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Chemical
Engineering
(FChE)
FINAL REPORT
PROPYLENE PRODUCTION PLANT
LECTURER
ASSOC. PROF. IR. DR. SHARIFAH RAFIDAH WAN ALWI
DESIGN TEAM
EQUINOX
1
TABLE OF CONTENTS
Page
TABLE OF CONTENTS 2
CHAPTER 1 INTRODUCTION
1.1 Background of Propylene 5
1.2 Uses of Propylene 6
1.3 Propylene Manufacturing 8
1.4 Market Survey 9
1.5 1.4.1 Introduction 9
1.4.2 Production of Propylene 9
1.4.3 Propylene Consumption 11
1.4.4 Outlook for Production of Propylene in Malaysia 12
1.4.5 Market Prices of Polypropylene 12
1.5 Raw Materials 14
1.5.1 Source of Raw Materials 14
1.5.2 Raw Material Specifications 14
2
3.1.4 Mass Balance for Reactor 37
3.1.5 Mass Balance for Separation Unit 2 38
3.1.6 Mass Balance For Separation Unit 3 39
3.1.7 Mass Balance For Separation Unit 4 40
3.2 Energy Balances 40
3.3 Simulation Result from ASPEN HYSYS 60
3.3.1 Material Balance 60
3.3.2 Energy Balances 60
3.4 Percentage Differences between Manual Calculation and HYSYS 61
3.4.1 Mass Balances 61
3.4.2 Energy Balances 61
CONCLUSIONS 79
APPENDICES A
APPENDICES B
APPENDICES C
APPENDICES D
APPENDICES E
4
CHAPTER 1
INTRODUCTION
Propylene, also called propene is generally described as a volatile and a colorless gas
at room temperature. It has same empirical formula with cyclopropane but different ways of
atom connected. Propylene is categorized as a alkene hydrocarbon compound with a molecular
formula of C3H6. The presences of the double bond make it slightly lower boiling point than
propane and thus more volatile. The existences of natural propylene are in the environment
from sources such as vegetation and combustion such as fires, motor vehicle exhaust, and
tobacco smoke. Propylene is not expected to persist in the environment. Since propylene is a
gas, the exposure of propylene into the air is expected to be lower amount when released into
the environment. Because of its relatively short half-life in the atmosphere and typically low
environmental concentrations, propylene’s contribution to potential global warming is
considered minor and its ozone depletion potential is negligible.
5
Figure 1: Structural formula of Propylene.
Propylene reacts violently with oxide of nitrogen and also a number of other substances
and condition. Essentially all of the propylene produced for chemical purposes is consumed as
a chemical intermediate in other chemical manufacturing processes. This hydrocarbon is
widely used in the manufacture of cumene, resins, fibres, elastomers and other chemicals which
enable the manufacture of many chemicals and plastics. In addition to its use as a chemical
intermediate, propylene is produced and consumed in refinery operations for the production of
gasoline components.
6
Table 1.1: Selected Propylene Application
7
Oxo Process Chemicals Propylene is used to manufacture Isobutyraldehyde, which is
converted to isobutanol solvent for surface coatings.
Propylene is also used to make n-Butyraldehyde, which is
converted to n-butanol or 2-EH. n-Butanol is a solvent for
lacquers and coatings, and is an intermediate for several
chemicals.
Lotte Chemical Titan Holding Sdn. Bhd. is one of the manufacturer and supplier of
propylene, located at Pasir Gudang, Johor Bahru. This company will be the benchmark of
Equinox Team to design a plant that can produce 100,000 lb/hr of propylene. The team will
propose a variety of production reactions of propylene and there are several production
processes such as catalytic dehydrogenation of propane, reformation of olefins reaction
(metathesis reaction), and the conversion of methanol to propylene. The most sustainable and
economically reaction processes will be chosen for the plant design. This includes the
comparison between the cost of raw materials, safety, environmental impacts, percentage yield
of conversion, energy consumption, and other factors that might affect the reaction process.
8
1.4.1 Introduction
Market survey or market outlook will cover a review on the production and
consumption of propylene in addition to that there will be another section to discuss the prices
of propylene and its raw materials.
Propene production increased in (Europe and North America only) from 2000 to 2008,
it has been increasing also in East Asia, most notably Singapore and China. Total world
production of propene is currently about half that of ethylene. About 56% of the worldwide
production of propylene is obtained as a co-product of ethylene manufacture, and about 33%
is produced as a by-product of petroleum refining. About 7% of propylene produced worldwide
is on-purpose product from the dehydrogenation of propane and metathesis of ethylene and
butylenes; the remainder is from selected gas streams from coal-to-oil processes and from deep
catalytic cracking of vacuum gas oil (VGO). The supply of propylene remains highly
dependent on the health of the ethylene industry as well as on refinery plant economics.
Figure 1.1 below shows how the production of propylene increased from 11 million
tons in 1994 to 16 million tons in 2007 but it had dropped since that time to 14.3 million tons
in 2013.
9
Figure 1.1: Wastern European Propylene Capacity, Production and Consumption 1994-2013
Top world companies are leading the production of propylene with LyondellBasell,
Netherlands on top of propylene producing companies by 2009. The top propylene-producing
companies are listed as bellow:
3.8
4
4
4
5
5.8
6.1
9
15.8
10
1.4.3 Propylene Consumption
After experiencing zero growth or declines in 2008 and 2009, global propylene
consumption grew at a rate of almost 7.5% in 2010, led by Asia at 11% year-on-year. The
economic recession of 2008/2009 reflected both a reduction in pull-through demand for
polypropylene, as well as a supply-chain inventory rundown, reminiscent of the early 1980s
downturn. World petrochemical industries have historically witnessed very few upheavals that
combined the effects of both energy volatility and depressed downstream demand.
The fifteen largest worldwide producers of propylene accounted for almost 51% of
world capacity as of 2010, representing about the same level of concentration as five years ago.
The most significant changes in the last two years have been Sinopec taking over the top spot,
a position long occupied by ExxonMobil, and PetroChina jumping from the seventh spot to
number four.
World consumption of propylene is forecast to grow slightly better than global gross
domestic product (GDP) rates over the next five years. Average growth will be 5% per year,
higher than GDP in general and higher than ethylene specifically, with growth for
polypropylene being much better than that for polyethylene. Growth will be led by the Middle
East, Asia, Central and Eastern Europe, and South America at 12.5%, 6.5%, 5%, and 4.5% per
year, respectively. Asia is a mixed bag of growth rates with China and India at 8–10% annually
and the mature economies of Japan, the Republic of Korea, and Taiwan at 1–2% per year. Near-
term growth will be relatively slow in the mature economies of North America and Western
Europe.
