Professional Documents
Culture Documents
By
NAVDEEP KUMAR
CH15156
PANJAB UNIVERSITY
CHANDIGARH – 160014, INDIA
Dr. S. S. BHATNAGAR UNIVERSITY INSTITUTE OF CHEMICAL
ENGINEERING & TECHNOLOGY
PANJAB UNIVERSITY
CHANDIGARH – 160 014, INDIA
CERTIFICATE
I also take this opportunity to express a deep sense of gratitude to Prof. Sanchita
Chauhan (Chairperson, Dr.SSBUICET) for her cordial support, valuable information
and guidance, which helped me in completing the project.
Lastly, I am also thankful to all staff members of the department without whose help
my project would not have been a successful one.
NAVDEEP KUMAR
1. INTRODUCTION
Ketones are organic compounds containing one or more carbonyl groups bound to
ketones can be classified. MEK has the molecular structure : CH3 – CO – C2H5.
2-Butanone ,methyl ethyl ketone, MEK, is the 2nd link in the homologous series of
aliphatic ketones and next to acetone, the most important commercially produced ketone.
or zinc or bronze catalyst at 400 – 500 0C. At 80-95% sec butylalcohol conversion, MEK
selectivity is greater than 95%. Butenes (dehydration) and higher ketones (auto
Methyl Ethyl Ketone (MEK) is a low –boiling, chemically stable compound also
ketonic odor. It has very good solvent properties, a fast evaporation rate, and is
miscible with organic solvents. MEK is an excellent solvent for a variety of resin
1
Interest in MEK as a solvent for paints and adhesives has been growing in
acetatebutyrate, ethylcellulose, acrylic resins, vinyl acetate and vinyl chloride – vinyl
1.2 USES:-
More than half the MEK produced in the United States finds application in
surface coatings end uses. Significant volumes are also used in the production of
systems. Its active solvency for vinyl acetate and vinyl chloride – vinyl acetate
for nitrocellulose and is extensively used in furniture and automotive lacquers. The low
lacquers or thinners per pound than is possible with heavier solvents. MEK is also a
coatings solvent for many resin systems including alkyds and air-dried epoxies. It
performs extremely well in fast-drying traffic paints and has become an important
component in placing air pollution regulated solvents, such as toluene, which are
2
MEK is a dewaxing agent in the refining of lubricating oils and is a
solvent for adhesives, rubber, cement, printing inks, paint removers and cleaning
Demand for MEK has increased at a rate of 6.5% per year and is continued to grow
at about this rate in future. Apparently the long term decrease in demand owing to
Adhesives – 11%
Miscellaneous – 16%
1.4 TOXICOLOGY :
The inhalation of MEK vapours has narcotic effects. The vapour irritates the eyes
and the nasal and pharyngeal membranes. Frequent and prolonged contact with MEK
causes skin moisture loss and slight irritation .Sensitive persons may develop demitasses
.Liquid MEK temporarily irritates eyes and corneas .MEK is usually absorbed through
the respiratory track. It may also be absorbed through the skin. The odour threshold for
MEK is 10 ppm .
3
Maximum permissible concentration for pseudomonas putida – 1150 mg / lit
4
2. PHYSICAL AND CHEMICAL PROPERTIES OF MEK
Physical Properties of MEK (all values are at 200c, except where noted)
5
Thermal conductivity, cal/cm2 .s. (0C/cm) 3.58 x 10-4
Vapor pressure, mmHg 80.21
Viscosity, cP 0.43
Methyl Ethyl ketone can be widely utilized in chemical synthesis. Its reactivity
centers around the carbonyl group and its adjacent hydrogen atoms. Condensation,
ammonolysis, halogenations, and oxidation can be carried out under the proper
conditions. Some typical reactions are described below.
Self-Condensation
2CH3CCH2CH3 CH3CH2CCH2CCH2CH3
OH
CH3 O
CH3CH2C == CHCCH2CH3+H2O
Reaction with aldehydes gives higher ketones, as well as ketals and cyclic compounds,
depending on reaction conditions. β - ii ketones are produced by the condensation of
MEK with aliphatic esters. MEK condenses with glycols and organic oxides to give
derivatives of dioxolane. sec-Butyl amine is formed by reacting MEK with aqueous
ammonia and hydrogen:
O NH2
OH
6
Miscellaneous Reactions
OOH
This initial addition product is the unstable precursor of seven stable peroxides and hydro
peroxides. Of these, 2,2 –dihydroperoxy-2,2’-dibutyl peroxide is present in the largest
amount (about 45%) in the peroxide mixture:
CH3 CH3
HOOC – OO - COOH
C2H5 C2H5
MEK peroxides are widely used as catalysts for the polymerisation of polyester
resins at room temperature. The condensation product of MEK and m-phenyl diamine is
an efficient curing agent for epoxy resins. MEK and cobalt acetate function together as a
specific catalyst for single-stage oxidation of p-xylene to terephthalic acid. Aliphatic
monoketones, such as MEK also function as catalysts in the polymerisation of
polyethylene terephthalate where, it is claimed, they speed condensation times and cause
less yellowing of the polymer than antimony trioxide. MEK is also used in the
preparation of complex catalysts used in the syndiotacic polymerisation of α- olefins such
as propylene.
7
3. PROCESS SELECTION AND DETAILS
There are a few processes listed below for the production of MEK.
