L equilibrium: WilsowNRTL/UNIQUAC chemical equilibrium: Gibbs minimalization HH 2 Lee-kesler/SRK/PR Ss idem 3. LV high pressure BWR, BWRS _: very good if parameters are available, time consuming PR 4 required SRK ‘cumbersome in critical region VL + AV': 10-20% SRK 53-15% PR LK, LKP. 2 time consuming Appendix - 6 -4 peed App.4 — Thermodynamics ae Te Ce CeCe ee eee eee Sdargules. Van Laar + binary, non-polar Wilson. NRTL, UNIQUAC : multicomponent, polar Wiison NRTL NRTL/UNIQUAC way = A+ B/T+ C/T : for low molecular mass alcohol H,0 L-L equilibrium. if y (2) is important 5. Abbreviations and their meaning SRK PR BWR LK LKP NRTL UNIQUAC UNIFAC Soave-Redlich-Kwong Peng Robinson + Benedict-Webb-Rubin 2 Lee-Kesler : Lee Kesler-Plockner : Non Random Two Liquid : Universal Quasi Chemical + UNIQUAC Functional Group Activity Coefficients Appendix = 7- ‘equation equation equation method equation equation equation equation1 App.5 — Drawing a Process Flow Scheme Appendix 5 Drawing a Process Flow Scheme Introduction The PFS is intended to transfer information to the user on interconnection of process units (Unit Operations) and process conditions, ie., the “process logic”, in a comprehensive and realistic way. It is essential to realize, however, that although many companies have made up their own standards for a PFS, in practice, a uniform standard does not exist. Nevertheless, some ISO standardization is available on, eg, Symbols for Process Flow Schemes. Moreover, a number of “heuristic” rules can be given, which, if applied, can lead to the comprehensive PFS we are after. In this respect, it can be mentioned, that, e.g., positioning equipment on the PFS in a sequence that is expected to occur in practice, already considerably contributes to this aforementioned comprehensiveness. Many times. the “optimal” composition of a PFS is also a matter of taste, which justifies the statement that the Preparation of a PFS to some extent is also an artistic effort. Nevertheless, in the following sections some guidance on drawing a PFS will be provided. Please note that AUTOCAD is required for drawing a PFS. For, PFS-examples, see Appendices no. 7-1 and 81. For ‘drawing conventions, see Appendix 6, + Concepts ~ Always first prepare a PFS-draft in pencil. Arrange the equipment so that they appear in practical sequence on paper, although oceasionally compromises have to be accepted. The paper offers only limited space! + Use a large size paper sheet (e-g., A3, A2 or the back of a wail calendar), a pencil and an eraser. Start drawing without being inhibited by limitations mostly imposed on you by Paper size. ~ Follow the concept of positioning equipment, as it most likely will be placed in practice. Position equipment from up-stteam, i.e, the lefi-hand side of the paper to downstream, i.e., towards the right hand side of the paper. Approach the actual situation by placing the equipment as much as possible at “ground level”. In practice, it does not float in the air either. = Have equipment through which the main reactants and the main product(s) are flowing lined up in a straight line (from left to right on the paper). The same trick can be done with. e.g., recycling reactants and “treat” them from left to right as well, tn such cases two trains of process equipment can run in parallel (on the paper). + Process streams are defined as streams that are introduced in or extracted from other process streams or process equipment, thus influencing the process mass balance. Utilities, for instance, do not affect the process mass balance; because they always re separated from the process by the process “containment”, i.e., an equipment wall, pipe walls, etc. (E.g.. cooling water), However, “open steam” is not a utility but a process stream. = All incoming process streams (repeat: ALL incoming streams) should enter at the left- hand side of the paper. All outgoing process streams (repeat: ALL outgoing streams) should leave at the right hand side of the paper. This is regardless their point of introduction into or extraction from the process. Be imaginative! For utilities an - exception is made, but specify the name of the utility at the application point. Appendix - 8 -‘App.5 ~ Drawing a Process Flow Scheme ‘Never draw large-sized symbols for columns, vessels, etc. This will force your connecting flows towards a layout that is “sub-optimal”. Try to do it the other way around: size the symbols as dictated by the “flow logic”. Strive for connecting flows with straight lines as much as possible, Avoid “corners”, although the connecting stream between the two vessels (liquid) will have at least three “corners”. Also