11
other western other asia; 3
Oceania; 1 canada; 0.5
Mexico; 1 europe; 2
Brazil; 3
France; 3
India; 4 USA; 20
Taiwan; 5
Benelux; 6
China; 19
Germany; 6
Japan`; 7
Middle Rep. of
east ; 7 korea ;
8
12
1.4.5 Market Prices of Polypropylene
Polypropylene prices are on the rise since the last decade and it is expected to
continue rising as the demand increases for the chemical material, Capacity and Prices for
Polypropylene - End-Use Sectors in Asia-Pacific to Drive Growth" 2014 market research report
says worldwide polypropylene capacity increased at a Compound Annual Growth Rate
(CAGR) of 5.2% from 2003, reaching 65 million tons per year (MMTY) in 2013, and is
expected to continue rising to 86 MMTY by 2018, at a slightly higher CAGR of 5.8%. It
forecasts China and Russia to be the leading contributors to future polypropylene capacity
increases, and will account for a combined 45% of global additions over the next five years.
As Malaysia is part of the global market it is normal for prices in Malaysia to be affected by
the global prices, following are prices of PP and its raw material (propane, ethylene, butene
and methanol) as achieved from ICIS.com.
13
1.5 Raw Materials
The raw material that is utilized in this process is liquefied petroleum gas (LPG)
propane. The term LPG actually encompasses more than one variety of gaseous fuel. There
are a number of hydrocarbon gases that fall into the classification of “LPG”. Their common
distinguishing characteristic is that they can be compressed into liquid at relatively low
pressures. LPG is stored under pressure, as a liquid, in a gas bottle. It turns back into gas vapor
when you release some of the pressure in the gas bottle by turning on your appliance. Almost
all of the uses for LPG involve the use of the gas vapor, not the liquefied gas.
The gases that fall under the “LPG” label, including Propane, Butane, Propylene,
Butadiene, Butylene and Isobutylene, as well as mixtures of these gases. The two most
common are Propane and Butane.
The main supplier of LPG used in this process is Kleenheat Gas which is part of
Wesfarmers Chemicals, Energy and Fertilizers, one of eight divisions of Wesfarmers Limited,
with origins dating back to 1914.
They have a long history in the Australian gas industry with over 55 years of experience
retailing and distributing Liquefied Petroleum Gas (LPG), over a decade of experience
distributing Liquefied Natural Gas (LNG) and advancing technology through their brand
EVOL LNG, and most recently retailing natural gas in Western Australia.
Propane 80
Butane 18
14
CHAPTER 2
15
About 86 wt% of propane is converted to propylene. To mitigate cracking reactions,
dehydrogenation reaction in this technology occurs in conditions such as temperature
ranges between 580 and 650 °C, and pressures slightly below atmospheric. For further
information, Table 2.1 shows the thermophysical property data for this process.
16
Process Description of Propylene Dehydrogenation
From Figure 2.2, the process flow diagram consists of a reactor section, product
recovery section and catalyst regeneration section. Hydrocarbon feed is mixed with
hydrogen-rich recycle gas and is introduced into the heater to be heated into the desired
temperature (over 540 °C) and then enter the reactors to be converted at high mono-
olefin selectivity. Several interstage heaters are used to maintain the conversion through
supplying heat continuously since the reaction is endothermic. Catalyst activity is
maintained by continuous catalyst regenerator (CCR) or shutting down reactors one by
one and regenerating the reactor by the regeneration air, the continuous catalyst
regenerator is where the catalyst is continuously withdrawn from the reactor, then
regenerated, and fed back to the reactor bed.
Table 2.1: Physical And Chemical Properties Of Reactant And Product For
Dehydrogenation Reaction
Properties
17
Appearance Colourless gas Colourless gas Colourless gas
Density 2.0098 mg mL−1 (at 0 1.81 kg/m3, gas (1.013 0.08988 g/L (at 0 °C,
°C, 101.3 kPa) bar, 15 °C) 101.325 kPa)
3
613.9 kg/m , liquid
Melting point −187.7 °C; −305.8 °F; − ,185.2 °C (−301.4 °F; 13.99 K (−259.16 °C,
85.5 K 88.0 K) −434.49 °F)
Boiling point −42.25 to −42.04 °C; − 47.6 °C (−54 °F; 20.271 K (−252.879 °C,
−44.05 to −43.67 °F; 226 K) −423.182 °F)
230.90 to 231.11 K
Vapor pressure 853.16 kPa (at 21.1 °C) 144.06 psia 100kPa (at 20 ºC)
Thermochemistry
To screen out whether this reaction will bring profit or not, the gross profit is calculated as
shown below:
C3H8 C3H6 + H2
C3H8 C3H6 H2
lbmol 1 1 1
Molecular weight 44.09 42.08 2.016
lb 44.09 42.08 2.016
lb/lb of propylene 1.0478 1 0.048
RM/lb 0.79 1.96 11.30
18
Gross profit for reaction path 1 = 1.96(1) + 11.30(0.048) – 1.0478(0.79) = RM 1.67 /lb
propylene
Metathesis Reaction
19
Figure 2.4: Detailed process flow diagram (Metathesis)
us C4 recycle) are mixed with ethylene feed (plus recycle ethylene) and sent
through a guard bed to remove trace impurities from the mixed feed. The feed is heated
prior to entering the vapour phase fixed-bed metathesis reactor where the equilibrium
reaction takes place. The reactor is regenerated in-situ on a regular basis. The catalyst
promotes the reaction of ethylene and butene-2 to form propylene and simultaneously
isomerises butene- 1 to butene-2. The per-pass conversion of butylene is greater than
60 per cent, with overall selectivity to propylene exceeding 90 per cent.
The product from the metathesis reactor is primarily propylene and unreacted
feed. Reactor effluent is sent to the ethylene recovery tower where the unreacted
ethylene is recovered and recycled to the reactor. The C2 tower bottom is processed in
the C3 tower to produce propylene product and a C4 recycle stream. Purge streams
containing non-reactive light material, C4s and heavier are also produced. Ultra-high
20
purity propylene exceeding polymer grade specification is produced without a
propylene fractionation system, since the only source of propane is that contained in
the C4 and ethylene feeds.