OH O
The MEK concentration in the reaction mixture increases and reaches its maximum at
approximately 3500C. Copper, Zinc or Bronze are used as catalysts in gas phase
dehydrogenation. Commercially used catalysts are reactivated by oxidation, after 3 to 6
months use. They have a life expectance of several years.
8
LIQUID PHASE OXIDATION OF BUTANE:
n – C4 H8 + ½ O2 CH3 – C – C2H5
95% conversion of n-butanes can be obtained with the MEK selectivity of about 86%.
The main disadvantage of this product is the formation of chlorinated butanones and b-
butryaldehyde and corrosion caused due to free acids.
9
The vapor phase dehydrogenation process gives high conversion of 2-butanol and
high selectivity of MEK of about 95 mole%. Other advantages of this process include
better yield, longer catalyst life, simple production separation and lower energy
consumption.
Of all the processes, it has been found that dehydrogenation of 2-butabol has more
advantages and is more economical compared to other processes, so this process has been
selected for design in following text.
The cold feed of 2-butanol will be pumped from the feed tank to a steam heater to
a vertical thermosyphon vaporizer in which alcohol is vaporized. The thermosyphon
vaporizer will be heated by reaction products discharged from the reactor. The wet
alcohol vapor will be passed to a knock out drum to remove any entrained liquid. The
liquid separated will be recycled and the dry alcohol will be fed to the reactor via super
heaters heated by flue gas. The super heaters will be designed to raise the temperature of
alcohol vapors to 5000C at which temperature the vapors enter the reactor.
OH O
This vapor will be fed to the bottom of the packed bed absorption column where
MEK and 2-butanol will be absorbed in water. The water will be recycled from the
extraction column and its rate will be controlled to provide an aqueous effluent
containing 10% MEK. The hydrogen discharged from the top of the absorber will be
dried and fed to the furnace.
10
The aqueous effluent from the absorber will be pumped into an extraction column
where it will be contacted with 1,1,2-Trichlorethane to extract MEK and alcohol. In
excess of about 95% of the MEK and alcohol will be extracted and remainder will be
recirculated back to the absorber.
The trichloroethane extract phase will be pumped to a distillation unit for the
separation unit for the separation of solvent, which is recycled. The distillate from this
column will be MEK and alcohol, which will be, mixed liquid product form the
condenser and this will be treated in a MEK product still for the purification of MEK. The
alcohol discharged from the bottom of this column will be replaced back to alcohol feed
tank. The MEK product will be cooled and stored.
11
4. MATERIAL BALANCE
The alcohol balance over each unit will be based on hourly production rate. For a
production rate of 500 TPD of MEK, the hourly production rate will be
=20833.33 kg/hr
However allowing for 8 % spillage and other losses, the hourly production rate will be
=22500.00 kg/hr
Material balance is done over the whole process. In this diagram most of the inner processes are
BLOCK
MEK
X Reactor Prod
still
MEK = 100% 2
R1 = Recycle ratio
13
Total MEK from reactor = X (1 + 0.99 R1) x 0.891x72 + 0.0092 XR1 kg
74
MEK Balance: -
14
MATERIAL BALANCE ACROSS THE CONDENSER:-
Alcohol =12.04 %
L MEK = 87.96%
F Condenser V
Alcohol = 5.38%
Alcohol=10.9% MEK = 80.72%
MEK= 86.70% H2 =13.90%
H2=2.41%
F= Feed
L= Condensate from condenser
V= Vapor from the condenser
F=L+V
Component balance
V = 0.19204X L
= X( 1 + R1) – V
L = 1.1113X – 0.19204
= > L = 0.9193X
15
F = 1.1113X
L = 0.9193X
V = 0.19204X
Alcohol = 0%
VR2 MEK = 0.5%
Water = 99.5%
Absorption
Column
V K
Alcohol = 5.38% Alcohol = 0.65%
MEK = 80.72% MEK = 10.32%
H2 = 13.9% water = 89.05%
M
Alcohol = 0.92%
MEK= 8.22%
H2 = 88.49%
Water = 22.37%
V = Vapor from condenser.
VR2 = Absorber feed.
M = Vapor from absorber.
K = Absorber effluent.
V + VR2 = K+M
Alcohol balance
H2 balance
(V x 0.139) + 0 = 0 + M (0.6849)
M= 0.139
0.6849 V
M = 0.20294 V
M = (0.20294) (0.19204X)
16
M = 0.039X
Alcohol balance
K= 1.5343X
From (1)
VR2 = K + M - V
= 1.5343X+0.039X-
R2 = 1.38126X
0.19204X
R2 = 7.19256
V = 0.19204X kg/hr.
VR2 = 0.19204 x 7.19256 = 1.38126X kg/hr
K = 1.5343X kg/hr
M = 0.039X kg/hr
VR2
Alcohol = 0.0%
MEK=0.5%
Water=99.5%
N
Extraction Alcohol = 1.24%
K column MEK = 19.00%
TCE = 79.62%
Alcohol =0.65% Water = 0.14%
MEK=10.32%
Water=99.5%
C
Alcohol= 0%
MEK=0.14%
TCE=0.99.69%
Water =0.17%
17
N = Extract
C = Solvent
K + C = N + VR2
Alcohol balance
K x 0.0065 + 0 = N x 0.0124 + 0
=> N = 0.80427X
C = N + VR2 – K
=> C = 0.65123X
N = 0.80427 X kg.
C = 0.65123 X kg.
