MANUFACTURE OF METHYL ETHYL KETONE

CAPACITY: 500 Metric Tonnes per day

Project Report Submitted in Partial Fulfillment of the

Requirements for the Degree of
B.E. (Chemical)
2019

By

NAVDEEP KUMAR
CH15156

Dr. S. S. BHATNAGAR UNIVERSITY INSTITUTE OF CHEMICAL

ENGINEERING & TECHNOLOGY

PANJAB UNIVERSITY
CHANDIGARH – 160014, INDIA
Dr. S. S. BHATNAGAR UNIVERSITY INSTITUTE OF CHEMICAL
ENGINEERING & TECHNOLOGY
PANJAB UNIVERSITY
CHANDIGARH – 160 014, INDIA

CERTIFICATE

This is to certify that the project entitled “MANUFACTURE OF METHYL ETHYL

KETONE (CAPACITY: 500 TPD)” carried out by Mr. NAVDEEP KUAMR, CH15156
of final year B.E Chemical Engineering during the year 2018-19 is a bonafide work
submitted to the Dr. S. S. Bhatnagar University Institute of Chemical and Technology,
Panjab University, Chandigarh in partial fulfillment of requirements for the award of degree
of Bachelor of Engineering in Chemical Engineering.

PROF. MEENAKSHI GOYAL

Dr.SSB UICET
PANJAB UNIVERSITY
CHANDIGARH
 Acknowledgement

I take this opportunity to express my profound gratitude and deep regards to

Prof. Meenakshi Goyal for her exemplary guidance, monitoring and constant
encouragement throughout the course of this project. The blessing, help and guidance
given by her time to time shall carry me a long way in the journey of life.

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

1.1 METHYL ETHYL KETONE:-

Ketones are organic compounds containing one or more carbonyl groups bound to

two carbon atoms and are represented by the general formula:

O
R --- C --- R’

Based on the hydrocarbon ( R , R’ ) groups attached to the carbonyl group,

ketones can be classified. MEK has the molecular structure : CH3 – CO – C2H5.

It is unsymmetric or mixed aliphatic ketone. It’s IUPAC name is 2-butanone.

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.

It is commercially produced by dehydrogenation of the secondary butyl alcohol. It is

analogus to the production of actone by dehydrogenation of isopropyl alcohol on copper

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

condensation) are the by-products.

Methyl Ethyl Ketone (MEK) is a low –boiling, chemically stable compound also

known as 2- butanone. MEK is a flammable, colourless liquid possessing a typical

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

systems used in the preparation of paints and lacquers.

1
 Interest in MEK as a solvent for paints and adhesives has been growing in

recent years. It has broad applications as solvent for nitrocellulose, cellulose

acetatebutyrate, ethylcellulose, acrylic resins, vinyl acetate and vinyl chloride – vinyl

acetate copolymers. Moreover, MEK can be used as an activator for oxidative

reactions, as a selective extractant, as a special solvent for dewaxing mineral oil

fractions and as a chemical intermediate.

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

adhesives, magnetic tapes, printing inks, solvent extraction, cleaning fluids,

dewaxing agents, and dyes.

In surface coatings MEK is widely used as a component in vinyl lacquer solvent

systems. Its active solvency for vinyl acetate and vinyl chloride – vinyl acetate

copolymers makes it possible to formulate high solids lacquers containing large

amounts of economical hydrocarbon diluents. In addition, it is a strong, active solvent

for nitrocellulose and is extensively used in furniture and automotive lacquers. The low

specific gravity of MEK enables formulators to produce larger volumes of base

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

frequently used in these alkyd formulations.

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

solutions. It is used in vegetable oil extraction process and in azeotropic

separation schemes in refinery.

1.3 ECONOMIC ASPECT:-

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

increase in solventless coatings has not materialized .

The percentage sales distribution for MEK is as follows :

Paints, lacquers, printing inks, aluminium foils – 40%.

Coating and printing of plastics – 20%

Chemical industry, pharmaceutical industry – 13%

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 .

Toxic concentration for water organisms :

Average lethal concentration for fish – 5600 mg / lit

3
Maximum permissible concentration for pseudomonas putida – 1150 mg / lit

Maximum permissible concentration for scendesmus quadricanda – 120 mg / lit

Maximum permissible concentration for small crabs -- 2500 mg / lit

4
 2. PHYSICAL AND CHEMICAL PROPERTIES OF MEK

2.1 PHYSICAL PROPERTIES:-

MEK is a low boiling solvent with an atmospheric boiling point of 175.3 0F

0
(79.6 C). Methyl Ethyl Ketone (MEK) is a chemically stable compound also known as 2-
butanone. MEK is a flammable, colourless liquid possessing a typical 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 systems used in the
preparation of paints and lacquers. It is highly miscible with water and many
conventional organic solvents and forms azeotrope with number of organic solvents.

Some of the physical properties are listed below.

Physical Properties of MEK (all values are at 200c, except where noted)

Boiling point at 1 atm, 0C 79.6

Azeotrope with water , bp, 0C 73.4
Wt.% ketone in vapor 88.7
Autoignition temperature, 0C 515.6
Coefficient of cubic expansion, per 0C 0.00119
Critical pressure, atm 43
Critical temperature , 0C 260
Density, g/mL at 200C 0.8037
Dielectric constant 18.51
Dipole moment, debye units 2.74
Electrical conductivity, mho 5.0 x 10-8
Explosive limits in air, vol.%
Upper 10
Lower 1.8
Flash point, 0C
Tag open Cup 1.11
Tag Closed Cup -2.22
Freezing point, 0C -86.3
Heat of combustion, cal/g 8084
Heat of fusion, cal/g 24.7
Heat of vaporization, cal/g 106
Molecular weight 72.104
Refractive index nD 1.3791
Solubility, wt. %
Ketone in water 26.3
Water in ketone 11.8
Solubility parameter 9.3
Specific heat, cal/g 0C 0.549
Surface tension, dyn/cm 24.6

5
Thermal conductivity, cal/cm2 .s. (0C/cm) 3.58 x 10-4
Vapor pressure, mmHg 80.21
Viscosity, cP 0.43

2.2 Chemical properties:-

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

Aldol condensation of 2 moles of MEK yields a hydroxy ketone, which readily

dehydrates to an unsaturated ketone:
O CH3 O

2CH3CCH2CH3 CH3CH2CCH2CCH2CH3

OH
CH3 O

CH3CH2C == CHCCH2CH3+H2O

Condensation with other Compounds

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

CH3 CCH2CH3 + NH3 + H2 Ni CH3 CHCH2CH3 + H2O

An excess of MEK in this reaction will produce di-sec-butylamine.

Reacting MEK with acetylene gives methyl pentynol, a hypnotic compound:

O CH3

CH3CCH2 +HC ≡CH CH3CH2CC ≡ CH

OH

6
Miscellaneous Reactions

Oxidation of MEK with oxygen produces diacetyl, a flavouring material. Chlorination

yields mixtures of several monochloro and dichloro derivatives in various percentages
depending on reaction conditions. The reaction of MEK with hydrogen peroxide gives a
mixture of peroxides and hydro peroxides which is used to cure polyester resins at room
temperature:
O OH

CH3CCH2CH3 + H2O2 CH3CCH2CH3

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.

Phenol, glyoxal, formaldehyde, acetaldehyde, furfuraldehyde, and other chemicals

can be reacted with MEK to form resins useful for adhesives, coatings, molded products,
and electrical insulation. MEK reacts with acrylonitrile to produce a dinitrile, which upon
hydrogenation produces amines.

7
 3. PROCESS SELECTION AND DETAILS

3.1 PROCESSES AVAILABLE:

There are a few processes listed below for the production of MEK.

1) Vapor phase dehydrogenation of 2- Butanol.

2) Liquid phase oxidation of n-Butane.
3) Direct oxidation of n-Butanes, Hoechst-Wacker process.
4) Direct oxidation of n-Butanes, Maruzen process.

VAPOR PHASE DEHYDROGENTAION OF 2-BUTANOL:

MEK is prepared by vapor phase dehydrogenation of 2-butanol. A 2 step process

from butanes , which are first hydrated to give 2-butanol, is used. The dehydrogenation of
2-butanol is an exothermic reaction (51 KJ/Kgmol). The reaction is as follows.

OH O

CH3 – CH –C2H5 CH3 – C – C2H5

The equilibrium constant for 2-butanol cab be calculated as follows:

log Kp = -2790/T + 1.51 *log T + 1.856

Where T = reaction temperature, K

Kp= equilibrium constant, bar.

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.