Table 2.2: Physical And Chemical Properties Of Reactant And Product For Metathesis
Reaction
Properties
Density 1.178 kg/m3 at 15 °C, gas 0.62 g/cm3 1.81 kg/m3, gas (1.013 bar,
15 °C)
613.9 kg/m3, liquid
Melting point −169.2 °C (104.0 K, - −185.3 °C (−301.5 °F; − ,185.2 °C (−301.4 °F;
272.6 °F) 87.8 K) 88.0 K)
Boiling point −103.7 °C (169.5 K, - −6.47 °C (20.35 °F; − 47.6 °C (−54 °F; 226 K)
154.7 °F) 266.68
Thermochemistry
21
To screen out whether this reaction will bring profit or not and whether it is better from reaction
A, the gross profit is calculated as shown below:
Lbmol 1 1 2
Molecular weight 28.05 56.10 42.08
Lb 28.05 56.10 84.16
lb/lb of propylene 0.33 0.667 1
RM/lb 2.16 1.18 1.96
Gross profit for reaction path 2 = 1.96(1) – 2.16(0.33) – 1.18(0.667) = RM 0.46 /lb
propylene
22
Table 2.3: Summary of Review and Screening of Alternative Processes
Metathesis of from
Dehydrogenation of propane
Ethylene & Butenes
C3H8 C3H6 + H2
C2H4 + C4H8 2C3H6
Gross Profit
RM 1.67 / lb propylene RM 0.46/lb propylene
(Appendix 1)
From the table above, it shows that the dehydrogenation of propane reaction is a better process
compared to the metathesis reaction.
23
2.2 Step 2 – Distribute the Chemicals
Reactor
T = 500 OC
R lb/hr C3H8
C3H8 C3H6 H2
Stoichiometry 1 1 1
Mass flowrate (lb/hr) m1 m2=100,000.00 m3
Assume 100% conversion, the mass flow rate of feed, m1 = 2376.43 x 44.1
= 104800.56 lb/hr
24
for 86% conversion, the mass flow rate of recycle, R = (1-0.86)/0.86 x 104800.56
R = 17060.53 lb/hr
Mass flowrate of H2 , m3
= (no. of mole) X (molecular weight)
= (2376.43) x (2.01)
= 4776.62 lb/hr
25
2.3 Step 3 – Eliminate Differences in Composition
Pt-Sn C3H6
0.99 C3H8 H2 H2 C3H8 C3H6
0.009 C4H10 C3H8 -137.1˚c 40˚C
0.001 C5H12 Reactor C3H6
600˚C, 1.0 bar C4H8 33˚C
47°C
C4H10
C5H12
10 bar
17.5 bar
S2
52.°C
S1 15 bar S3 S4 15 bar
LPG: -137.1°C 42˚C
C3H8
C4H10
C5H12 -137.1˚C
C3H8
C3H6
108.4˚C
110.7°C C4H8
C4H10 C4H8 42˚C
C4H10
C5H12 C5H12 C4H10 C3H8
C5H12
In order to enable all chemicals involved to be supplied to their sinks, separation operations are needed.
Figure 2.5 shows the separation units that are needed in a propylene production process. Since the raw material
using in this process is from LPG that consists 80% propane, 18% butane and 2% pentane, so S1 as a separating
unit is needed to separate propane from butane and pentane. However, the separation is not perfect. There will
still have some butane and pentane that will be distillate but in a small proportion. As referred to table 2.4, S1
will be operated at 15bar. The bubble point at distillate product is 47˚C and the dew point of mixtures at the
bottom product is 110.7˚C.
When the separation between propane, butane and pentane is done, propane as a reactant will enter the
reactor which will be operate at 600˚C and 1 bar. These pressure and temperature is selected because the
dehydrogenation process of propylene only will occur at these conditions.
After the reaction occurs, there have a lot of products produced. In order to separate the products, 3
separation units will be used. The first product that will be separated is hydrogen gas. The reason is, hydrogen
gas has a low value of critical pressure and it will be difficult to separate the other products if the hydrogen
26
maintain in the product mixtures. S2 will be used as separation unit that will be operated at pressure 10 bar and
temperature -137.1 at dew point of vapor of the product mixture.
Next, after separate hydrogen gas, we will separate propane and propene from the side product. From
Table 2.4 at 1 atm, the boiling point of C3 is very low, - 48˚C, and hence if C3 were recovered at 1 atm as the
distillate of the S3, very costly refrigeration would be necessary to condense the reflux stream. At 18 bar , the
bubble point of propane and propylene mixture is at 40˚C and much less cost refrigeration could be used. The
bottom products which are consists butane, butene and pentane has a dew point 108.4˚C at 17.5 bar.
After separation unit S3 is inserted into the process design, S4 follows naturally. The distillate from S3
is separated into nearly pure species in the S4, which is specified at 15 bar. Under these conditions, the distillate
(nearly pure propylene) boils at 33˚C and can be condensed with inexpensive cooling water, which is available
at 25˚C. However, S4 need special separation unit due to small difference of boiling point between propane and
propylene.
27
2.4 Step 4 – Eliminate Differences in Temperature, Pressure, and Phase
Figure 2.6: Flowsheet with temperature-, pressure-, and phase-change operations in the propylene production process.
28
Figure 2.6 shows the changes of the state of chemicals. Since the original state of the raw
material (LPG) is at 20°C and 18 bar, its temperature is raised to 52°C at 15 bar. The LPG is then
introduced into a separation column (S1) at 15 bar with 99% conversion that separates the propane
gas from other LPG products. Here, only 99% of LPG is converted to propane gas where another
1% is butane gas and pentane gas.
The process begins by mixing the upper products from S1 (propane gas, butane gas and pentane
gas) with a stream of recycle propane gas at 47°C and 15 bar. The mixing of upper products from
S1 and recycle propane undergoes the following operations:
1. The product mixture is preheated before it is introduced to the reactor. The reaction occurs
at around 600oC and 1 bar.
2. The products mixture is then cooled to its dew point -137.1oC at 10 bar.
3. Then, the product mixture is introduced into a condenser (S2) that separates the hydrogen
gas from other liquid products.
In addition, the liquid mixture that condensed at -137.1oC at 10 bar from the condenser is
operated upon as follows:
Next, the upper products (propane gas and propylene gas) from separation column (S3) are
then entered into separation column (S4) at 40oC. The propylene gas with a boiling point of 33oC
at 15 bar is come out as an upper product from separation column (S4).
Finally, the propane liquid from the recycle stream (at 42oC and 15 bar) undergoes the
operation where its temperature is raised to the mixing temperature at 47 oC at 15 bar.
29
2.5 Step 5 – Task Integration
Figure 2.7 shows task integration for the propylene production process. At this stage in process
synthesis, it is common to make the most obvious combinations of operations, leaving many
possibilities to be considered when the flowsheet is sufficiently promising to undertake the
preparation of a base case design. Below are the descriptions of unit process shown in Figure 2.7:
1. Heat exchanger
Heat exchanger is needed to increase or decrease the temperature of the stream. A heat
exchanger is a piece of equipment built for efficient heat transfer from one medium to
another. The media may be separated by a solid wall to prevent mixing or they may be in
direct contact.