L
Alcohol = 12.04%
MEK = 87.96%
Solvent
D
Recovery
N Still
Alcohol = 1.24% Alcohol = 11.17%
MEK = 19.00% MEK = 88.82%
TCE = 79.62% TCE = 0.01%
Water = 0.14%
MEK = 0.14%
TCE = 99.69% C
18
Water = 0.17%
N+L=D+C
D=N+L–C
D = 1.07234X
MEK
Prod
still
D P
Alcohol = 11.17% Alcohol = 1.00%
MEK = 88.82% MEK = 99.00%
TCE = 0.01%
P = MEK product
XR1 = Alcohol recycle
D = P + XR1
=> P = 0.96104X
P = 22500 kg/Hr
19
(0.96104X) = P = 22500.00
X = 22500
0.96104
X = 23412.13685 kg/Hr
Putting the values of X we get all the flow conditions of all the streams.
The material balance is shown in the flowsheet in the next page.
20
5.FLOWSHEET
Feed Liq. from condenser Absorber feed Absorber Effluent MEK Still Feed Alcohol Recycle
Wt. % Wt. % Wt. % Wt. % Wt. % Wt. %
Alcohol 23412.136 100.00 2591.342 12.04 -- -- 233.488 0.65 2804.315 11.17 99.00
MEK -- -- 18931.435 87.96 161.691 0.5 3707.072 10.32 22298.946 88.82 23.9731 0.92
Hydrogen -- -- -- -- -- -- -- -- -- -- -- --
TCE -- -- -- -- -- -- -- -- 2.5098 0.01 2.0846 0.08
Water -- -- -- -- 32176.557 99.5 31980.681 89.05 -- -- -- --
Total 23412.136 100.00 21522.777 100.00 32338.248 100.00 35921.241 100.00 25105.770 100.00 2605.77 100.00
ReRrr B C D E F
A
Vapour From Reaction Products Vapour From Solvent Extract MEK Product
Absorber Condenser
Wt. % Wt. % Wt. % Wt. % Wt. % Wt. %
Alcohol 8.391 0.92 2834.24 10.89 241.838 5.38 -- -- 233.488 1.24 225.00 1.00
MEK 74.977 8.22 22556.739 86.70 3626.371 80.72 21.345 0.14 3577.639 19.00 22275.00 99.00
Hydrogen 624.722 68.49 626.921 2.41 626.921 13.90 -- -- -- -- -- --
TCE -- -- -- -- -- -- 15199.421 99.69 14992.191 79.62 -- --
Water 204.045 22.37 -- -- -- -- 25.919 0.17 26.361 0.14 -- --
Total 912.136 100.00 26017.907 100.00 4495.130 100.00 15246.685 100.00 18829.679 100.00 22500.00 100.00
21
6. ENERGY BALANCE
= 26017.91 kg
26017.91 kg per hour of 2-butanol is to be preheated from 250C it boiling point 107.50C.
= 3.603 x 106 KJ
The heating medium is used is dry saturated steam at 420K
= 1696.8 kg/hr
2-BUTANOL VAPORIZER:-
22
T = 400 K
2-butanol vapors is to be heat4ed from 380.5 k to 573k . using flue gas which enters at
673 k & cools to 423k.
Cp = 2.038 kj/kg k.
It raises the temperature of vapor from 573 to 773 k . using flue gas which enters at 873k
abd cools to 623k
Cp = 2.674 kj/kg k
The feed enters the reactor at 773k and leaves at 663k. The conversion obtained in
the reactor is 89.1%. The heat balance includes two terms i.e , sensible heat change due
to cooling of reaction mixture and heat consume due to reaction.
Q = M x Cp x(T2 – T1) + M x H
23
H = 73900 kj/kgmol
Cp = 1.195 kj/kg k
CpH2 = 14650 J/ kg k
Cpalcohol = 1760 J/ kg k
CpMEK = 1664 J/ kg k
24
= 1.544 x 106 kj/hr
25
=> T = 311.25 k
It is assume that the extraction process is isothermal. All that streams come at 270C
and leaves at 270C.
R= 2Rm = 0.76
Feed:
Alcohol = 233.48 = 3.155 kmol /hr
74
MEK = 3577.639 = 49.689 kmol/hr
72
TCE = 14992.191 = 112.3kmol/hr
133.5
Water = 26.3613 = 1.465 kmol /hr
18
Total = 166.609 kmol /hr
26
Distillate:-
Residue:
27
Cp TCE = 148.56 kj/kmol k
Condenser :-
VHv = (D + L ) . HL +Qc
Qc = V x (Hv - HL)
Qc = V x
V = (1 + R ) x D
D = 52.5886 kmole/hr
V = ( 1 + 0.76 )x 52.5886 = 92.556 kmole/hr.