avoid “crossings” with other streams where possible. Always interrupt the vertical streams; do not interrupt the horizontal ones. Th other words, do not interrupt the “left to right” rule. Sometimes compromises will have to be made, e.g., with respect to the number of “crossings”. In other cases more “erossings” can also make the PFS more comprehensive, 3. Conventions The process installation can be divided into “Plant Units”, e.g, U100, U200, etc. Relevant equipment, process streams, valves, and instrumentation should be numbered ly, te, VIO (vessel), <101> (stream), CV105 (control valve), RCVLI3 (remote control valve), FRCI30 (flow recorder controller), ete. Never start the numbering with, ¢.g., V100, but always with the number 101, ete. For complex processes, plant units can be drawn each on a separate A4 paper. In that case also provide a block diagram, including all the units on one page, showing all in- coming, out-going and inter-connecting streams. If possible, draw more units on one Paper. A3 size paper is also acceptable. The choice is left to the designers, ‘The PFS Symbols should resemble actual contours and where possible a simple sketch of “internals”. See Appendix 6 for the recommended symbols, Vapors should normally leave over the top of the relevant equipment. Liquids/solids should leave through the bottom, e.g., for vessels, distillation columns, extractors, etc, although exceptions may exist. See Appendix 6 for a distillation column and a stripper/absorber unit. Draw thick lines for the main reactants and product(s) containing streams. See the relevant PFS examples, Equipment identification characters are based on English international conventions. See Appendix 6, For process control, the CPD only requires simple (basic) control systems, ¢.g., where Pressure drop occurs between equipment, control (including a control valve) must be specified. The plant throughput must be controllable. For abbreviations, coding, efc., see Appendix 6. Essential equipment should be properly specified, e.g., distillation columns should have Complete overhear and reboiler systems drawn up. Pumps should be included, if obviously required. Remember that only pressure (drop), ie., impulse will force fluid flow, not the other way around! Different stream numbers are required for streams with different process conditions, €.g. ‘when pressure, temperature, (mass) flow, composition, et., differ. A complete equipment summary (identification, useful name) must be provided at the bottom of the PFS (“P101: Pump” is not sufficient). Small fonts are allowed. Appendix - 9 -Hee eee ee eee App.6- Process flow Scams Appendix 6 Process Flow Scheme (PFS) - Symbols and Coding =— —>>— — —— ‘Streams “IN” ‘Streams “OUT” Process Control Flow Temperature Pressure Level Controller Controller Controller Controller pre DPC Temp. difference controller Pressure difference controller Ratio Control (master-slave) ‘Summary of equipment coding * ill c Column D Rotary Kiln, Spray Dryer E Hester, Cooler, Heat Exchange, et /Ejetr! Injector r | Fumsce K Blower. Compressor M Miner P Pump R Reactor s | Separator, ¢.g., Sieve, Centrifuge, Hydrocyclone, Electrostatic Precipitator, Filter it ‘Storage Tanke Turbine To ‘Steam turbine as generator dive | v Vessel (hue. collecting separation, et), Hopper, Barometric Condenser V's. E's | Boiler (vesseVexchanger combination) x Other equipment (transporte, eleva. rolling machine) Common abbreviations au Ve Vapour TFT pressure Lol Liquid MP = Mesum pressure S_+_ Solid HP = High pressure E,W 7 Ca¥ Conia V fdas wl | | > soum Fontev) A 7 “ Column (C) general Absorber (C) Stripper (©) (with reboiler and total condenser) Appendix - 10 -‘App.6 - Process flow Scheme 1 aaa dete a te TD Pipeline Pipeline Process Flows Process Flows pe pe tee i a Safety Relief Bursting Disk Condense Trap Transporter Valve Belt (X) i : SS be Se aL a ge Atmospheric (buffer, Pressurized (T) collecting, etc.) (for gases, liquids) > 4 cy ay " Centtifugal Blower (K) Reciprocal Pump(P) Centrifugal Pump (P), (piston, membrane) Compressor (K) “Hy — Hs Ejector/Injector (E) Turbine (T) Pump (P) (general, (or vacuum pump) ‘only use i.c.0. ona Appendix = 11 - > Valve (open) ple ‘Non-Return Valve bm ‘Trans; Screw (X) ‘Hopper (V) i q x Reciprocal Compressor (K) (or vacuum pump) soe ‘Compressor (K) (general)App.6 - Provess flow Scheme kts ee Firs L sania) Sieve (S) Rolling Machine X) Centrifuge (8) (Rolle) bo kes ie bi ca [ NI le al L838 Bow Centrifuge (S) Decanting Liguidiguid SeparcioV) _Thickener (V) Centrifuge (S) (Gravity) Lys v Neck ade [een . fo oH 1 > s s Liquid’Vepour Sepursto(V) _Hydrocyclone (S) Electronic