Sec-butyl alcohol is dehydrogenated in a multiple tube reactor, the reaction heat

being supplied by heat transfer oil. The reaction products leave the reactor as gas and are
split into crude MEK and hydrogen on cooling. The hydrogen is purified by further
cooling. The crude MEK is separated from uncreated reactants and by-products by
distillation.

8
LIQUID PHASE OXIDATION OF BUTANE:

MEK is produced as a by-product in the liquid phase oxidation of n-butane to

acetic acid. Autoxidation of n-butane of n-butane takes place in the liquid phase
according to the radical mechanism yielding MEK as an intermediate and acetic acid as
end product. MEK and acetic acid (mass ratio 0.2 : 1.0) are obtained by non-catalyzed
liquid phase oxidation at 1800C and 53 bars with remixing. Continuous oxidation under
plug flow conditions at 1500C, 65 bars and a residence time of 2- 7 minutes forms MEK
and acetic acid at a mass ratio of 3:1. this process has slight economic advantage over the
dehydrogenation of 2-butanol. But the key factor is availability and price of butane.

DIRECT OXIDATION OF N-BUTENES, HOECHST-WACKER PROCESS:

In direct oxidation of n-butanes by Hoechst-wacker process, oxygen is transferred

in a homogenous phase on to n-butanes using redox salt pair, PdCl2 / CuCl2.
O

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.

DIRECT OXIDATION N-BUTENES, MARUZEN PROCESS:

The Maruzen process is similar to the Hoechst-Wacker process except that

oxygen is transferred by an aqueous solution of palladium sulfate and ferric sulfate. This
method is attractive commercial route to get MEK via direct oxidation of n-butenes, but it
is patented and very less information is available about this process. This process is
generally not accepted due to formation of undesirable by products.

3.2 PROCESS SELECTION:

Commercially, MEK is predominantly produced by the catalytic dehydrogenatio

of SBA in vapor phase over ZnO or Brass catalyst. It can, however be produced by the
selective direct oxidation of the olefin in a variety of processes, including the Hoechst-
Wacker-type process employing a palladium(II) catalyst .

Most MEK (88%) is produced today by dehydrogenation of 2-butanol. 2-butanol

can be easily produced by the hydration of n-butenes(from petrochemically produced C4
raffinates). The remaining MEK is produced by process in which liquid butane is
catalytically cracked giving both acetic acid and MEK.

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.

MEK is produced as by product from liquid phase oxidation of n-butenes to acetic

acid. The process has slight economic advantage over dehydrogenation of 2-butanol, but
the key factor is the availability and price of n-butanes.

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.

3.3 PROCESS DETAILS:

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.

The dehydrogenation reaction of SBA is as shown

OH O

CH2 – CH – C2H5 H2C – C – C2H5 + H2

The dehydrogenation reaction is endothermic and reversible and therefore a

considerable amount of heat is to be supplied and hence, a multi-tube reactor is selected.

The gaseous reaction products discharged from the reactor at a minimum of

0
400 C will be passed on to the thermosyphon vaporizer in order to initiate the preheating
of alcohol reactor feed. The reaction products will be cooled to near saturation in the
vaporizer so that they will enter the water condenser at 1500C. There about 80% MEK
and alcohol will be condensed and sent to the storage while the remainder will leave this
unit as saturated vapor in non-condensable hydrogen.

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

=500 x 103 /24 kg/hr

=20833.33 kg/hr

However allowing for 8 % spillage and other losses, the hourly production rate will be

= 1.08 x 20833.33 kg/ hr

=22500.00 kg/hr

Material balance is done over the whole process. In this diagram most of the inner processes are

shown in the BLOCK.

Alcohol = 99 % Alcohol Recycle

MEK = 0.92%
TCE = 0.08%
XR1

BLOCK
MEK
X Reactor Prod
still
MEK = 100% 2

X = Pure alcohol feed, kg/Hr

R1 = Recycle ratio

MATERIAL BALANCE ACROSS THE REACTOR:-

Total feed of alcohol to reactor = X + 0.99XR1 = X (1+099R1)

For 89.1% conversion MEK produced,

= X(1 + 0.99R1 )x 0.891 x 72 Kg MEK

74

13
Total MEK from reactor = X (1 + 0.99 R1) x 0.891x72 + 0.0092 XR1 kg
74

The overall conversion = 98.5886%

MEK at final stream(2) = X x 0.985886x72 kg

74

Hydrogen produced due to dehydrogenation reaction

= X (1 + 0.99 R1) x 0.891 x 2

kg. 74

H2 produced are all coming out in the stream (1) is 68.49 wt % .

Total quantity of hydrogen at stream (1) = X ( 1 + 0.99 R1 ) x 0.891x2 kg/hr

74 x 0.6849

MEK in stream (1)

= X( 1 + 0.99R1 ) x 0.891 x2 x 0.0822 kg

74 x 0.6849

MEK Balance: -

(MEK from reactor) = (MEK at recycle)

+ (MEK at stream (1))

+(MEK at stream (2))

X(1 + 0.99R1) x 0.891 x 72 +0.0092 XR1= 0.0092 XR1 + X x 0.985886 x 72

74 74

+ (1 + 0.99R1 ) x 0.891 x 2 x 0.0822

74 x 0.6849

(1 + 0.99 R1) (0.8669 – 2.8902 x 10-3) = 0.9592

(1 + 0.99 R1) = 1.1102
R1 = 0.1102 = 0.1113
0.99

14
MATERIAL BALANCE ACROSS THE CONDENSER:-

Amount of feed to condenser = X (1 + R1 ) kg/hr

MEK = X(1 + 0.99 R1) 0.891 x 72 + 0.0092XR1 kg

74

Alcohol = X( 1 + 0.99 R1) x 0.109 kg

H2 = X( 1 + 0.99 R1) x 0.891 x 2 kg

74

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

Overall material balance

F=L+V

Component balance

(Alcohol)Feed = L(0.1204) + V( 0.0538)

(Alcohol)Feed = F(0.1204) + V(0.0538 – 0.1204)

X(1 + 0.994R1) x 0.109 = X ( 1 + R1 ) (0.1204) + V(0.0538 – 0.1204)
0.1210X = 0.1338X – 0.0666V.

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

MATERIAL BALANCE ACROSS THE ABSORPTION COLUMN:-

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.

Overall material balance

V + VR2 = K+M

Alcohol balance

V x (0.0538) + 0 = K (0.0065) + M (0.0092) –(2)

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 (0.0065) = (0.19204X) (0.0538) – (0.039X) (0.0092)

K= 1.5343X

From (1)

VR2 = K + M - V
= 1.5343X+0.039X-

0.19204X VR2 = 1.38126X

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

MATERIAL BALANCE ACROSS THE EXTRACTION COLUMN:-

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

Overall material balance,

K + C = N + VR2

Alcohol balance

K x 0.0065 + 0 = N x 0.0124 + 0

= > N = (1.5343X) 0.0065

0.0124

=> N = 0.80427X

From overall mass balance,

C = N + VR2 – K

=> C = 0.80427X + 1.38126X – 1.5343X

=> C = 0.65123X

N = 0.80427 X kg.

C = 0.65123 X kg.

MATERIAL BALANCE ACROSS THE SOLVENT RECOVERY UNIT:-

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%

L = Condensate from condensate.

D = MEK still feed.

Overall material balance

N+L=D+C

D=N+L–C

D = 0.80427X + 0.9193X – 0.65123X

D = 1.07234X

MATERIAL BALANCE ACROSS THE MEK PRODUCT STILL:-

Alcohol =12.04 % XR1

MEK = 87.96%

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

Overall material balance

D = P + XR1

=> 1.07234X = P + 0.1113X

=> P + 1.07234X – 0.1113X

=> P = 0.96104X

P = 22500 kg/Hr

19
(0.96104X) = P = 22500.00
X = 22500
0.96104

X = 23412.13685 kg/Hr

Fresh feed of alcohol required = 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

A = REACTOR D = EXTRACTION COLUMN

B = CONDENSER E = SOLVENT RECOVERYCOLUMN
C = ABSORPTION COLUMN F = MEK PRODUCT STILL

21
 6. ENERGY BALANCE

Basis:- 1 Hr. Operation

ENERGY BALANCES ACROSS THE FEED PREHEATING EQUIPMENT:-

The heating of cold 2-butanol feed is to be completed in three stages in order to

avoid large heat losses. The cold feed is first preheated to its boiling point using steam
as heating medium and then vaporized in a thermosyphon reboiler utilizing the heat
contained in the reaction products. The vapor, which has entrained liquid is removed
from the knock out drum, and then heated to reaction temperature using flue gas.