Reboiler:-
F. HF + QB = Qc + D . HD + WHw
QB = Qc + D . HD + WHw - F. HF
28
Steam requirement is = 4.90525 x 106
2153.4
= 2277.91 kg/hr
One more heat exchanger is used to raise the temperature of the mixed liquor
of condensate and the distillate from the solvent recovery column to 820C
2591.3424 x 170.058 + 18931.435 x 165.726 (26.6)
74 72
Condenser:
Qc = V x
Qc= V x = 541.261 x 3.1 x 107 + 5.4673 x 4.5 x
107 = 17.025 x 106
29
4.187 x (42-24)
= 2.25899 x 106 kg/hr
Reboiler:
= 0.97632 x106
30
Heat load = 2579.7131 x 260 + 239731 x 175 + 2.0846 x 148.65 (107- 27)
74 72 133.5
31
7. MAJOR EQUIPMENT
DISTILLATION COLUMN:
0
79.5 C
D = 312.416 k-moles
xD = 0.99
Enriching
section
F= 347.604 k. moles
xF = 0.891
0
TF =82 C Stripping
section
0
107 C
Total Reboiler
W= 35.188
Xw= 0.012
32
Rm = minimum reflux ratio
R = actual reflux ratio
L = molar flow rate of liquid in the enriching section, kmol/hr G
= molar flow rate of vapor in the enriching section, kmol/hr L
= molar flow rate of liquid in stripping section, kmol/hr G =
molar flow rate of vapor in stripping section, kmol/hr
M = 72.218
xD
Rm+1 = 0.66
Rm+1 = xD 0.99
= = 1.5
0.66 0.66
R= 1.5 Rm = 0.75
xD 0.99
= = 0.566
R+1 0.75 +1
33
(A) ENRICHING SECTION:
PLATE HYDRAULICS :
34
Properties
35
Average conditions and Properties
80.5 94.5
O
Tliq ( c
)
81.5 95.5
Tvapor (Oc )
750.01 744.94
liq (kg/m3)
2.4765 2.483
vapor (kg/m3)
0.2 0.5
Unf = 0.3 18 750.01 – 2.4765 = 5.105 ft/s = 1.556m/s
20 2.4765
36
Net Area (An) = Volumetric flow rate of vapor = 4.419= 3.549m2
Let Lw = 0.75
Dc
Lw = Weir Length
Dc = Column Diameter
Area of column (Ac ) = D 2 = 0.785 D 2
c c
4
c= 97.20
Area of down comer (A ) = D 2 c - Lw Dc Cos ( c)
d c
4 360 2 2 2
= 0.0879 D 2
c
An = Ac – Ad.
Dc = 2.26m.
Dc 2.3m
Lw = 0.75 Dc = 1.725m.
Lw 1.7m
Ac = (2.3)2 = 4.155m2
4
An = Ac- Ad =4.155-0.465 =3.69 m2
Lw = 1.7 = 0.74
Dc 2.3
c = 95.5
.
37
Lw = 0.74(2.3) 1.7m
Acz = 5.32% Ac
Awz is the waste zones area.
A wz
=2 D 2 - (D – 0.05)2
c c
4 360 4 360
= 0.084 m2
A wz = 0.084 = 0.0202
Ac 4.155
Awz = 2.02 Ac
Ap = Area of perforation.
Ap = Ac – 2Ad – Acz – Awz
= 2.92 m2
(8) Hole Area (Ah):
Ah = Area of holes.
Ah = 0.1 Ap = 0.292 m2
nh = number of holes.= nh = 4x 0.292= 14872
(5 x 10-3)2
(9) hw = 50mm
hw = weir height
38
(10) Weeping check: (Sieve Tray)
For Ah = 0.0905
Aa
tT = 0.6
dh
Cv = 0.75.
39
€
how = Fw 664 q
Lw (Ref: 1, pg: 18-10, eq:18-12 (a)).
q = Lt
L
Lw = 0.74
Dc
Fw = 1.01
hd + h = 68.23+1.963 = 70.193mm
For Ah = 0.09
Aa
hw + how = 65.99 mm
There is no weeping
40
(11) Flooding check:
Since the maximum flow rate is at the bottom, flooding checked at the bottom.
(how )bottom = 16 mm
g = 2.4765 kg/m3
hf = hl l = 39.1 = 185.5mm
t 0.22
2
41
hap = hds - c = 66.125-25.4 = 40.725mm
2
hda = 165.2 6.266 x10-3 = 1.36mm
0.069
ht = hd + hl l = 68.68+39.1 =107.78 mm
hdc = ht + hw + how + hhg + hda (Ref :1, eg:18-3, pg:18-7)
42
Nsc,g = gas phase Schmidt number
Df = Lw + Dc = 1.7+2.3 = 2.0m
2 2
Df = width of flow path on plate
W= q
Df
Ng = 1.44
KL a = 0.833 m/s
43
NL = 0.833 x 20.14 =16.78
mtop=0.3375 G m = 2.3333
Lm
mbottom = 0.413
t = mtop Gm = 0.7875
Lm
b = mbottom Gm = 0.9637
Lm
avg = 0.876
= stripping factor
1
Nog = (Ref: 1, pg:18-15, eq:18-34)
1 +
Ng NL
= 1
= 1.34
1 + 0.876
2.51 1.44 16.78
EOG= 1- e– (Nog)
(Ref:1, pg: 18-15, eq:18-33)
– (1.34)
EOG= 1- e = 0.738
which is large.
Npl=Zl 2
DE l
44
Zl 'F FRV F
= 1.55 m
DE=6.675x10-3Ua1.44+0.922x10-4hl – 0.00562
=0.0084 m2/s
Npe= 1.552
(0.0084x 20.14)
=14.20
Ea = 1
Emv (Ref:1, pg:18-13, eq:18-37)
1+ Emv
1-
= fractional entrainment
0.5
For L g = 0.0246 G
L
= 0.15
45
Ea= 0.93 x 1 = 0.79
1+0.93 x 0.15
1-0.15
NA = Actual tryas;
NA = NT = 4 = 5.14 ~ 6
Eoc 0.78
PLATE HYDRAULICS :
lar pitch
(5) Ah = 0.10
Ap
46
Un =1.1472 m/s
c = 93.80
= 86.20
Ac = 4.524 m2
Ad = 0.462 m2
An = 4.062 m2
Aa = 3.6 m2
Acz = 0.192 m2 (5.17% of Ac)
Awz = 0.026 m2 (2.00% of Ac )
Ap = 3.126 m2
Ah = 0.3126 m2
nh = 16685
(9) hw =50mm
hw + how = 80.194 mm
hd + h = 59.43 mm
There is no weeping.
