Oligomerizare Instalatie Model
Oligomerizare Instalatie Model
Oligomerizare Instalatie Model
In order to design a chemical plant, a whole design calculation of the main units, where
all sizing parameters including volume, height, diameter, etc. should be held. In this chapter we
will elaborate a detailed design for the main units of the plant based on the results achieved in
mass and energy balance calculations.
Design calculation is a very important step in every chemical plant as it aims to optimize
the units’ sizes and dimensions. In addition, it contributes heavily in budget estimation.
III.1- Pump
There are three main types of pumps in the industry: positive-displacement pumps, gravity
pumps and centrifugal pumps. Centrifugal pumps are the most commonly employed in industrial
plants since they are designed to move high flows. In addition, they have low maintenance cost
and they are easily maintained.
In order to calculate the pump’s parameters, Bernoulli equation is used.
Table 3.1 lists all the assumptions used during calculation.
Pipe Length 15 m
Velocity 5 m/s
Minor losses hL 3m
The pump is used to transport a feed of propylene and propane with a mass flow of 20,000 kg/h.
Density of propylene: 513 kg/m3
Density of propane: 493 kg/m3
m propylene 18000
V propylene = = = 35.09 m3/h
ρ propylene 513
m propane 2000
V propane = = = 4.09 m3/h
ρ propane 493
Volumetric flow rate of the mixture: 35.09 + 4.09 = 39.18 m3/h = 0.0109 m3/s
4 Q 0.5
The pipe diameter d = ( )
π∗v
Q is the volumetric flow rate and v the velocity of the fluid in the pipe.
4∗0.0109 0.5
d=( ) = 0.053 m = 53 mm = 2”
π∗5
Now we have to find Reynolds number in order to find Darcy coefficient from Moody Diagram.
v∗d∗ρ
Reynolds number Re =
µ
Calculating the average density of the mixture:
ρ propylene∗V propylene+ ρ propane∗V propane 513∗35.09+ 493∗4.09
ρ avg = = = 510.91
Total Volume 39.18
kg/m3
The viscosity of propylene is 0.00009 Pa.s [20]
The viscosity of propane is 0.00011 Pa.s [20]
Calculating the average viscosity of the mixture:
µ propylene∗V propylene +µ propane∗V propane 0.00009∗35.09+ 0.00011∗4.09
µ avg = = =
Total Volume 39.18
0.000092 Pa.s
v∗d∗ρ 5∗0.053∗510.91
Re = = = 1,471,643.
µ 0.000092
Relative roughness ε/d = 0.015/53 = 0.000283, assuming that the pipe is made of stainless steel
having a roughness of 0.015 mm.
According to Moody Diagram above, for Re = 1,471,643 and ε/d = 0.000283, Darcy coefficient
λ = 0.015.
λ∗L v 2 0.015∗15 5
2
Friction losses hf = * = * = 5.4 m
d 2g 0.053 2∗9.81
Total losses H = hf + hL = 5.4 + 3 = 8.4 m
III.2- Heater
The function of this heat exchanger is heating the feed stream of propylene and propane from
25oC to 150oC. In heat exchangers, fluids are used to transfer the heat to the medium to be
heated. These two mediums are in indirect contact as shown in Figure 3.1.
Figure 3.1: Heat Exchanger Layout
Steam at a temperature of 165oC is used as a heating fluid. At this temperature, the vapor
pressure of steam is 6 bar [24].
According to design heuristics, the pressure drop inside the heat exchanger is 0.3 bar
P2 = P1 – 0.3 = 6 – 0.3 = 5.7 bar. The temperature corresponding to this pressure is 160 ºC [24].
As the heating fluid is steam and the cold stream is propylene and propane mixture, the overall
heat transfer coefficient U is ranging between 2500 and 3500 W/m2.ºC [25].
∆ T 1−∆ T 2 135−15
The mean temperature ∆TLM = ∆T 1 = 135 = 54.61°C
ln ( ) ln ( )
∆T 2 15
Heat load of feed Q = 4.18 MW (energy balance results).
Q = U * A * ∆TLM
Q 4180000
The area A = = = 25.51 m2
U∗∆ T LM 3000∗54.61
A < 50 m2 therefore a multiple pipe heat exchanger will be selected.