COLD FEED PREHEATER:-

Total feed = 23412.14+2605.77 kg

= 26017.91 kg
26017.91 kg per hour of 2-butanol is to be preheated from 250C it boiling point 107.50C.

Heat load on preheater, Q = 26017.91 x 1.497(380.5 – 288)

= 3.603 x 106 KJ
The heating medium is used is dry saturated steam at 420K

Steam requirement = 3.603 x 106

2123.4

= 1696.8 kg/hr

2-BUTANOL VAPORIZER:-

2-butanol feed is vaporized at 107.50C using reaction products.

Heat load on vaporizer is , Q = M x 

= 26017.91 x 557.43 kj

= 14.5032 x 106 kj/hr

Average Cp of reaction products = 2.3 KJ / Kg 0k

14.5032 x 106 = 26017.91 x 2.304 (642 – T)

22
 T = 400 K

FIRST SUPER HEATER:-

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.

Heat load on super heater, Q = M x Cp x (T2 – T1)

= 26017.91 x 2.038 (573 – 380.5)
6
Q = 10.207 x 10 kj/hr
Mass flow rate of flue gas = 10.2072 x 106
1.2 x ( 673-423)
= 3.4024 x 104 kg/hr

SECOND SUPER HEATER:-

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

Heat load on super heater Q = M x Cp x (T2 – T1)

= 26017.91 x 2.674 (773 – 573)
= 13.9144 x 106 kj/hr
Flue gas requirement, = 13.9144 x 106
1.195 x (873- 623)
= 4.6575 x 103 kg/hr

ENERGY BALANCE ACROSS THE REACTOR:-

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

Mean Cp = 2.68 kj/kg k

23
H = 73900 kj/kgmol

Total 2-butanol feed = 23412.14 + 2579.71 kg

= 25991.85 kg/hr
= 351.24 kmol/hr

Q = 26017.91 x 2.68 x (663- 773) + 351.24 x .891 x

73900 = 15.457 x 106
It is assume that a flue gas is available at 800k & leaving 750k.

Cp = 1.195 kj/kg k

Flue gas requirement, = 15.457 x 106

1.195 x (800-750)
= 25.869 x 104 kg/hr

ENERGY BALANCE ACROSS THE CONDENSER :-

The vapor enters condenser at 1270C (400k) at 1 bar pressure.

Liquid and the vapor leaving the condenser is in equilibrium. At the more mole fraction x
= 0.88 of the condensate we get both liquid and vapor temperature from the T- x-
y diagram and temperature are

299.6 k. = liquid temperature., 335.7 k = vapor temperature

We take cooling water enters at 240C and leaving at 420C

CpH2 = 14650 J/ kg k
Cpalcohol = 1760 J/ kg k
CpMEK = 1664 J/ kg k

Cpmix = 0.867 x 1664 + 0.1089 x 1760 + 0.0241 x 14650

= 1987.42 J/kg.
Heat loss to reduction in vapor temperature from 400k to
335.7k Q1= 26017.91 x 1.98742 (400- 335.7)
= 3.325 x 106 kj/ hr

Heat loss due to condensation

Q2 = 2591.34 x 689.19 + 18931.44 x 486.11
= 10.989 x 106 kj/hr

Heat loss due to further cooling of a part of vapor is

Q3 = 21522.78 x 1.987 x (335.7 – 299.6)

24
 = 1.544 x 106 kj/hr

Total heat lost = Q = Q1 + Q2 + Q3

= (3.325 + 10.989 + 1.544) x 106 kj/hr
= 15.858 x 106 kj/hr
Mass flow of cooling water = 15.858 x 106
4.187 x (42- 24)
= 2.104 x 105 kg / hr

ENERGY BALANCE ACROSS THE ABSORBER :-

Heat of condensation of MEK = 3707.072 x 443.14

= 1.643 x 106 kj/hr

Heat of condensation of alcohol is = 233.488 x 560

= 0.1308 x 106 kj/hr

Heat of solution = (3707.072 + 233.488) x 0.35

= 0.001379 x 106 kj/hr

Heat loss in cooling gasses from 62.7 to 270C

= (74.98 x 1.47 + 8.392 x 1.53 + 624.723 x 14.65) (62.7 –
27)
= 0.3311 x 106 kj/hr

Total heat released = 2.1063 x 106 kj/hr

Heat removed by water vapor = (204.045 x 2437.9)

= 0.49744 x 106 kj/hr
Heat gained by irrigating liquor

a) Water: 31980.6816 x 4.186 (T – 300)

b) MEK: 3707.072 x 2.299 x ( T-300 )

c) Alcohol: 233.488 x 2.429 x (T- 300 )

Total heat gained = 0.49744 x 106 + 0.142961 x 106 (T-

300)kj/hr

Heat released = heat gained

=> 2.1063 x 106 = 0.49744x 106 + 0.14296 x 106 (T – 300)

25
 => T = 311.25 k

ENERGY BALANCE ACROSS THE EXTRACTION COLUMN:-

It is assume that the extraction process is isothermal. All that streams come at 270C
and leaves at 270C.

ENERGY BALANCE ACROSS THE SOLVENT RECOVERY & UNIT:-

Feed is not saturated liquid it is sub-cool liquid. Saturation temperature is

930C From x-y diagram we get Rm = 0.38.

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

Mole fraction of MEK

XMEK = 49.689 = 0.2982
166.609

Feed temperature = 270C

F . HF =3.155 x170.058 (27- 0) + 49.689x165.726 x 27+112.3 x148.56x27 + 1.465x75.36

x27
F . HF = 0.69025 x 106 kj/hr

26
Distillate:-

Alcohol = 233.488 = 3.1552 kmol /hr

74
MEK = (3577.639 – 21.3454 ) = 49.39 kmol/hr
72
Water = (26.3613 –25.9195) = 0.0246 kmol /hr
18
TCE = 2.5098 = 0.0188 kmol/hr
133.5
Total = 52.5886 kmol/hr
D = 52.5886 kmol/hr

Mole fraction of MEK, XMEK = 49.39 = 0.94

52.5886
from T-x-y diagram distillate temperature = 80.40C

Cp MEK = 170 kj/kmol k

Cp alcohol = 228 kj/kmol k

Cp water = 75.37 kj/mol k

Cp TCE = 148.56 kj/mol k

D. HD = 3.1552 x 228 + 49.39 x 170 + 0.4421 x 75.37 + 0.0188x 148.56 (80.4)

= 0.7358 x 106 kj/hr

Residue:

MEK = 21.2454 kg = 0.2965 kmol/hr

TCE = 15199.421 kmol = 113.85 kmol /hr

133.5
Water = 25.9195 = 1.4399 kmol /hr
18
Total = 115.5864 kmol/hr

XMEK = 0.2965 = 0.0026

115.5864
From T-x-y diagram the temoerature obtained .
T = 1120C = 385k (residue)

Cp MEK = 175 kj/mol k

Cp alcohol = 260 kj/kmol k
Cp water = 75.37 kj/kmol k

27
Cp TCE = 148.56 kj/kmol k

W. Hw =  0.2965 x 175 + 113.85 x 148.56 + 1.4399 x 75.37 x (112)

= 1.9123 x 106 kj/hr

Condenser :-

VHv =D.HD + L. HL + Qc.

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.

Vx = 92.556 x 3.18445 x104

= 2.9474 x106 kj/hr

Qc = 2.9474 x 106 kj/hr

Cooling water requirement = 2.9474 x 106

4.187 x (42 –24)
= 3.911x 104 kg/hr

Reboiler:-

Overall heat balance

F. HF + QB = Qc + D . HD + WHw
QB = Qc + D . HD + WHw - F. HF

QB = DHD = WHw + Qc - FHF

QB = 0.7358 x 106 +1.9123 x 106 + 2.9474 x 106 – 0.69025 x 106

QB = 4.90525 x 106 kj/hr

Steam is available at 3.302 bar steam temperature = 410 k

28
 Steam requirement is = 4.90525 x 106
2153.4

= 2277.91 kg/hr

One cooler is attached to cool the residue.

Residue enters the cooler at 1120C and leaves at 270C

So, cooling water requirement = 1.451299 x106

4.187 (42- 24)

= 1.92567 x 104 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

+ 212.9726 x 260 + 3367.511 x 175 + 2.5098 x 148.56

74 72 133.5

+ QB = 2804.315 x 260 + 22298.946 x 165.726 + 2.5098 x 148.56 (82)

74 72 133.5

QB = 2.981 x 106 KJ/hr

Steam is available at 3.302 bar, steam temperature = 410 K.