47
(11) Flooding check (Bottom)
how = 30.445 mm
hds =80.57 mm ; =0.60 ; t = 0.2
hl l =48.342 mm
hf = 241.71mm
hap = 55.17 mm
Ada = 0.097 m2
hda = 4.6 mm
ht = 107.192 mm
hdcl = 192.687 mm
h = 385.374 mm < 500 mm
dc
There is no flooding
(12) Column Efficiency (AIChE METHOD):
(a) Ng =2.384
(b) L = 10.88 s.
NL = 9.03
= 1.215
Nog=1.805
EoG=0.83
Zl = 1.64 m
DE = 7.94x10-3 m2/s
L = 10.88 s
Npe = 31.31
x Eog = 1.0
Emv = 1.7
Eog
Emv = 1.411
48
(C) Overall column efficiency :
= fractional entrainment
0.5
For L g = 0.0619 G
L
= 0.05
Ea = 1.312
Eoc = 1.276
NA = 9
0.83
=11
= 3.00 + 5.5
= 8.5 m
49
Summary of the Distillation Column
Enriching section
Tray spacing = 500 mm
Column diameter = 2.3m
Weir length = 1.7m
Weir height = 50 mm
Hole diameter = 5 mm
Hole pitch = 15 mm, triangular
Tray thickness = 3mm
Number of holes = 14872
Flooding % = 80
Stripping section
Tray spacing = 500 mm
Column diameter = 2.4m
Weir length = 1.75 m
Weir height = 50 mm
Hole diameter = 5 mm
Hole pitch = 15 mm, triangular
Tray thickness = 3mm
Number of holes = 16685
Flooding % = 80
50
DISTILLATION COLUMN
Specifications:-
Insulation thickness = 50 mm
Sp.gr of SS = 7.8
SKIRT = 2m
Shell thickness:-
ts = P.Dt +C
2fj -p
ts = shell thickness
P= design pr
51
DI = ID of shell
f = allowable stress
ts = 1.135 x 2400 +2
2 x 0.85 x 950 – 1.135
= 3.68 mm.
=> Ro = Do = 2412 mm
ro = 6% Ro
= 0.06 x 2412
= 144.72 mm
= 145 mm
t = 0.885 Prc +C
f x E – 0.1P
rc = crown radium
E = joint efficienc
f = allowable stress
C = corrosion allowance
52
Take head thickness to be 8mm approximate blank diameter can be found out as;
Diameter = OD + OD + 2 Sf + 2 icr
24 3
Sf = 800 mm
Wt of head = d2t [ !
4
= x (4.210)2 x 0.006 x
7700 4
= 643.13kg.
fap = p.di
4(ts-c)
= 1.135 x 2400
4 x (6 – 2)
= 170.25 kg/cm2
w1 = wt of shell = dit fs . X
53
w2 = wt of insulation = ( do2 in- do2)Sins . X
9
wh = wt of head = 643.13 kg.
w = w1 + w2 + wh + (wp + wL) x X
ts
= 348.34 X
= 1044.17 X kg.
wp = wt of each plate.
wp = 150 kg.
WL = wt . of liq
= 205.2 kg
= 2102.51 X + 643.13
54
Stress due to dead level (compressive) at dist X:
fdw = w .
di (ts –6)
= 2102.51 X + 643.13
x 2400 x ( 6 –2) x 10-1
= 6.971 X + 2.132 kg/cm2
fwx = 1.4 Pw X 2
do (ts –c)
= 6.783 kg/cm2
55
- 6.783 = - 0.693x2 + 170.25 – (6.971X +
= 11.64 m.
Which suggests that the design is safe. Since the design is being made on the basis of
higher diameter, so the design is assumed to before for the entire length of the tower.
Specifications:-
H = 14 m
W = W1 + W2 + (WP + WL) H + Wn
ts
56
Wind Load:
fds = w ,
Dmt.
Dm = Di + t = 2400 + 6 = 2.406 m
Seismic load:
fsb = 8cwH
3 Do2t
C= 0.08
= 0.492 kg/cm2
t
max possible tensile stress:-
j x f = fds – fsb
57
max permissible compressive stress:-
jt fds + fsb
t 40.292
807.5
t 0.0499 cm
fc = W + Ms
A 2
= 30083.87 x 4 + Msb
(2702 - 2402)2
Msb = 2 CWH.
3
Z = (Dop 4 – D 4) x
os
Dop x 32
= 2704 - 2404 x
32 x 270
fc = 30083.87 x 4 + 2 0.08 x 30083.87 x 14
(2702- 2402) 3 (2704- 2404)
32 x 270
= 2.5035 + 0.0309
= 2.5344 kg/cm2
Mmax = fc . b.l2/2
f = 6 Mmax = 3 fcl2 = 3 x 2.5344 x 152 kg/cm2
btB2 tB 2 tB2
= 1710.72 kg/cm2
58
tB2
f = 9.6 MN/m2 = 9.5 x 102 N/ cm2
= 96 kgf/cm2
tB = ¥ 1710.72
96
tB = 4.22 cm = 42.2mm
j = Mwt =W min R
Ms Ms.