2. Depropanizer
A propane rich liquefied petroleum gas (LPG) feedstock is sent to a depropanizer to reject
butanes and heavier hydrocarbons.
3. Furnace
Since the outlet temperature from the mixer is 47˚C and we need to increase the
temperature to 600˚C, the furnace is used to heat up the stream. This follows heuristics 26
which explained near-optimal minimum temperature approaches in heat exchangers
depend on the temperature level. For 250 to 350˚F, the stream must be heat up in a furnace
for flue gas temperature above inlet process fluid temperature. An industrial furnace or
direct fired heater is equipment used to provide heat for a process or can serve as reactor
which provides heats of reaction. Furnace designs vary as to its function, heating duty, type
of fuel and method of introducing combustion air.
4. Oleflex Reactor
The UOP Oleflex process is a catalytic dehydrogenation technology for the production of
light olefins from their corresponding paraffins. One specific application of this technology
produces propylene from propane. The Olexflex process uses a platinum catalyst to
promote the dehydrogenation reaction
30
5. Pump
Since the pressure change operation involves a liquid, it is accomplished by a pump, which
requires only 66 Bhp, assuming an 80% efficiency. The enthalpy change in the pump is
very small and the temperature does not change by more than 1˚C
6. Distillation Column
To separate the mixture of C3 and butane, butane and pentane, distillation column is
selected as the best separation unit. Distillation is based on the fact that the vapour of a
boiling mixture will be richer in the components that have lower boiling points. Therefore,
when this vapour is cooled and condensed, the condensate will contain more volatile
components. At the same time, the original mixture will contain more of the less volatile
material.
7. Propane-Propylene Splitter
C3 splitters are frequently designed with vapor-recompression heat pumps when sufficient
low-energy heat sources are not available. The heat of vaporization of propylene and
propane at 100psia are nearly identical. The only energy needed for a C3 splitter heat pump
is the compressor duty, which is typically only 11-12% of the total reboiler duty. Therefore,
the energy savings are significant. In addition, C3 splitter heat pump system operates at
much lower pressure than conventional columns without heat pumping. The high-pressure
compressor discharge stream is the same as the conventional tower’s top pressure.
31
P-P Splitter
Figure 2.7: Flowsheet task integration for the propylene production process
32
CHAPTER 3
Reactor
T = 500 OC
R lb/hr C3H8
33
C3H8 C3H6 H2
stoichiometry 1 1 1
Mass flowrate (lb/hr) m1 m2=100,000.00 m3
34
3.1.2 Mass Balance for Separation Unit 1
2
D1 lb/hr
0.990 C3H8
0.009 C4H10
0.001 C5H12
1
F1 lb/hr S-1
0.80 C3H8
0.18 C4H10
0.02 C5H12
3
B1 lb/hr
0.90 C4H10
0.10 C5H12
35
3.1.3 Mass Balance for Mixer
36
3.1.4 Mass Balance for Reactor
The percentage of conversion for propane and butane are 86% and 90% respectively and since
the weight percent of pentane is too small, we assume that pentane is remain unreacted.
Stream 4 Stream 5
37
3.1.5 Mass Balance for Separation Unit 2
H2 4811.36 lb/hr
6
123299.61 lb/hr
5
S-2
C3H8
7 118488.25 lb/hr
C4H10 C3H8
C5H12 C4H10
C3H6 C5H12
C4H8 C3H6
H2 C4H8
38
3.1.6 Mass Balance for Separation Unit 3
117060.68 lb/hr
8
C3H8
C3H6
118488.25 lb/hr 7
S-3
C3H8
C4H10
C5H12 1427.57 lb/hr
C3H6 C4H10
C4H8 9 C5H12
C4H8
39
3.1.7 Mass Balance for Separation Unit 4
100000 lb/hr
11
C3H6
117060.68 lb/hr
8
S-4
C3H8
C3H6
17060.53 lb/hr
10
C3H8
40
3.2 ENERGY BALANCES
Cp=A+B*T+C*T^-2+D*T^-3
Cp=A+B*T+C*T^-2+D*T^-3
Average
Molecular ∆Hv Cp for
Compound ∆Hf
Weight Kj/mol liquid
A*10^3 B*10^5 C*10^8 D*10^12 KJ/(mol.K)
-
Propane 44.09 18.77 68.023 22.59 -13.11 31.71 0.10584
103.8
-
Butane 58.12 22.306 92.3 27.88 -15.47 34.98 0.13367
124.7
-
Pentane 72.15 25.77 114.8 34.09 -18.99 42.26 0.167
146.4
41
Energy Balance
We use heat of vaporization instead of liquid heat capacities to calculate the stream
enthalpy and the value stated in Table 3.1. For a mixed stream, both equations are applied based
on the vapor/liquid fraction involved. If there is no reaction occur in a unit (i.e. initial component
= final component), enthalpy change for the unit is express as below:
Qv n y k [ C po.k (T )dT H f ,k ]
T2
(Vapor)
T1
k
2
D1 lb/hr
0.990 C3H8
0.009 C4H10
0.001 C5H12
1
F1 lb/hr S-1
0.80 C3H8
0.18 C4H10
0.02 C5H12
3
B1 lb/hr
0.90 C4H10
42
Liquid phase
Stream temperature, T = 325.13 K and consider datum at 298.13 K
∑ 4077274.484 KJ/hr
For Stream 2
Liquid phase