Filter (8) (horizontal) Precipitator (S) Ls Les se s t Rotary Filter (S) Filter Press (S) Rotary Kiln (D) ‘Spray Dryer (D) (calcination, exe.) 7 . Mixer (M) Propeller Mixer (M) Static Mixer (M) Venturi Mixer (M) (basic, streams) (impeller, others: radiat & axial turbine) ‘Appendix - 12 -—e @ SBS SB es SB SB ST SS BT ST ae ae aes eee | = App.6 = Process flow Scheme 32a 9 3 Presi ColelConderer(®) Haat Exchanger(€) _ Barometric Ai Cole Evaporator (E) (arrow indicates ‘Condenser (V) Condenser (FE) cnet ; ind Teetindice) Retina) gM im A) oe i —4 le we + 1 Air ‘Thin Film Boiler (W/E) (vessel (Boiler) Furnace Furnace (F) Evaporator (E) exchanger combination) with Burner (F) (electrical heating) Packing, e.g. Tubular Tubular Continuously Stirred Autoclave (R) capt rence encor(R) Task Reactor (Q) (high presse) ion exchanger, (tow pressure) (high pressure) (CSTR, structured’ low pressure) random poking X : Fi nos Mut-Tbolr Muli-Bed Column (CXpacked Column (C) ray, Reactor (R) (FBR) Reactor (R) Reactor (R) ‘vapor over top and vapor over top and liquid over bottom) liquid over bottom) Appendix - 13 -App. 7~ TAME Example Appendix 7-1 le - Process Flow Scan “ro "TAME" Examp! aed Maweoujen enn on gram «SD = ise Teme eee minim eae ‘Appendixeee ee eee ee eC eee Cee oe eee veer Cera Ure eer eo oer eee ee eee ree ieeree ee ene eae ee mee nel Appendix 7-2 “TAME? Example ~ Block Scheme Process Water 2,000Va drogen Paffinate 1 285,500 t/a (3.45) > Methanot 27, 100 a (0.33) op 1,700 Ya (0.02) ‘App.7 ~ TAME PFS i Raffinate 2 290.00 t/a (7.89 > TAME ~ product 82,100 v/s (1.00) Total IN: ‘Total OUT: 314,300 va (3.83) 314,300 va (2.83) N. B, : Figures between brackets () are t/t values, Please note: Blocks and character fonts could have still smaller size Figures normally are round off, however ALL streams ENTER at the LEFT hand side of the Block Scheme. ithout loosing consistency on balance. ALL streams LEAVE at the RIGHT hand side of the Block Scheme, N.NF. or NNF = Normally No Flow. ‘Appendix - 15 -E (sea)aseuC) @) diel aquwumns ms Bom 866r r Menuet: ea vousuoy seen i nn ieeeas: toad | | “SEH . “vOneUSIG Aq UoRerede5 auetaig/oueAdouy pelo BO ed g & I SuIONDS mots SeRDUL [Tessa 1 § i a B = = eg 1 Appendix 8 Example P/P Separation ee Appendix‘App.8 — P/P Sep. Example Appendix 8-2 PIP Separation Example — Pure Component Properties PORE COMPORENT PROPERTIES Cane Nae — Tesheloge Dan ‘aaa a Fela |Wi | Boling [Meng Desi} MN tos] Ras Doign Sptenatie weg | Paint | Pom’ | orcewa | tke Onl aM a) Q a at c °C | kgim’ | mgim? Travia Penton [ous peewwaa ae Taw ogre Pomme’ leon ($0 [Sar [Tos [Seo [ax wn [| | | | | | | | | i | | | | | | 1 | | | | | faucet jena] | | wa (1) At1OL3 kPa (2) Demy 28°C wes pce oer &) Oniineteanaest0tg weg () Desiy 47°C fen ous 3) Dasa 4s-cean toa i ad Naar CHOI Completion Date: January 1 1998 Appendix 17 -‘App.8— PIP Sep. Example Appendix 8-3 P/P Separation Example — Process Stream Summary Cor'powat f PROCISS STEAM SUMMARY —— [Sieam Nr, TW 2 3 7 +50 Cale Name: | PPbedCO1___| Ovid Vipoarcot_| Condensate VOi_| Discharge VOL Come MW | kwis Kol [igs kmolle [kg/s —_kmols | kys — kmolls | kgs Knol Proriene «200/700 “16667 | TOR G22 462 | Tona? 2.5862 | Tos a2 — 2.5802" | T0ead Soe Propane 45.00 / $90 0.1118 | 60004364 | 600 Ot36H | 600 136 | 600 OLles "Foal Tso iar aes | aes see ‘estilo RW] 1587 S703 Tse aa Ds Pose ie v L L Frost 133 me 3s we temp C530 soo 500 500 STREAMNE 3 = 7 i 5 OF ame: | picture PO1__| Rete COL Booms Co1___| Discharge P02 _| Propane Pract COME MW Tig emo [ig tao [tga km [igh emo ee Promise 4206 10210 24010 [21024310 | oa gate oa ois Toa a Propmme son | set otze2 | set nmr |a'se —otose [ase 01032 [458 Route al fr ie ee es ie ee Enhaipy KW ie ite ie 78 a Pawe L i L . Pes. Fa ey ar Bo Bs Lemp 500 00 510 570 300 STREAM 10 Tow 7 Out a Ow Name:_{ Dishuge P03 __| Prolene roduct_| reseed CO1____| Propviene Product | Propane Produ COMP Mw. ] gs kmail [kgs bol wfac aad] wees mee | oa Promise #200 [652 ——O.5s2 Fes oss [3903595 Poss aie Tie pee Propane 4400 [036 © omos2 | 036 0.4082 [asi —caons |o0s asm | os0 bse ‘teal ar po .065 | T5H pou] T5000 EntaipyW aie Ta 7a i Phase L Bae L sia Pres Baa | “360 ne was Be Temp, 500 530 500 joo ‘OVERALE SueamN i Wane CoM Prope 42.00 | F.00 —O.i6667 | 7.00 Tos Propane 4400 | 490 olla [490 ti Test Tao 03780 | i909 ose Pres Bae [Hemp__'c I = aig — KW Tt s a [ Projet TD Number ‘CPDSIOT Completion Dute P1998 ‘Ge es SS SESS SEES ET TAS E Appendix — 18 -P/P Separation Example Appendix 8-4 Apps ~ PIP Sep. Example ~ Mass and Heat Balance Total Streams ® our EQUIPMENT] quem, QUANT Pia F ee we | Seaa] wennie [Sear] Nas ae ane ee kee wy xw | Ne we | ige | aw | es | tw Reg eT 90 1381s] Ss tt worm am | Se <> | sar | “Hp oes sia En Mis.64 44a Tout ise | 94400 H62—~ 93103 | —s— Se] ass |e en tas oust et ise2 93703 Total uig62 | 93703 a SA DSP Wa62 3359 ea P| se 1376 pos | ioe ane ie Ne _ nase ot ni4e2 | _ 2254 688 a Te TS) 6a | ee ae en se a oss owe Toa oss | ioe gaze | o> | we | pe | $8 | oF eH 502719 Sa a 3a a0 Fos 8 502 Tosa sor | 7 Ti) —abas our Appendix - 19 - Project 1D Namber Completion Date January 1 1998 Toda 200209] ‘CPDI2OT£ i ta bear aD § woreda = 29qUINN GI HfDAd | & a ear oa] ee et [wig [a < P i & z os : 2 a gz : ai voasy ems] 156 “s suuwvies ww) 32 a a yang etal & g 8 3 aul = g Ps & it 5 B | stotememted ot | us va g ‘Aqwo Buyjo00 ronpoud 404) st pee, £03) K ost | amis ma & aa ia aa La a vee] eal iae ln mov | ea | SVN mod Bayooy ‘SALT ANGWdI03 SHI 0 RaVRAS 7 A 2 1 1 12 cc eee EgApp.8 ~ P/P Sep. Example Appendix 8-6 P/P Separation Example - Process Yields Process Streams Nae et igs ere [eee Siream our W our we our, Feed | 180 wa 17 C¥Produce | 68s 27 100 C3 Produc <> 502 mt | on Wass 7 7 Bisel Este 7 : : Taal, 1.9099} ae RE 178 iB} PeceeeeaEe Tilties ea) Wane Re] as RW wm ah | = aa | stream e 1c | TP Sieam ~ | aT 150 oor cw { - 8.3 al 1.26 [Btecriciey _: 958 a 9.54 3867... | \ LP Steam Cooling Water Electricity 150 Uh 31th 954 kWh (6.06 uy 259 68.67 Wun) ¥ 3-- product 247 [> | 100 bee Propylene/Propane Distitation eee C3 - product 2am Ee Bue [;}———————» | Iti 7300) COMMENTS ‘C3 losses (0.73 Ut) oceur, OF course, because by-product pencratng reactions do not occur 7 Above yield indicate no ascountabie tos on Feedstock (1.73 Wi), e, nther C3= losses (LOO Wi > reference) or is can also be seen from the material balance (Uh), This is understandable, ‘coonomically than 40 m) if compared This may force adoption of a water cooled sondensc acral 2. | The prooess requires minimal cooling water (1,25 Ut) because the main cooling load is satsfied by a eoolng COT” condenser. EOI) and the load of cooling water consuming heat exchangers (product coolers, 03/04) is low, Although FOI consumes about 90% of the plant’s total eiccrrial power requirements, it sill operates mors ‘oF water cooling. it may be mare economical 0 install a heat pump. 3 [ From the Utility Summary it can be seen that the reboiler Toad (91450 KW) Ts equal to the condenser Toad Prject 1D Naber cpm Compleion Date: tam 1998 | Appendix -21 =‘App.8 ~ PIP Sep. Example Eq, Sum & Spee. Appendix 8-7 P/P Separation Example Equipment Summary & Specification Sheets Appendix - 22 -‘App.8 ~ P/P Sep. Example REACTORS, COLUMNS & VESSELS - SUMMARY EQUIPMENT NR. Cai V-0i "MP Splitter | C-01 Reflux 20.9721.5 208 30.0/57.0, 30.0 103.1 4s 35 69.0 1.0 Sieve Trays | na, 130 na, i |na na. na, na, 1 1 Construction (2) Trays: Sara [CS Column: CS effective volume = 68.8 m? for residenc = Stainless Steel; Carbon Steel Project ID-Number Date ix - 23 = Accumulator ‘Column | Horizontal =App.8 - P/P Sep. Example HEAT EXCHANGERS & FURNACES - SUMMARY EQUIPMENTNR. =] Er Er 04 NAME +] Corovna | cor Propane Condenser_| _Reboiler Cooler Finned tubes | Themo- Fixed tube Aircooled | Syphon sheet Substance ~ Tubes Horimes | meee mC C= = Shell t LP? Steam Cooling W. [Duty TW 191.450 91,450 378 Heat Exchange area fm): | 12.760_ ay | 2.850 75 2 ‘Number ~ Series : : 7 i 1 = Parallel : - 6 : : Pressure [bara] ~ Tubes :] 209 247 260 26.0 = Shell 2] Atm. 40 40 40 Temperature In/Out rey ~ Tubes +] 500/500 | 570/570 | 500/300 | 570/300 = Shell :|25.0/41.0 | 1990/1330 | 200/400 | 200/400 Special Materials of — | Tubes : CS | Tubes 1 CS | Tubes : CS Tubes : CS Construction 2) _:| Shell_ na. | Shell_: CS_| Shell: ALBr | Shell: AbBr Oth + Plot Area 40 x 40m Remarks: (I) Bare tube surface, (2) Cs= Carbon Steel; AL-Br = Aluminum Bronze PUMPS, BLOWERS & COMPRESSORS - SUMMARY Designers: P.P Kolom W. Wisselaar Project 1D-Number CPD3201 HP. Pomp __R.G. Klep Date January 1* 1998 Appendix - 24 -App.8 —P/P Sep. Example Appendix - 25 EQUIPMENTNR.: | POT POZAB | POSAB NAME + | C01 Reflux | €-01 Bottom | Propylene Type > | Centrifugal | Centrifugat Fearne Number : 2 2 Medium ‘transferred : mOa C2 ‘Capacity Ikgs] one : | 0230 oon ors Density [kg/m'] | 450 450) fe Pressure [bara] Suct/Disch. + | 208/230 | 21.7/26.0 | 208/260 Temperature In/Out _ [°C] 2 | 50.0/500__| 570/570 | 50.0/300 Power kW] ~ Theor. [ss s 8 ~ Actual : | 75 8 13 Number ~ Theor. = Actual ila om |2 w |2 Special Materials of Construction MS casing | MScasing | MS casing Other Double Double Double Mechanical | Mechanical | Mechanical seals seals seals [sa (1) One installed spare included. Designers: P.P Kolom W. Wisselaar Project ID-Number CPDS201 H.P. Pom Date January 