Mwt = Wmin x R
= 2,50,00 x 270
= 67.5 x 105
j = 67.5 x 105
2.246 x 106
= 3.005
59
MINOR EQUIPMENT
CONDENSER
PROCESS DESIGN:
= 444.43 KJ/kg
fluid heat
60
qc = heat transfer by the cold fluid.
Cp = 4.187 KJ/kg K.
T1 T2
t2
t1
ln (T1- t2 )
(T2 - t1)
61
(C) Routing of fluids :
Assume : U =567.83W/m2K
A assumed = 5348.27x103
= 200.69 m2
567.83 x 46.93
= 0.289 m2
= 695
62
(iii) Choose Shell diameter:
lar
Choose TEMA : P or S. ¾” OD tubes in 1” pitch.
Acorrected =206.924m2
Ucorrected = 550.75 W/m2K
1000 x 0.0697
63
(II) Film Transfer Coefficient :
t
film = tv +1 tv + (t1+t2) 80.5 + 80.5 + (24+42)
2 = 2 = 68.63 0C
2 2
a) Shell side:
= 4 10.94
x = 422.6
€
0.000265 (716) x 4.88
3 2 -
Nu = 1.51 (0D) () g • (Re) •
2
(0.265 x 10 –3)2
Nu = ho (OD)
K
64
b) Tube side:
Gt = mpipe
atube
hi (ID)
K = 0.023 (Re ) 0.8 (Pr) 0.3
hi = inside –heat transfer coefficient
hi = 3951.93 W/m2K
Fouling factor
(Dirt –coefficient ) = 0.003
=5.28 x 10-4 (W/m2K)-1
1 1 (OD) 1
= + + wall resistance + Fouling factor
U0 ho (ID) hi
1 1 0.0191 1
= + x + 4.028x10-5 + 5.28x10-4
U0 1154.9 0.0157 3951.93
U0 =574.63 W/m2K
U0 > Uassumed
65
(III) Pressure Drop Calculations :
a) Tube Side :
Re = 20043.3
f = friction factor
= 4fLVp2 x x
g 2g(ID)
= 4.266 KPa
PT = pitch = 2.54 x 10 –2 m
66
ashell = shell diameter x C1 x B = 0.787 x 0.0063 x 0.787
PT 2.54x 10 –2
= 0.155 m2
( do) ( 0.0191)
2 2
= 18.29mm.
2 g De vapor
Nb = 0
67
MECHANICAL DESIGN:
b) Tube side :
ts = PDi
2fJ-P
ts = Shell thickness
P = design pressure =0.11 N/ mm2
Di = Inner diameter of shell = 0.787 m =787 mm
f = Allowable stress value = 95 N/mm2
J= Joint factor = 0.85
68
Head : (Torrispherical head)
th = PRCW
2fJ
th = thickness of head
W = ¼3+ ¥ Rc / Rk }
th = 10mm
Since for the shell, there are no baffles, tie-nods & spacers are not required.
Flanges :
do = y- pm ½
di y-p(m+1)
y= Yield stress
69
m= gasket factor
Gasket material chosen is asbestos with a suitable binder for the operating
conditions. Thickness = 10mm
m= 2.75
y=2.60 x 9.81 = 25.5 N/mm2
do = 25.5 - 0.11 (2.75 ) ½ = 1.0004
di 25.5 – 0.11 (2.75 +1)
At 80.50C.
Sg = 138 x 10 6 N/m2
70
Calculation for optimum bolt size :
g1 = go = 1.41 go
0.707
R = Radial distance from bolt circle to the connection of hub & back of
flange R= 0.027
C= Bolt circle diameter = ID +2 (1.415 go + R)
Hp = g (2b) m p
Wg. = g b y
Wg = 0.396 x 106 N
71
Wg > W0
GN
WQ = W1 +W2 +W3
W2 = H-W1
72
W2 = H- W1 =(0.0586 – 0.056) x 106 =0.0026 x 106 N
W3 = 9.39 x 103 N
= 0.06799x 106 N
a1 = C –B ; a2 = a1 + a 3 ; a3 = C -G
2 2 2
=2.255 x 103 J
Am =2.869 x 10-3
Ab = 44 x 1.5 4x 10-4 = 67.76 x 10-4
Sg = 138 x 106
Mg > Mo
73
M= Mg = 0.017 x 106 J
t2 = MCFY
BSFO
n= number of bolts = 44
Let CF = 1
SFO = Nominal design stresses for the flange material at design temperature.
M = 0.017 x 106 J
B = 0.807 m.
Y = 15
CF = 0.063 = 0.69
2(36 x 10-3) + 0.06
CF = (0.83)2
t = 0.0622 x 0.83 = 0.05 m
t = 50mm = 0.05m
74
Tube sheet thickness : (Cylindrical Shell) .
T1s = Gc KP / f
Saddle support:
Material: Low carbon steel
Total length of shell: 4.88 m
Diameter of shell: 0.807 mm
Knuckle radius = 0.06 x 0.807 = 0.0484 m = ro
Total depth of head (H)= (Doro/2)
= (0.807 x 0.0484 /2)
= 0.1398 m
Weight of the shell and its contents = 3750.43 kg = W
R=D/2=403.5 mm
Distance of saddle center line from shell end = A =0.5R=0.2 m.