Stream temperature, T = 320.13 K and consider datum at 298.13 K
∑ 2543540.36 KJ/hr
43
For Stream 3
/Stream temperature, T = 377.13 K and consider datum at 298.13 K
∑ 46962.25 KJ/hr
44
3.2.2 Heat exchanger 1
∑ 4832325.3 KJ/hr
45
3.2.3 Furnace
∑ 100118475 KJ/hr
46
3.2.4 Energy balance for Heat Exchanger 2 (HE2)
47
3.2.5 Energy Balance for Flash Separator (S2)
Stream 6
1˚C
Stream 5
Flash separator
1˚C
Stream 7
1˚C
∫CpdT
Compound Flowrate (kJ/mol) n∆H
(mol/hr)
H2 2393.7 -0.6922 -1656.91914
C3H8 386.86 -2.5392 -982.314912
C3H6 2376.4 -2.8776 -6838.32864
C4H10 1.9203 -3.2082 -6.16070646
C4H8 17.283 -2.255 -38.973165
C5H12 4.8009 -4.008 -19.2420072
∑ 5180.9642 -15.5802 -9541.938571
∫CpdT
Compound Flowrate (kJ/mol) n∆H
(mol/hr)
H2 2393.7 -0.6922 -1656.91914
∫CpdT
Compound Flowrate (kJ/mol) n∆H
(mol/hr)
C3H8 386.86 -2.5392 -982.314912
C3H6 2376.4 -2.8776 -6838.32864
C4H10 1.9203 -3.2082 -6.16070646
C4H8 17.283 -2.255 -38.973165
C5H12 4.8009 -4.008 -19.2420072
48
∑ 2787.2642 -14.888 -7885.019431
𝑄 = 𝛥𝐻 = 𝟎
Q = n∆Hout - n∆Hin
= 0 kJ/hr
49
3.2.6 Energy balance for heat exchanger 3
Stream Stream
inlet outlet
1˚C 42˚C
∫CpdT
Compound Flowrate (kJ/mol) n∆H
(mol/hr)
C3H8 386.86 1.2825 496.14795
C3H6 2376.4 1.1118 2642.08152
C4H10 1.9203 1.7249 3.31232547
C4H8 17.283 1.5516 26.8163028
C5H12 4.8009 2.1421 10.28400789
∑ 2787.2642 7.8129 3178.642106
Q = n∆Hout - n∆Hin
= 3178.642106– (-7885.019431)
= 63273.40588 kJ/hr
50
3.2.7 Energy Balance for Compressor (C1)
Inlet (stream 2)
Phase Vapor
Component Mixture
Pressure (bar) 1
Temperature (oC) 600
Total Molar Flow Rate (kmol/hr) 2349.64
Outlet (stream 3)
Phase Vapor
Component Mixture
Pressure (bar) 10
Hence,
51
𝟏.𝟑−𝟏
10 ( 𝟏.𝟑
)
𝑻𝟐 = 𝟔𝟎𝟎 ( )
𝟏
= 𝟏𝟎𝟐𝟎. 𝟕𝟓˚𝑪
For energy balance,
̂ 𝒊 − ∑ 𝒏𝒊 𝑯
𝑸 = ∆𝑯 = ∑ 𝒏𝒊 𝑯 ̂𝒊
𝒐𝒖𝒕 𝒊𝒏
𝑻 𝑻
= ∑ 𝒏𝒊 ∫ 𝑪𝒑 𝒅𝑻 − ∑ 𝒏𝒊 ∫ 𝑪𝒑 𝒅𝑻
𝒐𝒖𝒕 𝟐𝟗𝟖.𝟏𝟓 𝒊𝒏 𝟐𝟗𝟖.𝟏𝟓
× 10−12 𝑇 3 𝑑𝑇]
= 2476050.63 kJ/hr
52
3.2.8 Separation Unit 3 (S3)
117060.68 lb/hr
8
C3H8
C3H6
118488.25 lb/hr 7
S-3
C3H8
C4H10
C5H12
C3H6
C4H8 1427.58 lb/hr
9
C4H10
For Stream 7 C5H12
C4H8
Liquid stream
Stream temperature, T = 315.15 K and consider datum at 298.15 K
53
Butene 17.28 7836.735 0.09396 1.5973 12517.62
∑ 2533034.15
For Stream 8
Gas stream
Stream temperature, T = 317.15 K and consider datum at 298.15 K
2.8080 x 106
∑
For Stream 9
Liquid stream
Stream temperature, T = 381.55 K and consider datum at 298.15 K
54
∑ 101449.38
11
D1 lb/hr
C3H6
8
F1 lb/hr S4
C3H8
C3H6
12
B1 lb/hr
C3H8
For Stream 8
Liquid stream
Stream temperature, T = 318.15 K and consider datum at 273.15 K
55
66.51917 х 105
∑
For Stream 11
Gas stream
Stream temperature, T = 309.15 K and consider datum at 273.15 K
24.33963 х 105
∑
For Stream 12
Liquid stream
Stream temperature, T = 320.15 K and consider datum at 273.15 K
8.73105 х 105
∑
56
3.2.10 Pump (P1)
outlet
inlet
Inlet Stream
Phase Liquid
Pressure (bar) 1
Temperature (oC) -47
Outlet Stream
Phase Liquid
Pressure (bar) 18
Temperature (oC) -47
Q = ∑Fv ( P)
Q = 28906.35 х (18 -1) = 4.91408 х 105 kJ/hr
57
3.2.11 Energy Balance for Reactor
H2
C3H8 (g), 873K (600˚C), 1 bar C3H6 (g), 873K (600˚C), 1 bar
̂𝑅
𝐻 ̂𝑃
𝐻
>
>
>
C3H8 (g), 298K (25˚C), 1 bar C3H6 (g), 298K (25˚C), 1 bar
̂𝑟1
∆𝐻
̂𝑅2 + 𝑛𝐻
𝑄2 = 𝑛𝛥𝐻 = 𝑛 ∑ 𝑛𝐻 ̂𝑝2 + ∆𝐻
̂𝑟2 (for Butane)
𝑄 = 𝑄1 + 𝑄2
58
1. Energy balance for Propane
Component ̂𝑅1
𝐻 ̂𝑝1
𝐻 ̂𝑟1
∆𝐻
Flow rate
1253192.74 2330911.57 -
(mol/hr)
Specific
̂
Enthalpy, 𝐻 -91.8 184.72 -
(kJ/mol)
∆H
-115043093.5 430565985.2 140.21
(kJ/hr)
∑ 315523031.9
Component ̂𝑅2
𝐻 ̂𝑝2
𝐻 ̂𝑟2
∆𝐻
Flow rate
8708.84 16547.07 -
(mol/hr)
Specific
̂
Enthalpy, 𝐻 -119.0 240.61 -
(kJ/mol)
∆H
-1036351.96 3981390.5 125.87
(kJ/hr)
∑ 1945164.41
𝑄 = 𝑄1 + 𝑄2
kJ kJ
𝑄 = 315523031.9 + 1945164.41
hr hr
Q = 317.468 x 106 kJ/hr
59
60
3.3 Simulation Result from ASPEN HYSYS
3.3.1 Material Balance
Mass
Stream no. (lbmole/hr)
(Hysys)
stream 1 3179
stream 2 3179
stream 3 769.4
stream 4 2410
stream 5 2523
stream 6 2523
stream 8 4692
stream 9 4692
stream 10 4692
stream 11 4692
stream 12 2533
stream 13 2159
stream 14 2533
stream 15 2533
stream 16 156.3
stream 17 2377
stream 23 2263
stream 24 113.4
stream 25 113.2
Energy, kJ/h
Equipment
(HYSYS)
Q-HE00 5.76E+06
Q-HE01 1.79E+08
Q-HE02 1.65E+07
Q-Furnace 9.23E+07
Q-Compressor 6.78E+07
Q-Pump 6.90E+04
61
3.4 Percentage Difference between Manual Calculation and HYSYS Calculation
3.4.1 Mass Balance
Mass Mass
Stream no. (lbmole/hr) (lbmole/hr) % Diff
(manual) (Hysys)
stream 1 2971 3179 6.54
stream 2 2971 3179 6.54
stream 3 721.5 769.4 6.23
stream 4 2400.4 2410 0.40
stream 5 2787.3 2523 10.48
stream 6 2787.3 2523 10.48
stream 8 5181 4692 10.42
stream 9 5181 4692 10.42
stream 10 5181 4692 10.42
stream 11 5181 4692 10.42
stream 12 2787 2533 10.03
stream 13 2393 2159 10.84