1° 1998App.8- PIP Sep. Example DISTILLATION COLUMN & SPECIFICATION SHEET [EQUIPMENT NUMBER: Car (AME, :__ Propylene/Propane Splitter ‘General Data [Service 7 - distillation 7 extesotion 7 absorption 7 {Column Type packed tray / spray / — [Tray Type + -eap /sieve / valve / [Tray Number ~ Theoretical 90 ~ Actual Bo + Feed (actual) 85 vay Distance (HETP) |m] [Column Diameter [ma 0.500 Tray Material =: SS314 4.500 Column Material: CS [Column Height Im]: 69.000 Heating i __-none _/ open-steam / reboiler_/ ————~ “Process Conditions ream Details Feed ‘Top | Bottom | Reflux’ | Bxtractont ra 350 [500 370 300 ware [bara] 215 208 217 209 [Density fkg/m| ; 4500 |: 4500 |; 4300 |: 4500 [Mass Flow [kg/#] |; 1.9, 69 5.0 1077 [Composition lmol% weve [moiv% wie moive wire [mol% wi% [mole wit Peopstene G00] 388] 95.0] 9481 10.0] 9.6) 950] O48] opane 40.0] 412} so | s2| 9.0] so4| so} 52 L. Column Intervals (4) ar [Packing Nor Applicable fumber of Type eaps 1 sieve holes / —— 2a [Mlateriat [Active Tray Area Wm}: Volume Weir Length mm}... fLeagth fan} [Diameter of [Width Im} chute pipe _/ hole / ——-_ fmm): [Height __Im) Remarks: 1) Tray numbering from top to bottom, (2) SS = Stainless Steel; CS = Carbon Steel [(3) Reboiter is E-01; operates with LP steam/ K4) Sketch & measures of Column & Tray layout should have been provided. |) Tray layout valid for whole column, Designers: P.P Kolom W. Wisselaar Project ID-Number __: CPDS3201 HP. Pomp _R.G. Kk Date i _January 1" 1998 Appendix - 26 -SERRE EERE EERE ER EE ‘App.8 ~ PIP Sep. Example HEAT EXCHANGER - SPECIFICATION SHEET [PquiEMENT NuMBER > —E-or Tn Series PT [NAME 2 __C-01 Overhead Condenser In Parallel: none (General Data Service = Heat Exchanger Vaporizer ~ Cooler ~ Reboiter - Condenser (Air cooled) (2). 3) Type = Fined-Fube-Sheets ~ Floating Head - Finned Tubes - Hain Pin ~ Fhermosyphon = BoubleFabe Position + ~ Horizontal ~ ¥ertiea! Capacity hwy : 1,450 (Galey Heat Exchanger Area (oy : 12,760 Cale.) Overall Heat Transfer Coefficient (Wim? *c] S10 (Approx) Log. Mean Temperature Diff.(LMTD) [°C] : 153) Passes Tube Side : 1 Passes Shell Side : ma. Correction Factor LMTD (amin, : 0.917 Corrected LMTD, : 140 ‘Shell Side "Tube Side Medium : Air Bropylene/Propane Mass Stream hes) : 5.550 114.62 Mass Stream to : tkers} : = Condense Ie/s] : na, 114.62 ‘Average Specific Heat fig *C] Lo - Heat of Evap-/Condensation ikl: : 798.0 ‘Temperature IN re} : 25.0 50.0 Temperature OUT re] : 410 50.0 Pressure fbaray Am, 20.9 Material : os cs. (4) Bare tube surface, Tubes: Ot of Ait Cooler: “Applied Chemical Process Design”, F. Aerstin and Q. Street. (2) Cooler requires 40 x 40 meters plot space, which may not be available. (3) Requires Fan(s) for forced air circulation with 960 kW for electrical drive(s). * 5/8” fin; 2 5/16” triangular pitch; Designers: PP Kolom — W. Wisselaar Project ID-Number CPDS201 H.P. Pomp _R.G. Klep Date January 1* 1998 Appendix - 27 -im ‘App.8— PIP Sep. Example HEAT EXCHANGER - SPECIFICATION SHEET Appendix - 28 - 20 eee mT + __ C01 Reboiter Tn Parallel: none (General Data ~ Cooler + Reboiler = Condenser a 7 ~ Fixed-Fube Sheets - Plate Heat Exchanger Floating Head + Fianed-Fabes - Hair Pin ~ Thermoryphon = DoubleFube : Position 7 = Horizontal 2 = Vertical Capacity Ew 7 31,450 Gale) Heat Exchanger Area [m'] + 535/2315/2,850 1) (Cale) (Overall Heat Transfer Coefficient [Wim?*c] : .0.225/0450 2) (Approx) Log, Mean Temperature Diff. (LMTD) [°C] : 102.0 Passes Tube Side : 1 Passes Shell Side 1 Correction Factor LMTD (min. 0.75) 10 Corrected LMTD ra 102.0 Process Conditions Shell Side “Tube Side Medium : [TP Steam Propane Propyfene Mass Stream Tees] 4137 114.62 Mass Stream to vaporize keys} 7 114.62 ~ Condense Tees] 4us7 : Average Specific Heat Thing *c]: 1.88 Heat of Evap./Condensation os 2200 798.0 a ‘Temperature IN rey : 190.0 310 ‘Temperature OUT re : 13.0 310 Pressure {bara}: 40 27 5 nha Elitists 23 Remar (1) Duty desuperheating, condensation and total, respectively a (2) Overall HT coefficient for desupetheating and condensation, respectively. G) CS~ Carbon Steel Project ID-Number ‘CPDS201 2 Date 15 1998a as ae ae Ss Ss SS SS SB SB SB SE ESE SE SF EF EF SS HE ‘App.8 ~ PIP Sep. Example HEAT EXCHANGER - SPECIFICATION SHEET + Cooler ~ Reboiler ~ Condenser ‘Type + ~ Fixed Tube Sheets - Plate Heat Exchanger = Double Pube e Position + ~ Horizontal = erties! Capacity TW : ua ‘Caley Heat Exchanger Area Im} : 75 (Cale.) ‘Overall Heat Transfer Coefficient [Wim *c) 460 (Approx) Log. Mean Temperature Diff. (LMTD) _[*C] : 10.0 Passes Tube Side 1 Passes Shell Side 1 Correction Factor LMTD (min. 0.75) : 10 Correeted LMTD ro : 10.0 Process Conditions Shell