75
Longitudinal Bending Moment
M1 = QA[1-(1-A/L+(R2-H2)/(2AL))/(1+4H/(3L))]
Q = W/2(L+4H/3)
= 3750.43 (4.88 + 4 x 0.1398/3)/2
= 9500.6 kg m
M1=9500.6x0.2 { 1- (1-0.2/4.88+(0.40352-0.13982)/(2x4.88x0.202)) }
(1+4x0.1398/(3x4.88))
= 12.79 kg-m
76
8.COST ESTIMATION AND ECONOMICS
6 8
Cost of MEK plant of capacity 35000 TPY in 1967 is Rs.$3.75×10 = Rs.1.875x 10
Therefore cost of 178200 TPY in 1967 is:
0.6
C1 = C2 (Q1/Q2)
8 0.6
= 1.875x 10 (178200/35000)
8
= Rs.4.9786 x 10
77
8 8 8
= 20% of ×4.547x10 = 0.20 ×4.547×10 = Rs. 0.9095×10
4. Piping installed: (10-80% of Purchased equipment cost)
Consider the piping cost = 40% Purchased equipment cost
8
= 40% of Purchased equipment cost = 0.40 ×4.547×10
8
= Rs. 1.8188×10
8
Thus, Direct cost = Rs. 15.0519×10 ----- (82.74% of FCI)
II. Indirect costs: expenses which are not directly involved with material and
labour of actual installation of complete facility (15-30% of Fixed-capital
investment)
A. Engineering and Supervision: (5-30% of direct costs)
Consider the cost of engineering and supervision = 10% of Direct costs
8
i.e., cost of engineering and supervision = 10% of 15.0519 ×10
8 8
= 0.1× 15.0519 ×10 = Rs. 1.50519×10
B. Construction Expense and Contractor’s fee: (6-30% of direct costs)
Consider the construction expense and contractor’s fee = 10% of Direct costs
8
i.e., construction expense and contractor’s fee = 10% of 15.0519×10
8 8
= 0.1× 15.0519 ×10 = Rs. 1.50519×10
78
C. Contingency: (5-15% of Fixed-capital investment)
Consider the contingency cost = 10% of Fixed-capital investment
8 8
i.e., Contingency cost = 10% of 18.19×10 = 0.12 × 18.19×10
8
= Rs. 3.638×10
8
Thus, Indirect Costs = Rs. 6.64838×10 --- (28.54% of FCI)
III. Fixed Capital Investment:
Fixed capital investment = Direct costs + Indirect costs
8 8
= (15.0519×10 ) + (6.64838×10 )
8
i.e., Fixed capital investment = Rs. 21.7×10
79
ii. Local Taxes: (1-4% of fixed capital investment) Consider
the local taxes = 3% of fixed capital investment i.e. Local
8 8
Taxes = 0.03×21.7×10 = Rs. 0.651×10
iii. Insurances: (0.4-1% of fixed capital investment) Consider
the Insurance = 0.7% of fixed capital investment i.e.
8 8
Insurance = 0.007×21.7×10 = Rs. 0.1519×10
iv. Rent: (8-12% of value of rented land and buildings)
Consider rent = 10% of value of rented land and buildings
8
= 10% of ((0.2728×10 ) +
8 8
(1.819×10 )) Rent = Rs. 2.0918x10
8
Thus, Fixed Charges = Rs. 5.7702×10
8 8
Ö Raw material cost = 25% of 7.0126×10 = 0.25×34.468×10
8
Ö Raw material cost = Rs. 8.617×10
ii. Operating Labour (OL): (10-20% of total product cost) Consider
the cost of operating labour = 12% of total product cost
8 8
Ö operating labour cost = 12% of 34.468×10 = 0.12×34.468×10
8
Ö Operating labour cost = Rs. 4.1361×10
iii. Direct Supervisory and Clerical Labour (DS & CL): (10-25% of OL)
Consider the cost for Direct supervisory and clerical labour = 12% of OL
8
Ö Direct supervisory and clerical labour cost = 12% of 4.1361×10
8
= 0.12×4.1361×10
8
Ö Direct supervisory and clerical labour cost = Rs. 0.4963×10
80
iv. Utilities: (10-20% of total product cost)
Consider the cost of Utilities = 12% of total product cost
8 8
Ö Utilities cost= 12% of 34.468×10 = 0.12×34.468×10
8
Ö Utilities cost = Rs. 4.1361×10
v. Maintenance and repairs (M & R): (2-10% of fixed capital investment)
Consider the maintenance and repair cost = 5% of fixed capital investment
8 8
i.e. Maintenance and repair cost = 0.05×21.7×10 = Rs. 1.085×10
vi. Operating Supplies: (10-20% of M & R or 0.5-1% of FCI)
Consider the cost of Operating supplies = 15% of M & R
8
Operating supplies cost = 15% of 1.085×10 = 0.15
8 8
×1.085×10 Operating supplies cost = Rs. 0.1627×10
vii. Laboratory Charges: (10-20% of OL) Consider
the Laboratory charges = 15% of OL
8 8
Laboratory charges = 15% of 4.1361×10 = 0.15×4.1361×10
8
Ö Laboratory charges = Rs. 0.6204×10
viii. Patent and Royalties: (0-6% of total product cost)
Consider the cost of Patent and royalties = 4% of total product cost
8 8
Ö Patent and Royalties = 4% of 38.468×10 = 0.03×38.468×10
8
Ö Patent and Royalties cost = Rs. 1.1540×10
8
Thus, Direct Production Cost = Rs. 20.4076×10 ----- (61% of TPC)
C. Plant overhead Costs (50-70% of Operating labour, supervision, and
maintenance or 5-15% of total product cost); includes for the following: general
plant upkeep and overhead, payroll overhead, packaging, medical services, safety
and protection, restaurants, recreation, salvage, laboratories, and storage facilities.