We assume that the steam enters to the heat exchanger and flows outside the tubes (through the
annular cross section) at a temperature of 165°C and leaves at a temperature of 160°C in order to
heat the feed stream (which flows inside the tubes) from 25°C to 150°C, the average temperature
of the steam is:
T i+ T f 165+160
T avg , steam= = =162.5° C
2 2
The properties of steam are listed below:
Cp = 1926 J/kg.K
ρ = 3.419 kg/m3
µ = 0.000014 Pa.s
K = 0.02996 W/m.K
Cp∗µ 1926∗0.000014
Pr = = = 0.9
K 0.02996
m 7.8
The volumetric flow rate of steam Q̇ = = = 2.28 m3/s
ρ 3.419
The diameter of the external pipe D ext = Di + 2 * t
Di is the internal diameter and t is the thickness of the tube, assumed to be 2 mm.
The flow rate of propylene and propane in the internal tube is 19600 kg/h (5.45 kg/s)
Calculating the average density of the mixture:
ρ propylene∗V propylene+ ρ propane∗V propane
ρ avg =
Total Volume
m propylene 17640
The volume of propylene: V propylene = = = 34.38 m3/h
ρ propylene 513
m propane 1960
The volume of propane: V propane = = = 3.97 m3/h
ρ propane 493
513∗34.38+ 493∗3.97
ρ avg = = 510.92 kg/m3
34.38+ 3.97
m 5.45
The volumetric flow rate Q of the feed: Q = = = 0.0107 m3/s
ρ 510.92
Di =
√ 4∗Q
п∗V
=
√
4∗0.0107
п∗5
= 0.53 m = 530 mm
D = 2D ext = 1068 mm
V ( D−D ext )∗ρ 5 ( 1.068−0.534 )∗3.419
Reynolds number in the external pipe Re ext = = =
µ 0.000014
652052
Nu ext = 0.023 x Re0.8 x Prm = 998.68
Nu ext∗K ext 998.68∗0.02996
h ext = = = 56.03 W/m2K
D−Dext 1.068−0.534
U = 2921.6 W/m2oC
Q 4180000
A= = = 26.19 m2
U∗ΔTm 2921.6∗54.61
A 26.19
N= = = 2.6 tubes, say 3 tubes.
п Dext L п∗0.534∗6
The heat exchanger specifications are summarized in Table 3.2.
In this section we perform design calculations to select the best reactor volume. The reactor is
one of the major units of the process as it is where the oligomerization will occur. Packed bed
reactor PBR is favored in the oligomerization industry as it provides an adequate area of contact
between the reactants and the catalyst. The volume of the reactor must encase the reactants,
catalyst and any possible deviations. In addition, we will calculate the required mass of the
catalyst for the process. The catalyst used for oligomerization of propylene is solid phosphoric
acid.
In the reactor propylene is oligomerized to poly-gasoline. The operating initial temperature the
reactor is 150oC and the pressure is 60 bar.
The weight hourly space velocity of the reaction of oligomerization is in the range of 0.5 h -1 and
5 h-1 [28].
We will refer to the average of WHSV = 2.75 h-1.
mass of feed
WHSV =
mass of catalyst
The total mass flow rate of the feed entering the reactor is 19,208 kg/h (mass balance results).
19208
Mass of catalyst = = 6985 kg
2.75
mcatalyst
The bulk density of the catalyst ρb =
V reactor
The bulk density of SPA catalyst is ρb = 0.85 – 0.9 kg/L [29].
The average is 0.875 kg/L
6985
Reactor volume V reactor = = 7983 liters, say 8 m3
0.875
1 /3
4V π
Reactor diameter D reactor = ( + ) = 1.5 m
3 π 24
L
Since the reactor volume is below 40 m3, is between 2 and 5 [30].