Side Tube Side Medium : | Propytene’Propan Mass Stream : 6.88 Mass Stream to + Evaporize tkg/s} ia FE = Condense kg/s} : - Average Specific Heat Ddrkg °C Heat of Evap/Condensation Tednegy Temperature IN tcl 5 ‘Temperatare OUT re] 5 Pressure bara]: Material __(1) : Remarks? (1) CS= Carbon Steel; ALBr = Aluminum-Bronze Designers: PP Kolom W. Wissclaar Project ID-Number CPDI201 >H.P. Pomp _R.G. Klep Date January 1" 1998 Appendix - 29 -AApp.8~ PIP Sep. Example HEAT EXCHANGER - SPECIFICATION SHEET [EqurrsenT NUMBER > Eos Tn Series (AME, 1 __ Propane Product Cooler In Paraltel | Service ‘Type Position Capacity Caley Heat Exchanger Area i (Cale) Overall Heat Transfer Coefficient (Approx) Log. Mean Temperature Diff. (LMTD) Passes Tube Side 1 Passes Shell Side 1 Correction Factor LMTD (min. 0.75) 10 Corrected LMTD_ roy 132 Provess Conditions ‘Shell Side Tube Side Medium + [Cooling Water | Propane/Propylene ‘Mass Stream tke} : 452 5.02 Mass Stream to ~ Evaporize kes] : - - ~ Condense thes} : 2 Average Specific Heat frag °C} 418 2.80 Heat of Evap/Condensation Kaneg : - ‘Temperature IN rey 200 570 ‘Temperature OUT re} 40.0 30.0 Pressure [bara) 40 26.0 Material (1) : cs Abr Remarks: (1) CS Carbon Steel; AL-Br = Aluminum-Bronze ss st Designers: P-P_Kolom W. Wisselaar Project ID-Number CPDs20r > HP. Pomp RG. Klep Date 2_January 1" 1998 Appendix - 30 -@ BH BS 2 SS |) ff ese fe a2 ee el CU ‘App.8 ~ P/P Sep. Exammple (CENTRIFUGAL PUMP - SPECIFICATION SHEET [EQUIPMENT NUMBER > F-01 AB INAME. 1 C01 Reflux Pump Installed Spare [Service Retin pump type Centrifugal Number 2 ‘Operating Conditions & Physical Data Pumped Liquid 7 Propylene / Propane ‘Temperature m re 500 Density Ug") 450 Viseastty [Nm]: 0.0001 Vapour Pressure _(p) {bara}: 20.8 at Temperature {°C]__: 50.0 Power Capacity (@) (was): 0.239 Suction Pressure (p) [bara]: 208 Discharge Pressure (p) [bara] = 23.0 ‘Theoretical Power ww} 83 {= @e-PyIP} Pump Efficiency Power at Shaft RPM Drive : ‘Type electrical motor : Tension : Yes/No Rotational direction Yes/No Counter Ct | Smothering Gland 1 Yes/No Foundation Ptate + Combined! | Eyes twoparts | - Seal Liguid : Yes/No Flexible Coupling Yes Splash Rings : Yes/No Pressure Gauge Suction No ~ Packing Type : Pressure Gauge Discharge 2 Yes = Mechanical Seal 2 Yes/No Min, Overpressure above =N PSH. Im]: | Pepa oar]: 0.1 = Construction Materials 2) ‘Pump House MS ‘Wear Rings 7 Pump Rotor + HT Steel ‘Shaft Box : Shaft 2 HY Steel Special provisions + none | Operating Pressure [bara]: 23.0 ‘Test Pressure __fparaj_: Remarks: (1) Double mechanical seals and seal fluid required for LPG service. Further details to be specified by Rotating Equipment specialist Steel; HT High Tensite Steel Designers: P.P Kolom — W. Wisselaar Project ID-Number +: CPD3201 a >_ HP. Pomp __R.G. Klep_ Date January 1" 1998 Appendix - 31 -‘App.8 - PP Sep. Example CENTRIFUGAL PUMP - SPECIFICATION SHEET [EQUIPMENT NUMBER = [NAME [Service Bottom pump Pa2 AB C01 Bottom Pump ‘Operating Installed Spare [Designers PP Kolom Ww. Wisselaar Project ID-Number ‘CPD3201 + HP Pomp _R.G. Klep Date 2 _January 1° 1998 Appendix - a Itype Centrifigat IWamber 2 ‘Operating Conditions & Piyaieal Data a Pumped Liquid = Propane / Propylene Temperature ™ to: sto Density 7) ke/m'y 2 430 Viscostty ()— [(Nes/m]: 0.0001 nO Oe ee Power Capac CT TOIT | Soction Pressure (p) [bara] 217 Discharge Pressure (py) {baral 260 ‘Theoretical Power ikw) 5 {=(@)-@e- p10} a Pump Efficiency iol ' 07 Power at Shaft IkWL 8 Construction Details 7 a RPM 7 3000 Nomi Drive Electrical ‘Suction Nozzle fe) Type electrical motor Discharge Nale [i]: Tension Mm: 380 Cooled Bearings 2 Yes/No a Rotational direction } Clock/ | Cooled Seating Box : Yes/No Gounter-Ck. | Smothering Gland : ¥es/No Foundation Plate Combined / | Ityes evoperts | | -Seal Liquid 2 Yes/No 1 Peel ile: one Preonure Gawge Suction : No ; Pressere Gauge Discharge 2 Yes 2 Yes/No | Min, Overpressure above my: |, ary: ‘i Construction Maer i Pump House MS: "Wear Rings © Pump Rover Ur sted | Shat Box : shan HT Steel Special provisions none a | Operating Pressure fbaray 23.0 Test Pressure fara): Remarks: (1) Double mechanical seals and seal uid required for LPG service. Further details to be specified by l Rotating Equipment specialist. 