Equipment: Ethanol heater
Equipment Code: EH-01
Type: Screw Plug Immersion Heater
Data and Assumptions:
1. Heat requirement is 4790193.921 kJ (From Energy Balance)
2. Heat efficiency is 75%
Design Requirements:
1. Power rating
2. Watt Density
3. Number of Elements
4. Sheath Material
5. Screw Plug Material
6. Immersed length
Design Calculation:
Solving for Total Power Rating:
4790193.921 kJ 1 hour 1
Power rating= × ×
8 hour 3600 sec 0.75
Power rating= 221.76 kW
Solving for Number of Elements:
Using 100 KW Power rating per heater:
221.76 kW
Elements =
100 kW/Heater
Elements = 2.2 or 3 Elements
To compute for the design of the electric heater’s cubic vessel with 10% volumetric allowance,
Mass of Feed: 6212.064197 kg
Density of Feed: 785.7193513 kg/m3
6212.064197
Theorical Volume: = 7.91 𝑚3
785.7193513
Actual Volume: 7.91 𝑚3 × 1.25 = 9.85 𝑚3
𝑉 = 𝑆3
9.85 = 𝑆 3
𝑆 = 3.138 𝑚 ≅ 3.2 𝑚
Specification Summary:
Equipment EH-01
Total Power Rating 221.76 kW
Number of Elements 3
Voltage 600 V
Screw Plug Size 3 in
Pressure rating 300 psig
Screw Plug Material Carbon Steel
Immersed Length 130 in
Sheath Material Incoloy Steel
Watt Density 75 watts per square inch
Cubic Vessel’s Edge 3.2 m
Equipment: Air heater
Equipment Code: EH-02
Type: Screw Plug Immersion Heater
Data and Assumptions:
1. Heat duty is 5193027.619 kJ (From Energy Balance)
2. Heat Efficiency 75%
Design Requirements:
1. Power rating
2. Watt Density
3. Number of Elements
4. Sheath Material
5. Screw Plug Material
6. Immersed length
Design Calculation:
Solving for Total Power Rating:
5193027.619 kJ 1 hour 1
Power rating= × ×
8 hour 3600 sec 0.75
Power rating= 240.42 kW
Solving for Number of Heaters in Series:
Using 100 KW Power rating per heater:
240.42 kW
Number of Elements=
100 KW/Heater
Elements= 2.4042 or 3 heaters in series
To compute for the Air duct design:
Air velocity (𝜐) = 1.5 m/s
Mass of air = 24200.04139 kg/shift
Volume of air:
P= 4 atm
T= 513 K
19118.0327 5082.008692
( 28
+ 32
)×0.08205×513 𝐾
V=
4
V= 8856.079 m3
8856.079 m3
Q=
8×3600 𝑠
Q = 0.3075 m3/s
Solving for Duct Cross-sectional Area:
𝑄
A=
𝜐
0.3075 m3/s
A=
1.5 𝑚/𝑠
Solving for Duct Width:
A= 0.205 𝑚2 W
𝑊2 = 𝐴
𝑊 2 = 0.205 𝑚2
𝑾 = 0.452 m
Solving for Duct Length:
For 5 minutes residence time,
𝑚 60 𝑠
L = 1.5 × × 5 𝑚𝑖𝑛𝑠
𝑠 1 𝑚𝑖𝑛
𝑳 = 450 m
Specification Summary:
Equipment EH-02
Total Power Rating 240.42 kW
Number of Elements 3
Voltage 600 V
Screw Plug Size 3 in
Pressure rating 300 psig
Screw Plug Material Carbon Steel
Immersed Length 130 in
Sheath Material Incoloy Steel
Watt Density 75 watts per square inch
Air velocity in duct 1.5 m/s
Duct Width 0.45 m
Duct Length 450 m
Equipment: Oxidation Reactor
Equipment Code: OR-01
Type: Vertical tubular reactor
Data and Assumptions:
1. Adiabatic operation
2. Flat velocity profile