stream 14 2787 2533 10.03
stream 15 2787 2533 10.03
stream 16 165.4 156.3 5.82
stream 17 2663.5 2377 12.05
stream 23 2376.4 2263 5.01
stream 24 124.5 113.4 9.79
stream 25 124.5 113.2 9.98
62
CHAPTER 4
HEAT INTEGRATION
∆Tmin = 10˚C
63
4.2 Algorithm Table
∑FCpC -∑FCpH
T (˚C) ∆T (˚C) ∆Hi (MW) 1st Cascade
0.049 (MW/K)
865.70 H1 0
Pinch
h
284.4 -0.049 -13.9356
581.30 13.94
55.08 14.46
48.85 C2 14.14
0.048
13.85 0.004 0.0554
35.00 14.08
10 0.032 0.3200
25.00 C1 13.76
0.053
156.8 -0.021 -3.2928
-131.80 C3 17.06
0.028
10.3 -0.049 -0.5047
17.56
-142.10
Qc min
64
4.3 Heat Exchanger Network
T pinch
∆H (MW) FCp(MW/K) (870.7˚C)
1.5942 0.053 C1
50.08 20
25.5576 0.048 C2
576.3 43.85
4.6704 0.028 C3
30 -136.8
H1 E1
49.3822 0.049 E2 E3 C
1 2 -137.1
870.7 25.5576 1.5942 4.6704 17.56
65
Figure 4.3:
66
. Process Flow Diagram Heat Exchanger Network
67
CHAPTER 5
OPTIMIZATION
Optimization is the tool to maximize our profit by minimizing the supply of raw material
and maximizing the product. In this case, our target that we want to maximize it the production
of propene (100000 Ib/hr) and our supply that we want to minimize it is the propane which is
initially set to 104800 Ib/hr depending on the stoichiometric coefficient of (propane/propene
=1.048) and (Hydrogen/propene= 0.0457).
Ibmol 1 1 1
Step 1:
68
Define decision variables:
P1= amount of product (Propene)
P2=amount of byproduct (Hydrogen)
R=amount of reactant (Propane)
Z=maximum profit
Step 2:
Define objective function
Maximum profit (Z) = (1.96*P1 +11.3*P2)-(0.79*R)
Step 3:
Defining equality and inequality constraints:
a) Inequality constraints
Propane supply R << 104800 Ib/hr
Propene production P1>> 100000 Ib/hr
b) Equality constraints
R= 1.048*P1
P2=0.0457*P1
c) Non-negativity constraint
R, P1, P2 ≥ 0
Step 4
69
Optimization technique
We used solver add-in in Microsoft excel:
P1=100000 Ib/hr
P2=4789.36 Ib/hr
R=104800 Ib/hr
Z=167327.768 RM/hr
After optimization the maximum profit is close to the manually calculated one= RM
167327.768/hr.
70
CHAPTER 6
6.1 Introduction
In this chapter, the equipment sizing is done to all equipment that is involved in the
proposed propylene production plant. Equipment sizing is a very important aspect of process
design as it enables the subsequent analysis that is involved in process design such as
mechanical design and economy analysis. The sizing involves the reactors, distillation column,
compressor, pump, and heat exchangers.
6.2 Reactor
Parameter SI
Volumetric Flowrate , Q 3517.02 ft3/hr
Retention time (half-full), t 5 min
Reactor Volume, V 586.17 ft3
Vessel Inside Diameter, Di 7.20 ft
Vessel Length, L 14.4 ft
Design Type Vertical
Material of Contruction Low- Alloy Steel SA-387B
71
6.2.2 Costing of Reactor
6.3 Pump
Parameters S1
Domed head wall
13.7 mm
thickness, a
Tray spacing, b 2ft
72
Column wall thickness,
0.5 in
d
Mineral
Material of insulation
wool,60mm
Costing in $:
Parameters S1
Domed head wall
13.7 mm
thickness,
73
Material of Construction Carbon steel
Mineral
Material of insulation
wool,60mm
After bare-model:
Cost= $ 223290
Parameters S1
Length of tube 20 ft
fixed head,
Type of HE shell tube
exchanger
Cp= $ 21721
After bare-module,
Cost= $ 68857
74
6.4.4 Sizing and costing of the re-boiler:
Parameters S1
Length of tube
20 ft
CB= $ 65325
With bare-module
$ 3.17(65325) = $ 207080
Total 984036
75
6.5 Compresssor
6.5.1 Main Sizing Parameters
Parameters Compressor
Compressor Type Centrifugal
Drive Type Steam turbine
Material of Construction Stainless steel
Inlet Volumetric Flow Rate, QI 83283.83 ft3/min
Inlet Pressure, PI 14.5 psi
Outlet Pressure, PO 72.52 psi
Specific Heat Ratio, k 1.10
6.5.2 Costing in $:
Hot Cold
Tin (C̊) 870.7 43.85
Tout (C̊) 349.12 576.3
76
LM 314.74o F
870.7 349.12
R
576.3 43.85
R 0.98
576.3 43.85
S
870.7 43.85
S 0.644
Ui = 235.5 Btu/oF.ft2.hr
5.44x106 Btu / hr
Ai
235.5 Btu / oF . ft 2 .hrx0.85x314.74o F
Ai 86.34 ft 2
Velocity of tube-side;
111244.12lb ft 3 hr
Aci x x
hr 0.421lb 1.68x106 ft
Aci 0.157 ft 2 / pass
By using 0.75 in. O.D. 16 BWG tubing with I.D. of 0.62 in.;
0.302in 2 ft 2
Inside area/tube = x
tube 144in 2
= 2.097x10-3 ft2/tube
77
0.157 ft 2 / pass
Nt
2.097x10 3 ft 2 / tube
N t 75tubes / pass
86.43 ft 2
=
4 passx75tubes / pass
= 0.288 ft2/tube
0.288 ft 2 / tube
L
0.62in
x
12in / ft
L = 5.58 ft
Ai 86.34 ft 2
FBM = 3.17
86.34 0.5
𝐹𝑀 = 1.08 + ( )
100
= 2.01
145.04 145.04 2
𝐹𝑃 = 0.9803 + 0.018 ( ) + 0.0017 ( )
100 100
= 1.01
Fixed head:
𝐶𝑃 = (2.01)(1.25)(1.01)(7,334.88)
= $18,613.18
78
CHAPTER 7
By using method 3, which is based on the individual factors method of Guthrie, 1969,
1974 there are few steps to find the total capital investments, CTCI.