Steam requirement = 2.981 x 106
2153.4
= 1384.32 Kg/hr

ENERGY BALANCE ACROSS THE DISTILLATION COLUMN:-

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

So, mass flow rate of cooling water = 17.025 x 106

29
 4.187 x (42-24)
= 2.25899 x 106 kg/hr

Reboiler:

QB = DHD + WHw + Qc - FHF

FHF = 2804.315 x 260 + 22298.946 x 165.726 + 2.5098 x 148.56 (82)

74 72 133.5

= 5.01696 x106 kj/hr

DHD= 225.0 x 228 + 22275.0 x 170 (80.5)
74 72
6
=4.2896 x 10 kj/hr
WHw = 2579.7131 x 260 + 23.9731 x 175 + 2.0846 x 148.65 x (107)
74 72 133.5

= 0.97632 x106

kj/hr QB = 17.274 kj/hr

Steam available at = 3.302 bar. Steam temperature = 410 k

Steam requirement = 17.274 x 106

2153.4
= 8021.733 kg/hr.

Distillate & the residue both has to be cooled

Heat load to cool the distillate from 80.5 to 30 0C = 225 x 228 + 22275 x 170 (80.5 –
30)
74 72
6
= 2.69099 x 10 kj/hr.

So, cooling water requirement, = 2.69099 x 106

4.187 x (42- 24)
=3.57056 x 104 kg/hr

Recycle 2-butanol is 107 to 270C

30
 Heat load = 2579.7131 x 260 + 239731 x 175 + 2.0846 x 148.65 (107- 27)
74 72 133.5

= 0.72996 x 106 kj/hr

Cooling water requirement = 0.72996 x 106

4.187 x (42 –24)
= 9685.52 kg/hr.

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

Glossary of notations used

F = molar flow rate of feed, kmol/hr

D = molar flow rate of distillate, kmol/hr
W = molar flow rate of residue, kmol/hr.
xF = mole fraction of MEK in liquid
xD = mole fraction of MEKin distillate
xW = mole fraction of MEKin residue

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 = average molecular weight of feed, kg/kmol

q = Thermal condition of feed

Feed = Saturated liquid at boiling point .

M = 72.218
xD
Rm+1 = 0.66

Rm+1 = xD 0.99
= = 1.5
0.66 0.66

Rm = 1.5 – 1.00 = 0.5

R= 1.5 Rm = 0.75

xD 0.99
= = 0.566
R+1 0.75 +1

Number of trays from graph =14

L = RD = 0.75x312.416 = 234.312 K-moles

G =L+D = 234.312 + 312.416 = 546.728K-moles

q=1 (Feed is saturated liquid)

L = L+qf = 234.312 + 1(347.604) = 581.916 K-moles

G = G+(q –1) F = 546.728 +0 = 546.728 K-moles

33
(A) ENRICHING SECTION:

PLATE HYDRAULICS :

(1) Tray spacing ( ts) = 500 mm

(2) Hole diameter (dh) =5mm

(3) Pitch (lp) =3dh = 3x 5

=15mm lar pitch

(4) Tray thickness (tT ) =0.6 dh = 3mm

(5) Ah = Area of hole= 0.10

Ap Area of pitch

(6) Plate diameter (Dc) :

(L/G)(g/L)0.5 = 0.0246 (maximum at top)

 Flooding check at top

(Ref :1, p: 18-7, fig :18-10)

Csb,flood = 0.3 ft/s

Csb,flood = capacity parameter (ft/s)
Unf = Gas velocity through net area at flood (ft/s or m/s)

34
 Properties

Enriching section Stripping section

Top Bottom Top Bottom

Liquid (k- 234.312 234.312 581.916 581.916

moles/hr)
Liquid (kg/hr) 16875.15 16917.33 42046.34 43047.82

Vapor (k- 546.728 546.728 546.728 546.728

moles/hr)
Vapor (kg/hr) 39375.35 39419.09 39446.43 40444.75

x 0.99 0.9 0.8725 0.012

y 0.99 0.95 0.925 0.012

T liquid (o C) 79.5 81.5 82.0 107.0

T vapor(o C) 80.5 82.5 83.5 107.5

vapor(kg/m3) 2.482 2.471 2.466 2.500

liquid (kg/m3) 750.02 750.00 750.00 739.88

(L/G)(g/L)0.5 0.0246 0.0246 0.061 0.0619

 liq (dyn/cm) 18.00 18.00 17.28 17.28

 vapor 00048 0.0048 0.0048 0.0048

liq 0.27 0.27001 0.449 0.449001

0.0599 0.0.0059 0.148 0.149

2
Dvapor (m /s)
2 1.688x10-9 1.688x10-9 1.952x10-9 1.952x10-9
Dliquid (m /s)

35
 Average conditions and Properties

Enriching section Stripping section

Liquid (k-moles/hr) 234.312 581.916
(kg/hr) 16896.24 42547.08

Vapor ( k-moles/hr) 546.728 546.728

(kg/hr) 39397.22 39945.59

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)

Csb, flood = Unf 20 0.2 g 0.5

 L-g ( Ref; 1, pg: 18-7)


 = liquid surface tension
 g = gas density
L = liquid density

0.2 0.5
Unf = 0.3 18 750.01 – 2.4765 = 5.105 ft/s = 1.556m/s
20 2.4765

Consider , 80% flooding

Un = 0.8 Unf = 1.2448 m/s

Un = Gas velocity

Volumetric flow rate of vapor = 39397.22 = 4.419 m3/s

3600 x 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

Sin(C/2) = (LW/2)/(DC/2) = 0.75

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.

0.785Dc2 – 0.0879 Dc2 = 3.549

Dc = 2.26m.
Dc  2.3m

Lw = 0.75 Dc = 1.725m.
Lw  1.7m

Ad = 0.0879(2.3)2 = 0.465 m2

Ac = (2.3)2 = 4.155m2
4
An = Ac- Ad =4.155-0.465 =3.69 m2

Active area (Aa) = Ac – 2Ad = 4.155 – 2(0.465) = 3.225 m2

Lw = 1.7 = 0.74
Dc 2.3

c = 95.5
. 


37
 Lw = 0.74(2.3)  1.7m

(7) Perforated Area (Ap):

Acz = 260mm x Lw = 2 x 65 x10-3 x1.7 = 0.221 m2

A cz = 0.221 = 0.0532
Ac 4.155

Acz = 5.32% Ac

 = - c = 180 – 95.5 = 84.5


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

= 4.155 – 0.221 – 2 (0.465) – 0.084

= 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)

(a) (Ref:1, p:18-9, eq:18-6)

hd = K1 + K 2(g /L )Uh 2

K1 = 0 (for sieve tray)

Uh = Linear gas velocity through holes.

hd = pressure drop across dry hole (mm liquid)

K2 = 50.8 (Ref :1, pg :18-9).

2
Cv
Cv = Discharge co-efficient. (Ref :1, fig: 18-14, pg :18-9)

For Ah = 0.0905
Aa

tT = 0.6
dh

Cv = 0.75.

K2 = 50.8 = 90.31

0.752
(Uh)top = 39375.35 = 15.126 m/s (minimum)
2.482 x 0.292 x 3600

(hd) top = 90.31 2.4765 (15.126)2 =68.23 mm of clear liquid .

750.01

h = 409  ( Ref: 1, pg:18-7, eq:18-2 (a)

Ldh

h = head loss due to the bubble formation

h = 409 18 =1.963 mm of clear liquid

750.01x5

39
 €
how = Fw 664 q
Lw (Ref: 1, pg: 18-10, eq:18-12 (a)).

how = height of crest over weir

Fw = weir constriction correction factor.

q = Lt
L

q = liquid flow per serration (m3/s )

q= 16896.24 = 6.258 x10-3 m3/s

750.01 x 3600

q1 = 99.197 = 1.35 (Ref:1, pg:18-11, fig:18-16)

2.5
(Lw) (5.577)2.5

Lw = 0.74
Dc

Fw = 1.01

 how = 1.01 (664) 6.258 x10-3

€
= 15.99 mm of clear liquid
1.7

hd + h = 68.23+1.963 = 70.193mm

hw + how = 50+15.99 = 65.99mm

For Ah = 0.09
Aa
hw + how = 65.99 mm

(Ref :1, pg:18-7, fig:18-11)

hd + h = 18mm < 70.193 mm

 There is no weeping

40
(11) Flooding check:

Since the maximum flow rate is at the bottom, flooding checked at the bottom.

hds = hw + how + hhg (For sieve trays)

2
hhg = liquid gradient across plate (mm liquid)

(how )bottom = 16 mm

hds = Calculated height of clear liquid over the dispersers.

hds = 50+16+0.25 = 66.125 mm

2
Ua = linear gas velocity through active area.

Ua = 39397.22 = 1.37 m/s

3600 x 2.4765 x 3.225

g = 2.4765 kg/m3

Fga = Ua (g )½ =1.768(FPS)

( Ref:1, pg:18-10, fig:18-15)

Aeration factor (ß) =0.59

Relative froth density ( t) =0.22

hl l = pressure drop through aerated liquid

hf = actual height of froth.

hl l =  hds = 0.59 (66.125) = 39.1mm

hf = hl l = 39.1 = 185.5mm
t 0.22
2

hda = 165.2 qb ( Ref:1, Pg: 18-10, eq:18-14)

Ada

hda = head loss under the down –comer

Ada = minimum area of flow under the down comes apron.