2) MS~= Mild Steel; HT Steel = High Tensile Stee!cee ele lo mat eeeaeee Ee aE EE Ee ‘App.8 — P/P Sep. Example CENTRIFUGAL PUMP - SPECIFICATION SHEET EQUIPMENT NUMBER : P03 7B ‘Operating T NAME C-01 Propylene Transfer Pump Installed Spare : 1 [Service Propylene wansfer pump type Centrifugal Number 2 Operating Conditions & Physical Date Pumped Liquid Propylene Propane ‘Temperature om re 50.0 Density (o) Thg/ma') 450, Viscostty (a) [N's] 0.0001 Vapour Pressure _(p,)__ [bara] 20.8 at Temperature [°C] Power Capacity 76) Ima] 0.015 Suction Pressure (p) {bara} 208 Discharge Pressure (p) [bara 260 ‘Theoretical Power kw) oo: 8 {= (@dGo- p10} Pump Efficiency Hi + 07 Power at Shaft / ee Construction Details 77 REM + 3000 Drive Electrical bed ‘Type electrical motor : Discharge Nozzle...) Tension (+ 380 Cooled Bearings Yes/No Rotational direction + Clocks | Cooled Stuffing Box Yes/No Gounter-ch, | Smothering Gland 2 Yes/No Foundation Plate + Combined / | tyes Fwoperts Yes/No Flexible Coupling Yes Yes/No Pressure Gauge Suction : No Pressure Gauge Discharge 2 Yes Yes/No ‘Min. Overpressure above [mj]: | 2pm fbar]_:_0.1 Construction Materia Pump House MS F Pump Rotor HT Steel : Shaft HT Stoel Special provisions None Operating Pressure 20 Test Pressure bara] _: Remarks: (1) Double mechanical seals and sea! fluid required for LPG service. Further details to be specified by Rotating Equipment specialist. @ M igh Tensile Stel Seer acc | Designers: PP Kolom W. Wisselaar Project ID-Number > CPD3201 HP. Pomp _R.G.Klep Date z_ January 1% 1998 Appendix - 33 -y= Ee ae ae ae ese es se se Ss Ss SF SBS SS SF SS SS EE App. 9 ~ Batch Process Example Appendix 9-1 Batch Process Example Batch Process Flow Scheme (PFS) 1. Reactor Fill with “A sth coms ig ew ie Barter 4 Vessel T102 Rewianr=b*— “P1O2 P103, PIOs Product “P* Rewiaar™B* —PLO2 P103 Pros Prodact“P* Kewaat=B* — “PIO2 PI03 PIod 4. Discharge t V101 Appendix ~ 34 -an App.9 - Batch Process Exmmgie Appendix 9-2 Batch Process Example ~ Batch Cycle Diagram ‘Batch Cycle Diagram for Unit 106, Reaction Batch Cyde Time —— with=ar Reaction AB & Cooling = Coating Down = Discharge VIO} = tte Pio = Feed “A to RIO! Pio + Feed "Bw RIM 103 | Cooling R101 reaction | - Cooling down R01 ~ Discharge RIOK Effluent - Cireulating viot Feed from P1038 Pos += Continuous feed [~—cyete times “nit Reina] Teae too Rly 1 feo 2.00 fh) me | tot 1.00 my | | rae 0.0 th] te 030 fh) 1 500 | th fi Appendix - 35 -‘App.9 — Basch Precens Exammpics Appendix 9-3 Batch Process Example ~ Batch Remarks and Calculations Remarks: 11102 requited fr discharge of R101 content to Buffer Vessel VIOL. The rate required (40 Uh) is also considered sufficient for reactor cooling during reaction and fhe ‘cooling downs to the required storage temperature in Vi01. P03 therefore operates continuously at the same pumping rate (disturbance during switch. overs) diier discharge the pump is stopped. ‘The pump can also be kept ‘unning during idle time. In {hat case, in order to prevent runing the pump by running dry, some preduet ec remai {ke reactor continuously, This, however, would contaminate the next batch: whi this hich ie cancel ae ett: the pump has to be stopped, or a pump has to be purchaced the batch system’s internal consideration. Also, these streams must be included in the Stream Summary. The average flows (With fou, Of the total batch process as reference!) must not only be calculated for streams affecting the Actual flow oceurrir _selevant cycle time (h) “ie of actual batch (h) or Actual batch fore Of total batch (h) which provides the same answer. Heat should be trated in the same way, Le. average heat flows (with ‘oxte of the total batch 4s reference!) are calculated by: ‘Actual heat flow occurring (kW) relevant cycle time (h), ‘ewse Of actual batch (h) or ctu ch (kJ) Jorte Of total batch (h)-3600 > Tyom the above, it must be clear that without a Process Flow Scheme (PFS), a Batch Cycle psgram and a Process Stam Summary (“Average Streams for Balch Preccweite Goce process is not sufficiently defined. 4. From the detailed ‘equipment calculations, the relation between the Process ‘Stream Summary data and the equipment design data must be made explicitly clear Appendix - 36 -Appendix 9-3 Batch Process Example — Batch Remarks and Calculations ‘App.9— Busch Process Examples Calculations: Dimensions: a ‘Quant Tit Unt] Fear Time a ry Th ] Mass sete eee Flow uh or kgh kikgK Energy i eereeeien lang Power kW MW CoP Flow Mim Temp. “ or K Nonit a CprTFowFaaor | Mw 3600. [Input dats and derived values: fi Productos ‘Gate times Tit | “Renate Jes 52.00 (ay fae To hl lekgeecHecees 8000 ff] sean ae 2.00 | tht | Mem | 1.00 | hy [—Reseton eh} ‘e oso | hy 300.8 100854008 ‘ 030 | thy Exotherma reaction requires cooking | Conversion reactants “A and “B" Yoo J Leta 00 | py | reo Paramercr | ‘Description Value Unie To Remarks ~Towi-n | Feed =A" RTO is STee | Feed” ORIOL 1B “Tree | Temp. React. & Cooling cycle RIOL 0 Oye ent =Tae | Temp. end Cooling down RIOT 30% ele end Rho | Forall components 1.000 va? | = hut React. Total cycle time | on Batches (Cycles) /a “Paw | Proce“ oath Reactant “A” —Potch Rectan “B” Pach EuentE” —Peatch Reactor disch, time Given lw Effluent Discharge Flow: Erlt ay Reactor Cooling Flow: ey | 2) Reaction ime Given Circulation Reactor Coting ——foatch Sexi ee |B) A in circulation Renctor Cooling oats Swick. ER, | (3), reac start Bin Circulation Reacior Cooling hatch Swick. & CR, | (3) contin feed in Cicculation Reactor Cooling batch + Bea | G4), react. Vie <106>.