Firstly, we need to prepare an equipment list, giving the equipment tittle, label, size,
material of construction, design temperature, and design pressure.
After we get the value of total bare module cost, CTBM, we need to find the site
development cost, Csite, building cost, Cbuildings, and offsite facilities cost, Coffsite facilities by
assuming some factor. The calculation of total capital investment cost is shown below:
79
Assume it is grass-roots plant, the value fo CSITE is 10-20% of CTBM. Assume we take
15% of CTBM.
CSITE = 0.15 (17,081,138)
CSITE = $ 2,562,170.75
Thus,
CTCI = CTPI + CWC
CTCI = $ 39,969,863.01+ $ 7,034,695.89
CTCI = $ 47,004,558.90
80
7.2 Payback Period
Payback period is the time in which the initial cash outflow of an investment is expected
to be recovered from the cash inflows generated by the investment. It is one of the simplest
investment appraisal techniques.
The formula to calculate payback period of a project depends on whether the cash flow
per period from the project is even or uneven. In case they are even, the formula to calculate
payback period is:
Initial Investment
Payback Period =
Cash Inflow per Period
𝑅𝑀 152,764,816.40
=
RM 167,327.77/hr
𝟏 𝒅𝒂𝒚 𝟏 𝒎𝒐𝒏𝒕𝒉
= 𝟗𝟏𝟐. 𝟗𝟔𝟕 𝒉𝒓 × ×
𝟐𝟒 𝒉𝒓 𝟑𝟎 𝒅𝒂𝒚𝒔
= 1 month 9 days
81
CONCLUSION
Propylene is one of the highest volume of chemicals produced globally and primarily
used as an intermediate for the production of other chemical raw materials. These chemical
raw materials are then subsequently used to manufacture a large variety of substances and
products. Example of such product is propylene, a widely used plastic where the manufacturing
process consumes more than half of the world’s production of polypropylene. There are other
uses as well, such as manufacture of acrylonitrile, oxo process chemicals, cumene, isopropanol,
polygas chemicals, and propylene oxide. This shows that the production of propylene has its
demand in the global industry, hence a good marketability, especially in recent years where the
price of propylene in the market is expected to continue rising as the demand increases for the
chemical material. Market research report says worldwide polypropylene capacity increased at
a Compound Annual Growth Rate (CAGR) of 5.2% from 2003, reaching 65 million tons per
year (MMTY) in 2013, and is expected to continue rising to 86 MMTY by 2018, at a slightly
higher CAGR of 5.8%. As Malaysia is a part of the global market, it can be expected that prices
in Malaysia to be affected by the global prices.
In terms of reaction pathways for this particular project, a screening process was done
based on gross profit, economic potential as well as other factors related such as energy
consumption, toxicity, safety and environmental impacts. There are two reaction pathways
suggested for the production of propylene, which are dehydrogenation of propane, and
metathesis reaction of ethylene and butene. From the screening process, it was shown that
dehydrogenation of propane reaction is a better process compared to the metathesis reaction.
Based on the gross profit calculation, a dehydrogenation process would bring in a gross profit
of RM 1.67/lb propylene with 86% conversion compared to only RM 0.46/lb propylene for
metathesis reaction with a 90% conversion yield. Since the calculation was based on gross
profit, further analysis need to be done in order to optimize the production process of propylene
via the dehydrogenation of propane process for a sustainable plant design.
In addition to the reaction pathways and process screening, a process synthesis for the
production of propylene from dehydrogenation of propane was done by following the steps
82
that was introduced by Rudd, Powers, and Siirola. From these steps, a general overview of the
whole process, starting from the raw materials into products is translated into a process flow
diagram, as well as the operating parameters were obtained. This is an important step in
designing the production process of our desired product before performing a further
optimization of the processes and unit operations involved.
In a nutshell, after we had done a simulation, optimization and process integration, our
total capital investment is $ 47,004,558.90.
APPENDICES A
83
CALCULATION OF MATERIAL BALANCES
= (100,000 lb/hr)/42.08
= 104800.56 lb/hr
R = 17060.53 lb/hr
Mass flowrate of H2 , m3
= (2376.43) x (2.01)
= 4776.62 lb/hr
2. Separation Unit 1
F1 = D1 + B1
From the overall mass balance, we know that the mass flowrate of propane at D1 is
104800.56 lb/hr and the composition is assume 0.990 of C3H8, so
84
D1 = mass flow rate of C3H8 / 0.990
= 104800.56 / 0.990
Propane balance :
0.8 F1 = 0.990 D1
F1 = (0.990 x 106263.1)/0.8
F1 = D1 + B1
B1 = 140163.6 – 106263.1
3. Mixer
from previous calculation, the value of D1 = 106263.1 lb/hr and R = 17060.53 lb/hr. Hence,
a1 = 0.991
a2 = 0.007
4. Reactor
85
For dehydrogenation of propane, 0.86% of propane is converted. The unreacted propane
recycled.