Consider the plant overhead cost = 60% of OL, DS & CL, and M & R Plant
8 8 8
overhead cost = 60% of ((4.1361×10 ) + (0.4963×10 ) + (1.085×10 ))
8
Plant overhead cost = Rs. 3.4304×10
Thus, Manufacture cost = Direct production cost + Fixed charges + Plant
overhead costs.
8 8 8
Manufacture cost = (38.468×10 ) + (5.7702×10 ) + (3.4304×10 )
8
Manufacture cost = Rs. 47.6686×10
81
II. General Expenses = Administrative costs + distribution and selling
costs + research and development costs
A. Administrative costs:(2-6% of total product cost)
Consider the Administrative costs = 5% of total product cost
8
Ö Administrative costs = 0.05 × 38.468×10
8
Administrative costs = Rs. 1.9234×10
Ö
8
Thus, General Expenses = Rs. 10.8647×10
82
V. Gross Earnings/Income:
Wholesale Selling Price of MEK per kg = Rs.40
Break-even Analysis:
Data available:
8
Annual Direct Production Cost = Rs.38.468×10
Annual Fixed charges, overhead and general expenses = Rs.
8 8
5.7702×10 Total Annual sales = Rs. 71.28×10
Wholesale Selling Price MEK per ton. = Rs. 40000
8 8
Direct production cost per ton of MEK = (5.7702×10 )/ (71.28×10 /40000)
= Rs. 3238.047 per ton
Let ‘n’ TPA be the break even production rate.
Number of tons needed for a break-even point is given by
8
(5.7702×10 ) + (3238.047×n) = (40000×n)
=> n = 15696.1193 tons/year
n = 47.5639 tons/day = 47.5639 TPD
Hence, the break-even production rate is 47.5639 TPD or 10% of the
considered plant capacity.
83
9.PLANT LAYOUT
The location of the plant can have a crucial effect on the overall profitability of a project,
and the scope for future expansion. Many factors must be considered when selecting a
suitable plant site. The principal factors are:
Location, with respect to the marketing area
Raw material supply
Transport facilities
Availability of labor
Availability of suitable land
Environmental impact and effluent disposal
Local community consideration
Climate
Political and strategic consideration
PLANT LAYOUT
The economic construction and operation of a process unit will depend on how well
the plant equipment specified on the process flow sheet and laid out.
COSTS:
The cost of construction can be minimized by adopting a layout that gives
shortest run of connecting pipes between equipment, and adopting the
least amount of structural steel work. However, this will not necessarily be
the best arrangement for operation and maintenance.
PROCESS REQUIREMENT:
All the required equipments have to be placed properly within process.
Even the installation of the auxiliaries should be done in such a way that it
will occupy the least space.
OPERATION
Equipment that needs to have frequent operation should be located
convenient to the control room. Valves, sample points, and instruments
84
should be located at convenient position and height. Sufficient working
space and headroom must be provided to allow easy access to equipment.
MAINTENANCE
Heat exchangers need to be sited so that the tube bundles can be easily
withdrawn for cleaning and tube replacement. Vessels that require
frequent replacement of catalyst or packing should be located on the
outside of buildings. Equipment that requires dismantling for maintenance,
such as compressors and large pumps, should be placed under cover.
SAFETY
Blast walls may be needed to isolate potentially hazardous equipment, and
confine the effects of an explosion.
At least two escape routes for operator must be
provided from each level in the process building.
PLANT EXPANSION
Equipment should be located so that it can be conveniently tied in with
any future expansion of the process.
Space should be left on pipe alleys for future needs, service pipes over-
sized to allow for future requirements.
MODULAR CONSTRUCTION:
In recent years, there has been a move to assemble sections of the plant at
the manufacturer site. These modules will include the equipment,
structural steel, piping and instrumentation. The modules then transported
to the plant site, by road or sea.
85
SITE LAYOUT
8
1 3 2
10
5
2
4
11
3
1. TANK FARM
2; PLANT AREA
3. EXPANSION
4.PLANT UTILITIES
5. STORES
6. FIRE STATION
7. CANTEEN
8. EMERGENCY WATER
9. LABORATORY
10. WORK SHOP
11. OFFICE
86
87
10. HEALTH & SAFETY HAZARDS
1. HAZARD TO HEALTH
Element MEK is virtually non toxic; no Injuries from inhalation of dust are possible. The dust and
MEK vapor are irritants to eyes, ocular conjunctive mucous membrane, and skin, and may be
classified as nuisance dust. When MEK burns in air it form which is an irritant gas which readily
affected the eyes and respiratory tract. So the use of tight eye protection and dust respirators may
be desirable when working around MEK.
88
11.BIBLIOGRAPHY
RICHARD COULSON VOL-6
TREYBAL MASSTRANSFER
Perry’s Handbook for Chemical Engineers
Mcabe and Smith
Process Engineering Economics by Timmerhaus
Chemical Engineering Journal 2015
http://en.wikipedia.org/wiki/methylethylketone
89