41
 hap = hds - c = 66.125-25.4 = 40.725mm

Ada = Lw x hap = 1.7 x 40.725x10-3 = 0.069 m2

2
hda = 165.2 6.266 x10-3 = 1.36mm
0.069

ht = total head loss across the plate

hd= it’s calculated at the bottom(maximum) = 68.68 mm

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)

= 107.78 + 50 + 16 + 0.25 + 1.36

= 175.39 mm

Taking (dc) average = 0.50 ; dc = relative froth density

h l = actual back-up
dc

h1dc = 175.39 = 350.78mm <500 mm

0.5

 Flooding check is satisfied

i.e. There is no flooding.


(12) Column efficiency ( AIChE METHOD ):

(A) Point Efficiency: EOG

Ng = 0.776+0.00457hw – 0.238 Ua g 0.5 +105 w (Ref :1, pg:18-15, eq:18-36)

0.5
(Nsc,g)
Ng = gas phase transfer unit

Nsc,g = g= 0.0048 x10-3 = 0.324

g Dg 2.4765 x 0.0059 x10-4

42
Nsc,g = gas phase Schmidt number

39397.22 = 1.37 m/s Ua =

3600 x 2.4765 x 3.225

Df = Lw + Dc = 1.7+2.3 = 2.0m
2 2
Df = width of flow path on plate

W = liquid flow rate (m3/sm)

W= q
Df

q = 16896.24 = 6.26 x10-3 m3/s

750.01 x 3600

W= 6.26 x10-3 = 3.13 x10-3 m3/m-s

2.0

Ng = 0.776+0.00457(50) – 0.238 (1.37) (2.4765)0.5 +105 (3.13 x10-3 )

(0.324) 0.5

Ng = 1.44

NL = KL a L (Ref:1, pg: 18-15, eq:18-36 (a) )

NL = liquid phase transfer units

KL a = liquid phase transfer coefficient (m/s)
QL =Residence time of liquid in froth or spray zone.

(DL)average = 1.688 x10-9

KL a =( DL ) ½ (0.40 Ua g ½ +0.17) (Ref:1, pg:18-16, eg:18-40(a) )

KL a = (3.875 x108 x 1.688 x 10-9 ) ½ ( 0.40x1.37 (2.4765) ½ +0.17)

KL a = 0.833 m/s

L = hL A a (Ref:1, pg:18-16, eq:18-39)

1000qb

hl = liquid hold-up on plate

L = 39.1 x 3.225 = 20.14 s

-3
1000(6.26 x10 )

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

(B) Murphee plate efficiency : Emv

L = Residence time of liquid = 20.14 s

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

  x Eog =0.876 x 0.738

= 0.646

 Emv = 1.26 (from graph)

EOG
 Emv = 0.93

(C ) Overall column efficiency : Eoc

Eoc = log 1+Ea( - 1) (Ref:1, pg:18-17, eq:18-46)

log()

Ea = Murphee vapor efficiency

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

For 80% flood

From (Ref:1, fig:18-22, pg:18-44)

 = 0.15

45
Ea= 0.93 x 1 = 0.79
1+0.93 x 0.15
1-0.15

Eoc = log 1+0.79(0.876-1) = 0.78

log(0.876)

NA = Actual tryas;

NT= theoretical trays.

NA = NT = 4 = 5.14 ~ 6
Eoc 0.78

Height of enriching section = 6 x 0.500 = 3.00 m

(B) STRIPPING SECTION :

PLATE HYDRAULICS :

(1) Tray spacing (ts) = 500 mm

(2) Hole diameter (dn) = 5mm

(3) Pitch (lp) =15mm

lar pitch

(4) Tray thickness (tr) =3mm

(5) Ah = 0.10
Ap

(6) Plate Diameter (Dc) :

(L/G)(g/L)0.5 = 0.0619 (maximum of top)

Csb flood =0.28 ft/s

Unf = 1.434 m/s

Consider , 80% flooding .

46
 Un =1.1472 m/s

Volumetric flow rate of vapor =4.4939 m3/s

Net area (An ) =3.917 m2

Column diameter (Dc) =2.4 m

Lw =1.778 m
Value of Lw taken as 1.75 m.
Lw = 0.73
Dc
Lw = 1.75 m

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

(10) Weeping check (Top) :

(a) (hd)top = 57.54 mm of clear liquid

(hd)bottom = 93.83 mm of clear liquid

(b) h = 1.89 mm of clear liquid

(c ) how =30.194 mm of clear liquid

hw + how = 80.194 mm
hd + h = 59.43 mm

From graph, hd + h = 18mm < 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) Point Efficiency :EOG

(a) Ng =2.384

(b) L = 10.88 s.

(c) Kla = 0.83 m/s

NL = 9.03
 = 1.215
Nog=1.805
EoG=0.83

(B) Murphee plate efficiency :Emv

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

Height of stripping section = 11 x 0.500 = 5.5 m

Total height of the column = Enriching section + stripping section

= 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

6.2 MECHANICAL DESIGN

Specifications:-

Inside Dia :- 2.4m = 2400mm

Ht of top engaging section = 40cm.

Working pressure = 1atm = 1.032 kg/cm2

Design pressure = 1.032 x 1.1 = 1.135 kg/cm2

Shell material = Carbon steel ( Sp. gr. = 7.7)

Permissible tensile abs tress = 950 kg/cm2

Insulation material = asbestos

Density of insulation = 2700 kg/m3

Tray spacing = 500 mm

Insulation thickness = 50 mm

Down comer & plate material = S.S

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

J = joint factor (0.85)

C= corrosion allowance (2 mm)

ts = 1.135 x 2400 +2
2 x 0.85 x 950 – 1.135

= 3.68 mm.

Taking min shell thickness of 6mm

Shell out side Do = 2400+2x6 = 2412mm

The column is provided with torispherical head on both ends.

For torrispherical head, or radius

=> Ro = Do = 2412 mm

ro = 6% Ro
= 0.06 x 2412
= 144.72 mm
= 145 mm

Calculation of head thickness

t = 0.885 Prc +C
f x E – 0.1P

rc = crown radium

E = joint efficienc

f = allowable stress

C = corrosion allowance

ts = 0.855 x 1.135 x 2412 + 2

950 x 0.85 – 0.1 x 1.135
= 5.00 mm

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

Diameter = 2412 + 2412 + 2 x 800 + 2 x 145

24 3
= 4209.2
= 4210mm

Wt of head = d2t [ !
4
=  x (4.210)2 x 0.006 x
7700 4
= 643.13kg.

Calculation of thickness with Hight ;-

Carbon steel material

IS 2002 – 1962 Grade I

Tensile strength R20 = 37 kgf/cm2

Yield stress = 0.55 R20

= 20.35 kgf/cm2

fap = p.di
4(ts-c)

= 1.135 x 2400
4 x (6 – 2)

= 170.25 kg/cm2

fap = tensile stress due to internal pr ( kg/cm2)

Stresses due to dead load (compressive) :-

  w = (wt . of the shell + attachment)

+ (wt . of plate). (wt of liquid hold up)
+ (wt . of the head)

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.

Wp = wt of each plate = (An - Ah ) x t2 . !r + hw +( ts – hap) x t2[ !p + Wa

WL = wt of liquid = ( Aa * HL+ Ad * hdl)fL

w = w1 + w2 + wh + (wp + wL) x X
ts

w1 = wt of shell =  (2.4) x 6 x 10-3 x 7700 (X)

= 348.34 X

w2 = wt of insulation =  (2.5122 – 2.4122) x 2700

4

= 1044.17 X kg.

wh = wt of head = 643.13 kg.

wp = wt of each plate.