<107>.<1 10> during discharge. | Jn oder to avoid excessive wei, P103 continuously runs at reactor discharge capacity and is stopped 1 he end of each discharge evel. Via 106> trough mi) fmasitacion Tue [Klogam per kg [wy = mgt om eT ap Se klogam Po AB. | mele asica [ap mol pr als —— lino = mt te = Tr volume ty aim ree Frtion oo ~ lew Sl derived w special pames and symbols _ (Derived quanti ST base nit Commenis Value in Sas Nate Sane Simbel e ores newton Nike mst presurs * pascal Pa (Nim) | asseead Thar = 10 Pa | | bert) tam = 101525 kPa Liort =U mmiio = | 13331 Pa | Vkgticm? = 0.981 bar { | LemilO = 1 nar [auanty ote [9 ——T pare SICED) Teal = 1868 energy Toute Z zs work W_~Fyoate EE ‘power Twa Woy ia = Tiaew at ow rate, [wat w St derived units with special names and symbols derived from special names und symbols Derived quay Sls uni Comets Value in Tunis ‘Name | ‘Name “Symbor aE Fram 7 | passat second [Pa To (espe) viscosity jit = mPa specif 7 eae per oan Tg enthalpy zi 4 eee specific heal Te; joule pet rogram | Wikg Ry | a conan capacity hetvin J thermal i wart per meter) Wie Ry Trailer C) = 1167 conduaivity kelvin SETEEC| Wigs Eee teat wansier TAT watt per square] WAGERS Treallin™ RC) = coefficient ameter kelvin, —} 1.163 Wikn?-K) (Ctuolar enthalpy ‘oule per mole} mol i moat heat {ule per mole | Teno R) | at constant eapacsy | keWvie z pressure Appendix - 42 -App. 11 St Units & Values Notes in Tables SI prefixes to form multiples and submultiples of SI units, Molecular mass In the process industries it is oRen more convenient to use kmol instead of mol as the unit forthe amount of substance, because the molecular mass in kg/kmol has the same numerical value as the relative molecular mass M,. M(7C) = 0.012 kg/mol = 12ke/mol MC) = 12 Amount of substance {vis stil customary to express amounts of gas in terms of standard cubic meter. In the pV-product, or in or liter. For an ideal gas: 1 mv (at) (15 °C and 101.325 kPa) = 42.292 mol 1 Pam’ (275°C) = 0.4 mmol Vtorr 1 = 0,133.3 Pam? ‘Molar volume (ideal gas) Yq ~ 22.414 mmol —_(0°C and 101.325 kPa) Ve, = 23.685 m'Vkmol (15°C and 101,325 kPa) Vn = 2300.m‘/kinol (27.5 °C and 1a) Density and compressibility p= Mpltkrs) 7 = pMp(RD Compressibility factor 2 ~ 1 for an ideal gas. Wl Fagor Prax fees 108 yaa 10" eta 10 xa | 108 pera 10” tera 10° ign to mega io kite He hosto | 10! | aske ‘5. Values for Si derived Units Heat capacity of water and dry air at 101.325 kPa ‘Temperature ¢ (ki/kg K) rca Ter a © ea77 | 1.006 Is a1as8 | 1.006 20 sisi9 | 1.006 25 2176 | 1.006 (FeEa9 aims | 1006 Appendix - 43 -Values for SI derived units, compiled for quick estimates Dens) yim Overs HTC 1 air at 0°C and bar 129 steam heater i water a 4°C and 1 Atm, 1000 1 see) 7450 } “Modulus of Plasticiy (Ey Nim i steel 210,000 } concrete 14,000 - 30,000 i wood 8,000 22.000 ater cooler Micra srs, maximum allowable 3) MNin stce (lense and compressive) 100-200 steel (shear) 50-100 concrete (eompressve) 110 | steam vaporiers soncrete (shear) o7-17 tural sone (compressive) 25 brickwork (compressive) 125 “arf tension (7) Nim ater condensers agucous solutions: vate at 20°C (agains it) oor 1000 1500, so 902 cxeaies: Pas '00~ 1000 1103 210° Kinmatie visas OY mis HTC Wary water a 20°% T04 free convection fr _ait at 20 °C and 1 bar 15-10% tubes of S0°C and 1 | Bison soeien (Dy ————"prjg_———}_ bss ofS0 °C and CO; in water at 20°C 1.60.10? of 18°C Water vapor in air at O°C and | bar _25.6:10 -sondensating steam at ‘Spesiic Heat) ike Ky Dincasioaless numbers vate a2 Sebi ~ 8, Sogn seam 2 Schmid ~ igs Sop air i Seumiat — as, Prpy sel paatin 2 hydrocarbons (gas nd liquid) 33 aluminum 03 stec} os [___ concrete, pass 1 i | Tica of vaporization ae water har 220 ethanol a | bar 830 iydrocarbons 300 (practical coaitons: light st high pressure. hea in vacuum) Tower Heating Value (ATV) Mig ‘Natural gs Petroleum Brown coal Coat Cokes Thermal conductivity cocficiest @) Win RY ait 003 sass woo! 8 iydmgn 023 water 080 uur, la stunimum 27 |__commercial copper 403 i ‘Notes : "From Coulson & Richardson ‘Chemical Engineering, vol, 6, 27 ed., ‘Burterworth-Heinemann (1996) Ch.6 HTC = Heat ‘Transfer Coeficient et a Appendix - 44 -