D
L
We take the average = 3.5
D
Reactor length L = 1.5 * 3.5 = 5.25 m
The specs of the reactor are summarized in Table 3.3
Volume 8 m3
Diameter 1.5 m
Length 5.25 m
Based on material balance results, the table below summarizes the flash separator mass balance
where Fi, Vi and Li are the mass flow in kg/h of each component in the feed, vapor product and
liquid product respectively.
v max = K *
√ ρL− ρG
ρG
where,
ρL = density of the liquid product
ρG = density of the gas product
K is an empirical coefficient calculated as follows:
K = exp [A + B ln(FLG) + C (ln(FLG))2 + D (ln(FLG))3 + E (ln(FLG))4]
FLG =
G
L √ ρG
ρL
G and L refer to the mass flow of gas and liquid products respectively.
1 345.74∗614+96.04∗493+9853.704∗755
ρL = Ʃ L i ρi = = 747.82 kg/m3
L 10295.484
MP
We assume that the vapor would act as an ideal gas, then ρG =
RT
M = average molecular weight of the gas (kg/kmol)
P = drum pressure (Pa)
T = temperature (K)
R = ideal gas constant = 8.314 J/mol.K
1 6569.14∗42+1824.76∗44 +518.616∗93.5
M= Ʃ Gi Mi = = 45.4 kg/kmol
G 8912.516
MP 45.4∗3500
ρG = = = 60.1 kg/m3
RT 8.314∗318
v max = K *
√ ρL− ρG
ρG
= 0.032 *
√747.82−60.1
60.1
= 0.108 ft/s
The vessel diameter must be selected taking into consideration that the maximum velocity of
0.108 ft/s is not reached. A standard diameter of 52 in (4.33 ft or 1.32 m) is selected.
2
d 4
Area A = π = π = 14.72 ft2
4 4
G 8912.516
Volumetric flow of gas QG = = = 148.29 m3/h = 1.45 ft3/s
ρG 60.1
Q 1.45
v= = = 0.098 ft/s < 0.108 ft/s
A 14.72
Thus the selected diameter is suitable.
Now we will calculate the height of the vessel.
Estimation of the vessel height can be done by estimating height of each stage on the separator.
The height of the inlet nozzle to the top of the vessel is assumed to be 90% of the vessel
diameter, with a minimum length of 36 in.
H5 = 0.9 * D = 0.9 * 52 = 46.8 in; H5 = 48 in = 1.22 m
The inlet nozzle diameter must give the maximum allowable velocity to ensure liquid shock on
vessel entrance.
QG 1.45
Nozzle area An = = = 13.42 ft2
v max 0.108
Nozzle diameter Dn =
√ 4 An
π
= 4.13 ft = 49.56 in. Thus, we choose a nozzle diameter H4 = 50 in.
The high liquid level to the inlet nozzle can be estimated as 30% of the vessel diameter with a
minimum of 12 ft.
H3 = 0.3 * D = 0.3 * 52 = 15.6 in = 0.39 m
For liquid product, a retention time of 3 minutes would give total holdup in the vessel QH
L 10295.484
QL = = = 13.77 m3/h; QL = 0.135 ft3/s
ρL 747.82
QH = QL * t = 0.135 * 180 = 24.3 ft3
Assuming a slug capacity equal to the holdup quantity, the level range (H2) can be estimated as:
QH 24.3
H2 = = = 1.65 ft = 19.8 in, then H2 = 20 in = 0.508 m
A 14.72
Finally, the low liquid level to vessel bottom H 1 depends on the pressure (35 bar = 507 psi)
which is lower than 1000 psig then 𝐻1=6 𝑖𝑛 = 0.15 m
Total height H = H1 + H2 + H3 + H4 + H5 = 6 + 20 + 16 + 50 + 48 = 140 in = 3.5 m
H 140
= = 2.69
D 52
H
Since 2.5 < <5 , so the design is accepted.
D
III.5- Stabilizer
Streams in the stabilizer, and their molar composition, and flow rates are listed in the below
table:
Table 3.5: Stabilizer streams composition
Compound Feed Distillate Bottom
M X M X M X
(Kmole/h) composition (Kmole/h) Composition (Kmole/h) composition
Gasoline 105.39 0.93 1.05 0.11 104.33 0.99
Nm = log
[¿ ( xLK / xHK ) d∗( xHK / xLK ) b]
logαLK −HK
¿= ( )( )
log [
0.89
0.11
∗
0.99
]
0.01 = 2.016
1.44
Reflux Ratio:
The optimum reflux ratio is between 1.2 and 1.5 of the minimum reflux ratios.