= (4.062- 0.3276) x 0.003 x 7800

+ 0.05 + (0.500 – 0.0552) x 0.003 x 7800
+ wa

wp = 150 kg.

WL = wt . of liq

=  3.6 x 48.342 x 10-3 + 0.462 x 0.192687 x 744.94

= 205.2 kg

w = 348.34 x + 1044.17x+(150 + 205.2) X + 643.13

0.500

= 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

Stress due to wind load at a dist X:-

fwx = 1.4 Pw X 2
 do (ts –c)

This design is being due for a wind pressure of 150

kg/m2 Pw = 150 kg/m2

fwx = 1.4 x 150X2 .

-1
 x 241.2 x ( 6 –2) x 10 

= 0.693 x2 kg/cm2

Resultant longitudinal stress in the up wind

Ftmax = fax + fap – fdw

950 x 0.5 = 0.693 X2 - (6.971X + 2.132) + 170.25

=> 0.693X2 – 6.971 X – 302.618 = 0

X = 6.971  ¥ > 2 + 4 (0.693) (302.618)]

2 x 0.693
= 26.52 m

Resultant longitudinal stresses:- at down wind sides:-

- Fcax = - fwx + fap – fdw

Fcmax = 1 (yield stress) = 1 x 20.35

3 3

= 6.783 kg/cm2

55
 - 6.783 = - 0.693x2 + 170.25 – (6.971X +

2.132) => 0.693x2 + 6.971x – 174.898 = 0

X = - 6.971  ¥ 2 + 4 x (0.693 ) (174.898)

2 x 0.693
= - 6.971  23.096
2 x 0.693

= 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.

Design of skirt support:-

Specifications:-

Top disengaging space = 1.25 m

Bottom separator space = 2.25 m

Skirt Hgt = 2m.

Total Height of column including skirt height-

H = 8.50 + 2.00 +1.25 + 2.25 m

H = 14 m

Wt. of shell w1 = di x t x fs x H = 4876.76 kg.

Wt of insulation w2 =  ( 2.1522 – 2.4122 ) x 2760 x

14 4
= 14618.38kg

Wh = Wf. Of Head = 643.13 kg.

Wp = Wt. Of plate = 150kg.

W = W1 + W2 + (WP + WL) H + Wn
ts

= 4876.76 + 14618.38 + (150 + 205.2) x 14 +

643.13 0.5
= 30083.87 kg

56
Wind Load:

fwb = (K P1 H DO). (H/2)

 DO2. t
4
= 2K P1 H2 DO
 DO2 t.

K = 0.7, P1 = 128.5 kg/m2

fbw = 2 x (0.7) (128.5 x 142 x 2.412) kg/cm2

 x (2.412)2 x t x 104

fbw = 4653.289 = 0.46533 kg/cm2

t t

fds = w ,
Dmt.

Dm = Di + t = 2400 + 6 = 2.406 m

fds = 30083.87 = 3980.05 = 39.8 kg/cm 2

 x 2.406 x t t

Seismic load:

fsb = 8cwH
3 Do2t

C= 0.08

fsb = 8 x 0.08 x 30083.87 x 14

3  x(241.2)2 x t

= 0.492 kg/cm2
t
max possible tensile stress:-

j x f = fds – fsb

807.5  39.8 - 0.492

t t
807.5  39.308 t

t  0.0486cm. We can have t = 6mm

57
 max permissible compressive stress:-

jt  fds + fsb

807.5  39.8 + 0.492

t t
807.5  40.292 t

t  40.292
807.5

t  0.0499 cm

choose skirt thickness = 6mm

Skirt bearing plate:

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


This is much less than permissible compressive stress of concrete.

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

Bolting chair has to be used.

Assume Wmin = 2,50,00 kg.

fc = 2,50,00 x 4 - 2 x 0.08 x 30083.87 x 1400

2 2
 (270 - 240 ) 3  x (2704 - 2402)
32 x 270
= 3.09–2.08
= 1.01 kg/cm2

j = Mwt =W min R
Ms Ms.

Ms = 2 (8.08) x 30083.87 x 1400

3
= 2.246 x 106

Mwt = Wmin x R

= 2,50,00 x 270
= 67.5 x 105

j = 67.5 x 105
2.246 x 106
= 3.005

j  1.5 anchor bots are not required.

59
 MINOR EQUIPMENT

CONDENSER

PROCESS DESIGN:

(I) Preliminary Calculations:

(a) Heat Balance:

Vapor flow rate (G) = 546.728 K-moles/hr.

= 39375.35 kg/hr
= 10.94 kg/s

Vapor Feed Inlet Temperature =80.50c.

Let Condensation occur under Isothermal conditions i.e FT = 1.

Condensate outlet temperature = 80.5 0C

Average Temperature = 80.5 0C

Latent heat of vaporisation ()= 4.184 x { 105.93 (0.99)+134.38 (0.01) }

= 444.43 KJ/kg

qh = ( mass flow rate of condensing vapor ) x ( latent heat of vapor )

qh = heat transfer by the condensing vapor .

qh =10.94 x 444.43 = 4862.06 KJ

10% overload is taken

q’h = 1.1 x 4862.06 = 5348.27 KJ

qC= mass flow rate of cold x specific x t

fluid heat

60
 qc = heat transfer by the cold fluid.

Assume : q’h = qc.

Inlet temperature of water = 25 0C.

Let the water be untreated water.

 Outlet temperature of water (maximum) = 40 0C



 t = 42-24= 18 0C

Cp = 4.187 KJ/kg K.

mc = 5348.27x103 = 70.97 kg/s.

4.187x103x18

(b) LMTD Calculations:

assume : counter current

T1 T2

t2
t1

LMTD = ( T1- t2) – ( T2 - t1)

ln (T1- t2 )

(T2 - t1)

T1 = 80.50C; T2 = 80.5 0C ; t1 =24 0C ; t2 =42 0C

 LMTD = 46.93 0C

61
(C) Routing of fluids :

Vapors - Shell side

Liquid - Tube side

(D) Heat Transfer Area:

(i) qh = qC =UA ( T) LMTD,corrected.

U= Overall heat transfer coefficient (W/m2 K)

Assume : U =567.83W/m2K

 A assumed = 5348.27x103
= 200.69 m2
567.83 x 46.93

(ii) Select pipe size:

Outer diameter of pipe (OD) = ô” = 0.0191 m

Inner diameter of pipe (ID) =0.620” = 0.0157m

Let length of tube =16’ = 4.88m

Let allowance = 0.05m

Heat transfer area of each tube (aheat – transfer) =  x OD x (Length – Allowance)

=  x 0.0191 x (4.88 – 0.05)

= 0.289 m2

 Number of tubes (Ntubes) = A assumed 200.69

=
a heat-transfer 0.289

= 695

62
 (iii) Choose Shell diameter:

lar
Choose TEMA : P or S. ¾” OD tubes in 1” pitch.

1-2 Horizontal Condenser

Ntubes (Corrected ) = 716

Shell Diameter (Dc) =787 mm.

 Acorrected =206.924m2

 Ucorrected = 550.75 W/m2K

(iv) Fluid velocity check :

(a) Vapor side – need not check

(b) Tube side

Flow area (atube) = apipe x Ntubes

Per pass
Ntube passes

a pipe = C.S of pipe =  (ID2)

4

 atube =  (0.0157)2 x 716 = 0.0697 m2/pass

42

Velocity of fluid (Vpipe) vp = mpipe

in pipe pipe x atube

mpipe = mass –flow rate of fluid in pipe.

pipe = Density of fluid in pipe (water)

 vp = 70.97 = 1.018 m/s

1000 x 0.0697

 fluid velocity check is satisfied

63
(II) Film Transfer Coefficient :

Properties are evaluated at tfilm :

t
film = tv +1 tv + (t1+t2)  80.5 +  80.5 + (24+42)
2 = 2 = 68.63 0C
2 2

a) Shell side:

Reyonld’s Number (Re) = 4  = 4 W

  (N )€ x L
tubes

= 4 10.94
x = 422.6
€
0.000265 (716) x 4.88

For Horizontal condenser :

3 2 -
Nu = 1.51  (0D) () g • (Re) •

2

=1.51 {0.01913(750)2 x 9.81 }• (422.6)-• = 164.62

(0.265 x 10 –3)2
Nu = ho (OD)
K

ho = outside heat transfer coefficient (W/m2K)

k = Thermal conductivity of liquid.

ho = 164.62 (0.134) = 1154.9 W/m2K

0.0191

64
b) Tube side:

Gt = mpipe
atube

Gt= Superficial mass velocity

Gt = 70.97 =1018.2 kg/m2s

0.0697

Re = (ID) Gt = 0.0157 x 1018.2 = 20043.3

 0.8 x 10 –3

Pr = Cp = 0.8 X 10 –3 x 4.187 x 10 3 =5.79

K 0.578

hi (ID)
K = 0.023 (Re ) 0.8 (Pr) 0.3
hi = inside –heat transfer coefficient

hi = 0.023 (20043.3) 0.8 (5.79) 0.3 x 0.578

0.0157

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

Uo = overall heat –transfer coefficient

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 = 0.079 (Re)-¼ = 0.079 (20043.3 ) -¼ =6.64 x 10 –3

f = friction factor

Pressure Drop along

the pipe length ( P)L = ( H)L x  x g

= 4fLVp2 x  x
g 2g(ID)

= 4 x 6.64 x 10-3 x 4.88 x 1018.2 2 x 9.81

2 x 9.81 x 0.0157 x 1000

= 4.266 KPa

Pressure Drop in the

end zones ( P)e = 2.5  Vp2 = 2.5 x1000 x 1.018 2 =1.29591 KPa
2 2

Total pressure drop

in pipe ( P) total = [4.26 + 1.296 ] 2 = 11.1 KPa < 70 KPa

b) Shell side: Kern’s method

Baffle spacing (B) = Ds =787 mm

C1 = 2.54 x 10 –2 – 0.0191 = 0.0063

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

De = 4  P Tx 0.86 PT - 1(OD)2= 4(25.4 x 10–3)2x 0.86 -(0.0191)2

2 2 4 2 8

( do)  ( 0.0191)
2 2

= 18.29mm.

Gs= Superficial velocity in shell = mshell = 10.94 = 70.58 kg/m2s

ashell 0.155

(NRe)s = Gs Dc = 70.58x 18.29 x 10 –3 = 151955

-6
 8.5 x 10

f = 1.87 (151955) –0.2 = 0.172

 Shell side pressure

drop
( P)s = 4 f (Nb + 1)Ds Gs2 g ] x 0.5

2 g De  vapor

Nb = 0

 Ps= 4(0.172) (1) (0.787) (70.58)2 9.81 x 0.5

-3
2 x 9.81 (18.29 x 10 ) x 2.482

= 14.84 KPa (It very near to permissible pressure drop) .

67
 MECHANICAL DESIGN:

(a) Shell Side:

Material carbon steel (Corrosion allowance = 3mm)

Number of shells =1
Number of passes =2

Working pressure = 1 atm = 0.101 N/mm2

Design pressure = 1.1 x 0.101 = 0.11 N/mm2
Temperature of the inlet = 80.5 0C
Temperature of the outlet =80.5 0C

Permissible Strength for

Carbon steel = 95 N/mm2

b) Tube side :

Number of tubes =716

Outside diameter =0.0191m
Inside diameter = 0.0157m
Length = 4.88m
lar
Pitch, = 25.4 x 10-3 m
Feed =Water.
Working Pressure =1 atm = 0.101 N/ mm2
Design Pressure =0.11 N/mm2
Inlet temperature =24 0C.
Outlet temperature = 42 0C
Shell 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

ts = 0.11 x 0.787 = 0.54 mm

2 x 95 (0.85) –0.11

Minimum thickness = 6 + 3 = 9 mm (Including corrosion allowance)

 ts = 10 mm

68
Head : (Torrispherical head)

th = PRCW
2fJ

th = thickness of head

W = ¼3+ ¥ Rc / Rk }

Rc = Crown radius = outer diameter of shell =787mm

Rk = knuckle radius = 0.06 RC

 W = ¼3+ ¥ Rc / 0.06 Rc } = 1.77

 th = 0.11 x 787 x 1.77 = 0.95 mm

2 x 95x 0.85

Minimum shell thickness should be = 10 mm

 th = 10mm

Since for the shell, there are no baffles, tie-nods & spacers are not required.

Flanges :

Loose type except lap-joint flange.

Design pressure (p) =0.11 N/mm2
Flange material : IS:2004 –1962 class 2
Bolting steel : 5% Cr Mo steel.
Gasket material = Asbestos composition
Shell side diameter =787mm
Shell side thickness =10mm

Outside diameter of shell =787 + 10x 2 = 807mm

Determination of gasket width :

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)

di = inside diameter of gasket = outside diameter of

shell =807+ 5mm
=812 mm

do = outside diameter of the gasket

= 1.004 (812)
= 816 mm

Minimum gasket width = 816– 812 = 2 mm

2
But minimum gasket width = 6mm
 G= 812 + 2 x 6 = 824 mm

G = diameter at the location of gasket load reaction.

Calculation of minimum bolting area :

Minimum bolting area (Am) = Ag= Wg

Sg

Sg = Tensile strength of bolt material (MN/m2)

Consider , 5% Cr-Mo steel, as design material for bolt

At 80.50C.

Sg = 138 x 10 6 N/m2

Am = 0.6037 x 10 6 = 4.375 x 10-3 m2

138 x 10 6

70
Calculation for optimum bolt size :

g1 = go = 1.41 go

0.707

gl = thickness of the hub at the back of the flange

go = thickness of the hub at the small end = 10+ 2.5 =12.5mm

Selecting bolt size M18x2

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)

C= 0.787 +2 (1.41 (0.0125)+0.027)=0.876 m

Estimation of bolt loads :

Load due to design pressure (H) =  G2 P

4
H =  (824)2 (0.11) = 0.0586 x106 N
4

Load to keep the joint tight under operating conditions.

Hp =  g (2b) m p

b= Gasket width = 6mm = 0.006m

Hp =  (0.824 ) ( 2 x 0.006) x 2.75 x 0.11 x 106 = 9.39 x 103

N Total operating load (Wo) = H+Hp
= 0.06799 x 106 N

Load to seat gasket under bolt –up condition =Wg.

Wg. =  g b y

=  x 0.824 x 0.006 x 25.5 x 106

Wg = 0.396 x 106 N

71
 Wg > W0

  Wg is the controlling load

 Controlling load = 0.396 x 106 N

= 0.876 +0.018+ 0.02

= 0.914 m

Check for gasket width :

Ab = minimum bolt area = 44 x 1.54 x 10-4 m2

-4
Ab Sg = (44 x 1.54 x 10 )138 = 30.1 N/mm2
 GN  x 0.824 x 0.012

 GN

i.e., bolting condition is satisfied.

Flange Moment calculations :

(a) For operating conditions :

WQ = W1 +W2 +W3

W1 =  B2 P = Hydrostatic end force on area inside of flange.

4

W2 = H-W1

W3= gasket load = WQ - H = Hp

B= outside shell diameter = 807 mm

W1 =  (0.807)2 x 0.11 x 106 = 0.056 x 106 N

4

72
W2 = H- W1 =(0.0586 – 0.056) x 106 =0.0026 x 106 N

W3 = 9.39 x 103 N

Wo =( 0.056+ 0.0026 + .00939 ) x 106

= 0.06799x 106 N

Mo = Total flange moment = W1 a1 + W2 a2 + W3 a3

a1 = C –B ; a2 = a1 + a 3 ; a3 = C -G
2 2 2

C=0.876 ; B=0.807 ; G=0.824

a1 = 0.876 – 0.807 = 0.0345

2

a3 = C – G = 0.876 – 0.824 = 0.026

2 2
a2 = a1 + a 3 = 0.0345 +0.026 = 0.0303
2 2

Mo =[ 0.056 ( 0.0345) + 0.0026 ( 0.0303) +0.00939 (0.026) ] x 106

=2.255 x 103 J

(b) For bolting up condition :

Mg = Total bolting Moment =W a3

W = (Am +Ab) Sg .
2

Am =2.869 x 10-3
Ab = 44 x 1.5 4x 10-4 = 67.76 x 10-4
Sg = 138 x 106

W= ( 2.869 x 10-3 + 67.76 x 10-4 ) x 138 x 106 = 0.666 x

106 2

Mg = 0.666x 106 x 0.026 = 0.017 x 106 J

Mg > Mo

 Mg is the moment under operating conditions

73
 M= Mg = 0.017 x 106 J

Calculation of the flange thickness:

t2 = MCFY
BSFO

CF= Bolt pitch correction factor = ¥ Bs / (2d + t)

Bs = Bolt spacing =  C = (0.876) = 0.0625 m

n 44

n= number of bolts = 44

Let CF = 1

SFO = Nominal design stresses for the flange material at design temperature.

SFO = 100 x 106 N

M = 0.017 x 106 J
B = 0.807 m.