R = (1-0.86)/0.86 x 104800.56
R = 17060.53 lb/hr
86
APPENDICES B
298𝐾
𝐻𝑅1 = ∫ (68.023 × 10−3 + 22.59 × 10−5 𝑇 − 13.11 × 10−8 𝑇 2 + 31.71 × 10−12 𝑇 3 ) 𝑑𝑡
873𝐾
𝐻𝑅1 = −91.81𝑘𝐽/𝑚𝑜𝑙
298𝐾
𝐻𝑅1 = ∫ Cp(product) 𝑑𝑡
873𝐾
873𝐾
𝐻𝑝1 = ∫ (68.023 × 10−3 + 22.59 × 10−5 𝑇 − 13.11 × 10−8 𝑇 2 + 31.71 × 10−12 𝑇 3 ) 𝑑𝑡
298𝐾
+ (59.58 × 10−3 + 17.71 × 10−5 𝑇 − 10.17 × 10−8 𝑇 2 + 24.6 × 10−12 𝑇 3 ) 𝑑𝑡
+ (28.84 × 10−3 + 0.00765 × 10−5 𝑇 + 0.3288 × 10−8 𝑇 2 − 0.8698
× 10−12 𝑇 3 )𝑑𝑡
𝐻𝑝1 = 184.72kJ/mol
̂𝑟1 = ∑ 𝑣𝑖 ∆𝐻
∆𝐻 ̂𝑓 = (1)(∆𝐻
̂𝑓 ) ̂𝑓 )
+ (1)(∆𝐻 ̂𝑓 )
− (1)(∆𝐻
C3H6 H2 C3H8
20.41 𝑘𝐽 (−119.8)𝑘𝐽
̂𝑟1 =
∆𝐻 +0 − = 140.21 𝑘𝐽/𝑚𝑜𝑙
𝑚𝑜𝑙 𝑚𝑜𝑙
87
APPENDICES C
ASPEN HYSYS
88
APPENDICES D
E1
Q=FCpH∆T
T = 349.12˚C
Q=FCpC∆T
T = 576.3˚
E2
Q=FCpH∆T
T = 316.59˚C
Q=FCpC∆T
T = 50.08˚C
E3
Q=FCpH∆T
89
4.6704 = 0.049 (316.59-T)
T = 221.28˚C
Q=FCpC∆T
T = 30˚C
90
APPENDICES E
REACTOR
Q = 3517.02 ft3/hr
5 min×1 ℎ𝑟
Volume, V = (3517.02 ft3/hr) × ( × 2) = 586.17 ft3
60 𝑚𝑖𝑛
Assume L/ D = 2
V = 𝜋 (D/2)2L = (𝜋D3)/2
D = (2V/ 𝜋)1/3 = [2(586.17)/ 𝜋] 1/3 = 7.20 ft
L= 2D = 14.4 ft
91
PUMP
Pressure inlet, P1 = 1000kPa = 145.04psi
H = 356.82 ft
ln S = 8.962
𝑙𝑏.𝑓𝑡
= 26.16
min
ln Q = 6.024
= 0.6956
PT 26.16 𝑙𝑏.𝑓𝑡
PB = = = 37.61
ηp 0.6956 min
ln PB = 3.627
ηm = 0.80 + 0.0319(3.627) – 0.00182(3.627)2
= 0.892
PT 26.16 𝑙𝑏.𝑓𝑡
PC = = = 42.16
ηpηm (0.6956)(0.892) min
ln Pc = 3.741
CB = exp [5.8259+0.13141(3.741)+ 0.053255 (3.741)2 + 0.028628 (3.741)3 –
0.0035549(3.741)4]
= $ 2605.50
92
FT = 1.8 (assume explosion-prof enclosure)
CP = FTCB = 1.8(2605.50) = $ 4689.9 for motor
FBM = 3.30
CPTotal (Pump + Motor) = (6577.78 + 4689.9) (3.30)
= $ 37,183.34
DISTILLATION COLUMN
Distillation column, S1
Main vessel sizing
Diameter, DT
FLG= 0.1345
CSB=0.34
FST=0.757
Assume:
FF=1,FHA=1
C=0.2574
Uf=2.758 ft/s
Ad/AT=0.10378
Assume 80% flooding
425100
4( 3600 )
DT= =6.05 ft=1.844 m
0.8(2.758)(3.14)(1−0.10378)(2.09)
ts=0.375+0.125=0.5 in
W= π (Di+ts) (L+0.8Di) ts ρ= 21458 Ib
Cv= $ 67436
93
CPL=300.9 ∗ 6.050.63316 500.8016 = $21642
CT= $ 27462
Dvolumetric =3350
Volume flow = (1+3) *(3350) = 13400 ft3/hr
Assume residence time of 5 mins at full capacity and L/D=2
V=13400 ft3/hr * (5 min/ (60 min/hr))
V=116 ft3
D=8.924 ft3
L=17.85 ft3
tp =7/16=0.4375 in
ts =0.4375+0.125=0.562 in
W=π (Di + ts)*(L+0.8*Di)*(ts)*ρ
W=16150 Ib
Cv= $ 733210
After bare-model:
Cost= $ 223290
Condenser
Qc= -0.126*105
Uf=4.402 Btu/ (ft2*hr*F)
TLM= 10.48 F
Ac=273.1 ft2
Assume fixed head, shell tube exchanger and carbon steel, 20 feet long:
FL=1
94
FP=1
TM=2.732
CB= 7950
Cp= $ 21721
After bare-module,
Cost= $ 68857
Re-boiler costing
COMPRESSOR
(a) Preliminary estimate of brake horsepower, PB
95
1.10−1
1.10 83283.83×14.5 72.52 1.10
𝑃𝐵 = 0.00436 × ( )× × (( ) − 1) = 18430.94 𝐵𝐻𝑝
1.10−1 0.4952 14.5
Assumption:
Drive efficiency, ηC = 0.75
Material factor, FM = 1.00 (carbon steel)
Drive type factor, FD = 1.15 (steam turbine)
18430.94
𝑃𝐶 = = 24574.59 𝐻𝑝
0.75
96
HEAT EXCHANGER (HE2)
Sizing of Heat exchanger (HE 2)
Hot Cold
Tin (˚C) 870.7 43.85
Tout (˚C) 349.12 576.3
LM 314.74o F
870.7 349.12
R
576.3 43.85
R 0.98
576.3 43.85
S
870.7 43.85
S 0.644
Ui = 235.5 Btu/oF.ft2.hr
97
5.44x106 Btu / hr
Ai
235.5 Btu / oF . ft 2 .hrx0.85x314.74o F
Ai 86.34 ft 2
Velocity of tube-side;
111244.12lb ft 3 hr
Aci x x
hr 0.421lb 1.68x106 ft
Aci 0.157 ft 2 / pass
By using 0.75 in. O.D. 16 BWG tubing with I.D. of 0.62 in.;
0.302in 2 ft 2
Inside area/tube = x
tube 144in 2
-3 2
= 2.097x10 ft /tube
0.157 ft 2 / pass
Nt
2.097x10 3 ft 2 / tube
N t 75tubes / pass
86.43 ft 2
=
4 passx75tubes / pass
= 0.288 ft2/tube
0.288 ft 2 / tube
L
0.62in
x
12in / ft
L = 5.58 ft
98
Ai 86.34 ft 2
FBM = 3.17
86.34 0.5
𝐹𝑀 = 1.08 + ( )
100
= 2.01
145.04 145.04 2
𝐹𝑃 = 0.9803 + 0.018 ( ) + 0.0017 ( )
100 100
= 1.01
Fixed head:
𝐶𝑃 = (2.01)(1.25)(1.01)(7,334.88)
= $18,613.18
99
PROCESS FLOW DIAGRAM
(HEAT EXCHANGER NETWORK)
100
101
102
103
104