𝑅 = 1.25 ∗ 𝑅𝑚
𝑅 = 1.25 ∗ 1.44 = 1.8
Using Gilliland equation:
N −Nm R−Rm 0.566
= 0.75*(1- ¿
N +1 R+1
N = 8.7, so 9 trays
Column Heigh:
Trays, tray spacing, and top and bottom spaces are all part of the distillation column. The column
height includes the distance between trays, as well as the thickness of the trays, as well as 1 m of
top and bottom space.
The distance between trays is the same as the number of trays multiplied by the tray spacing. The
number of stages multiplied by the recommended tray thickness equals the thickness of the trays.
H = (Nactual - 1)*tray spacing + Nactual * ttray + 2
Where,
ttray = thickness of the tray 5mm
Tray spacing 0.6m
H = (8*0.6) + (9*0.005) + 2 = 6.8 m, so 7 m
PM 15000∗42
ρv = = =0.24 kg/m3
RT 8.314∗321∗1000
1
ρ l = 0.99 0.01 = 746 kg/m3
+
750 513
The diameter of the column will be obtained using the following equation:
√ 4xV ^w
Dc= = 0.86 m
π ρ v u^ v
^ is the maximum vapor flow rate = (1+R) D = (1+1.8)*0.15 = 0.42 kg/s
Where, V w
In the aim of determining the economic feasibility of a plant, the investment and cost of
production must be determined. The Module Factor approach is used to estimate the capital cost
at the referenced year. However, cost changes overtime due to several factors: inflation,
improvements in manufacturing, changes in quality, changes in supply and demand, standards
and regulations. Thus, to take these factors into account, a time correlation must be applied.
One of the most important factors in the estimation of equipment cost is selecting the
material of construction. The material is selected based on many factors such as temperature,
pressure, strength, and its ability to resist corrosion. The selection of material is a crucial step
while designing.
The following correlation is used to calculate the base purchased cost Cp0 of the equipment:
2
log 10 C P=K 1 + K 2 log 10 ( A ) + K 3 [ log 10 ( A ) ]
o
Where:
- A is the capacity or size parameter of the equipment: volume (m3), area (m2) or power
(kW)
- 𝐾1, 𝐾2, 𝐾3 are constants found from Figures 4.1 according to the equipment type.
The bare module cost CBM is the purchased cost multiplied by correction factors. It depends on
the material of construction and the pressure of the system.
C BM =C oP ( B1 +B 2 F M F p )
Where:
- 𝐵1 and 𝐵2 are bare module parameters that depend on equipment type
- 𝐹𝑃: pressure factor
- 𝐹𝑀: material factor
The data present in the tables below are related to the year 2001. However, due to price
fluctuations the calculated costs are corrected to the present year, 2022, using chemical
engineering plant cost indexes (CEPCI).
CEPCI , 2022
C BM ,2022 =C BM ,2001 *
CEPCI , 2001
The material factor FM is determined using the below chart according to the identification
number selected from the above figures.
Concerning the pressure factor Fp, it is defined as the ratio of the equipment thickness over the
minimum allowable thickness for construction, correlated function of operating pressure (P in
barg) as follows:
2
log 10 F P=C 1+ C2 log 10 ( P ) +C 3 [ log 10 ( P ) ]
Figure 4.6: Pressure Factors
The chemical engineering plant cost index of year 2001 used is CEPCI 2001 = 397 [31]
The chemical engineering plant cost index of year 2022 used is CEPCI 2022 = 810 [32]
Equipment Type A K1 K2 K3 B1 B2 FM Fp
Pump Centrifugal 64 3.3892 0.0536 0.1538 1.89 1.35 0.8 1.9
Heater Multiple 26 2.7652 0.7282 0.0783 1.74 1.55 1 1
pipe
Reactor PBR 8 3.4974 0.4485 0.1074 2.25 1.82 1.2 1.3
Flash Drum Vertical 4.6 3.4974 0.4485 0.1074 2.25 1.82 1 1
Stabilizer Vertical 4 3.4974 0.4485 0.1074 2.25 1.82 1 1