K = A = Flange diameter = 0.914 = 1.13

B Inner Shell diameter 0.807

Y = 15

t =  0.017 x 106 x 1 x 15 = 0.06 m

6
0.807 x 100 x 10
d = 18 x 2 = 36mm

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

Gc = mean gasket diameter for cover.

P = design pressure.
K = factor = 0.25 (when cover is bolted with full faced gasket)
F = permissible stress at design temperature.

t1s = 0.824  (0.25 x 0.11 x 106) / ( 95 x 106) = 0.014 m

Channel and channel Cover

th=Gc (KP/f) ( K = 0.3 for ring type gasket)

= 0.824 (0.3 x 0.11/ 95)
= 0.015 m = 15 mm
Consider corrosion allowance = 4 mm.
th=0.004 + 0.015 = 0.019 m.

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

Bending moment at center of the span

M2 = QL/4[(1+2(R2-H2)/L)/(1+4H/(3L))-4A/L]
M2 = 9380.4 kg-m

Stresses in shell at the saddle

(a) At the topmost fibre of the cross section
f1 =M1/(k1 R2 t) k1=k2=1
=12.79/(3.14 x 0.40352 x 0.01)
= 2500.54 kg/m2
The stresses are well within the permissible values.
Stress in the shell at mid point
f2 =M2/(k2 R2 t)
= 180.8 kg/cm2
Axial stress in the shell due to internal pressure
fp= PD/4t
= 0.11 x 106 x 0.787 /( 4 x 0.01)
= 216.4 kg/cm2
f2 + fp = 397.23 kg/cm2
The sum f2 and fp is well within the permissible values.

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

Chemical Engineering Plant Cost Index:

Cost index in 1967 = 110
Cost index in 2002 = 402
Thus, Present cost of Plant = (original cost) × (present cost index)/(past cost
8 8
index) = (4.9786 x 10 ) × (402/110) = Rs. 18.19×10
8
i.e., Fixed Capital Cost (FCI) = Rs. 18.19×10

9.1 Estimation of Capital Investment Cost:

I. Direct Costs: material and labour involved in actual installation of
complete facility (70-85% of fixed-capital investment)

a) Equipment + installation + instrumentation + piping + electrical + insulation

+ painting (50-60% of Fixed-capital investment)
1. Purchased equipment cost (PEC): (15-40% of Fixed-capital
investment)
Consider purchased equipment cost = 25% of Fixed-capital investment
8 8 8
i.e., PEC = 25% of 18.19×10 = 0.25 × 18.19×10 = Rs. 4.547×10
2. Installation, including insulation and painting: (25-55%
of purchased equipment cost.)
Consider the Installation cost = 40% of Purchased equipment cost
8 8 8
= 40% of 4.547×10 = 0.40 ×4.547×10 = Rs.1.819×10
3. Instrumentation and controls, installed: (6-
30% of Purchased equipment cost.)
Consider the installation cost = 20% of Purchased equipment cost

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

5. Electrical, installed: (10-40% of Purchased equipment cost)

Consider Electrical cost = 25% of Purchased equipment cost
8 8 8
= 25% of 4.547 ×10 = 0.25 ×4.547×10 = Rs. 1.1368×10

B. Buildings, process and Auxiliary: (10-70% of Purchased equipment

cost) Consider Buildings, process and auxiliary cost = 40% of PEC
8 8 8
= 40% of 4.547 ×10 = 0.40 ×4.547×10 = Rs. 1.819×10
C. Service facilities and yard improvements: (40-100% of Purchased
equipment cost)
Consider the cost of service facilities and yard improvement = 60% of PEC
8 8 8
= 60% of 4.547 ×10 = 0.60 ×4.547×10 = Rs. 2.7285×10
D. Land: (1-2% of fixed capital investment or 4-8% of Purchased equipment cost)
8 8
Consider the cost of land = 6% PEC = 6% of 4.547 ×10 = 0.06 ×4.547×10
8
= Rs. 0.2728×10

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

IV. Working Capital: (10-20% of Fixed-capital investment)

Consider the Working Capital = 15% of Fixed-capital investment
8 8
i.e., Working capital = 15% of 21.7×10 = 0.15 × 21.7×10
8
= Rs. 3.255×10
V. Total Capital Investment (TCI):
Total capital investment = Fixed capital investment +
8 8
Working capital = (21.7×10 ) + (3.255×10 )
8
i.e., Total capital investment = Rs. 24.955×10

9.2 Estimation of Total Product cost:

I. Manufacturing Cost = Direct production cost + Fixed charges +
Plant overhead cost.
A. Fixed Charges: (10-20% total product cost)
i. Depreciation: (depends on life period, salvage value and method
of calculation-about 13% of FCI for machinery and equipment
and 2-3% for Building Value for Buildings)
Consider depreciation = 13% of FCI for machinery and equipment
and 3% for Building Value for Buildings)
8 8
i.e., Depreciation = (0.13×21.7×10 ) + (0.03×1.819×10 )
8
= Rs. 2.8755×10

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

B. Direct Production Cost: (about 60% of total product cost)

Now we have Fixed charges = 10-20% of total product charges – (given)
Consider the Fixed charges = 15% of total product cost
Ö Total product charge = fixed charges/15%
8
Ö Total product charge = 5.7702×10 /15%
8
Ö Total product charge = 5.7702×10 /0.15
8
Ö Total product charge(TPC) = Rs. 38.468×10

i. Raw Materials: (10-50% of total product cost)

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

B.Distribution and Selling costs: (2-20% of total product cost); includes

costs for sales offices, salesmen, shipping, and advertising.
Consider the Distribution and selling costs = 15% of total
8
product cost Distribution and selling costs = 15% of 38.468×10
8
Ö Distribution and selling costs = 0.15 × 38.468×10
8
Ö Distribution and Selling costs = Rs. 5.7702×10

C. Research and Development costs: (about 5% of total product cost)

Consider the Research and development costs = 5% of total
8
product cost Research and Development costs = 5% of 38.468×10
8
Ö Research and development costs = 0.05 × 38.468×10
8
Ö Research and Development costs = Rs. 1.9234×10

D. Financing (interest): (0-10% of total capital investment)

Consider interest = 5% of total capital investment
8
i.e. interest = 5% of 24.955×10 =
8 8
0.05×24.955×10 Interest = Rs. 1.2477×10

8
Thus, General Expenses = Rs. 10.8647×10

IV. Total Product cost = Manufacture cost + General Expenses

8 8
= (47.6686×10 ) + (10.8647×10 )
8
Total product cost = Rs. 58.5333×10

82
V. Gross Earnings/Income:
Wholesale Selling Price of MEK per kg = Rs.40

Total Income = Selling price × Quantity of product

8
manufactured = 40 x 1.782 x 10
8
Total Income = Rs. 71.28×10
Gross income = Total Income – Total Product Cost
8 8
= (71.28×10 ) – (58.533×10 )
8
Gross Income = Rs. 12.747×10 Let
the Tax rate be 45% (common)
Net Profit = Gross income - Taxes = Gross income× (1- Tax rate)
8 8
Net profit = 12.747 x 10 (1-0.45) = Rs. 7.01085×10
Rate of Return:
Rate of return = Net profit×100/Total Capital
8
Investment Rate of Return = 7.01085×10 ×100/
8
(24.935×10 ) Rate of Return = 28.11%

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.

The principal factors to be considered are:

1. Economic consideration: construction and operation cost.
2. The process requirement
3. Convenience of operation
4. convenience of maintenance
5. Safety
6. Future expansion
7. Modular construction

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.

2. FIRE AND EXPLOSION HAZARDS

The only location in the MEK aplant where there are chances of fire and explosion is in MEK storage
and melted pit. The cause of such fire is the presence of MEK dust in the vicinity of solid MEK
storage. The MEK dust forms an explosive mixture at low concentrations in air and thus it is
important to minimize the formation of dust.

3. HEALTH & SAFETY FACTORS


 to provide natural draft ventilation
MEK storage tanks should also have adequate roof vents
 of MEK gas which may be released from liquid MEK.

 of ignition should be excluded from the immediate vicinity of liquid MEK storage
All sources
 tanks.

Persons engaged in liquid MEK operations should have the body completely protected from
 clothing, and in addition, should wear safety hats, safety glasses with side shields, and heat-

resistant gloves. An additional full-faceshield should be worn when disconnecting piping


 used for transporting liquid MEK.

Liquid MEK is a hot material, so it can cause severe burns when it contacts the skin. First-aid
 treatment should include immediate cooling of the affected area with cool running water, by

immersion in water, or by application of cold compresses.

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