3. No axial dispersion
4. No radial dispersion
5. Pseudo-homogeneous assumption
6. Bed void fraction (ε) is 0.375
7. Space time is 8 hours
Design Requirements:
1. Bed Diameter
2. Bed Length
3. Reactor Length
4. Shell Thickness
5. Head Thickness
Reactor composition:
Components Input Output
Ethanol 6087.822913 60.87822913
Water 124.2412839 2482.610943
Nitrogen 19118.0327 19118.0327
Oxygen 5082.008692 1146.361406
Acetaldehyde - 706.7771826
Acetic Acid - 6897.445129
Total 30412.10559 30412.10559
Operating temperature = 513 K
Operating Pressure = 4 atm
Activity= 200 g ethanol/l-catalyst-hr
Thermal Properties of Feed:
Density (ρ) = 3.101336866 kg/m3
Viscosity (μ) = 0.00002455293 Pa-s
Bed void fraction (ε) = 0.375 for close random packing, monodispersed, (Dullien, 1992)
Solving for Actual Bed Diameter( Db) by Ergun Equation:
μν (1-ε)2 ρν2 (1-ε)
∆P=150 { × [ ]} +175 { × [ 3 ]}
D2 ε3 D ε
Initially assume ∆P’ and D,
Pressure drop (∆P’) = 3480 Pa/m (average pressure drop in Packed-bed)
Bed Diameter (D) = 4.11 m (Maximum diameter of Packed-bed reactors)
0.00002455293 ν (1-0.375 )2 3.101336866 ν2 (1-0.375 )
3480=150 { × [ ]} +175 { ×[ ]}
4.112 0.375 3 4.11 0.375 3
3480 = 1.615 × 10−3 ν + 1565.0614 ν2
v= 1.49117 m/s
Solving for Reactor Diameter:
Volumetric flowrate, Vv;
Average molecular wt. = 32.63
30412.10559
( ) × 0.08205 × 513 K
32.63
Volume =
4 atm
Volume = 9807.659 m3
9807.659 m3 1 hour
Vv = × =0.340504 m3/sec
8 hour 3600 sec
Bed Area, A
0.340504 m3/sec
A= = 0.22837 m2
1.49117 m/s
Bed Diameter, D
4×0.22837 m2
D=√ = 0.5392 m (1.769 ft.)
3.1416
Use Step 8 on Table 7.1 Chemical Process Engineering Design and Economics by Silla, D is less
than 30 in (0.762 m), round off the diameter to 2.2748 ft (0.693374 m).
Solving for Actual Bed Area, Ab;
2
3.1416 × 0.6933742 m
Ab= = 0.377595 m2
4
Solving for Actual Superficial Velocity, νs;
0.340504 m3/sec
νs = = 0.90177 m/s
0.377595 m2
Solving for Bed length (Lb);
Vc
Lb=
Ab
Where:
Vc = Volume of Catalyst
Ab = Actual Bed Area
Solving for the volume of the catalyst;
6026.944 kg EtOH 1 L Catalyst 1m3
Vc = × ×
8 hours 0.200 kg/h HAc 1000L
Vc = 3.76684 m3
3.76684 m3
Lb= = 9.975 m
0.377595 m2
Solving for internal pressure;
PAbs =ρgh+Patm
PAbs =(3.101336866 × 9.81× 10.0403) + 405300 Pa
PAbs =405605.4340 Pa = 58.84 psi
For allowable working stress:
S=Su×Fm×Fa×Fr×Fs
Where:
S= allowable working stress
Su= Ultimate tensile strength
Fm= Material Factor
Fa= Radiograph factor
Fr= Stress relieving factor
Fs= Allowable factor for safety
Su = 55000 psi
S=55000×1.0×1.0×0.25
S=13750 psi
Solving for Shell thickness:
PD
ts = +C
2Se-P
Where:
ts = shell thickness
P = working pressure
D = diameter
S = allowable stress
e = efficiency
C = corrosion allowance; (min C = 1/16)
(58.84)(21.228) 1
ts = +
2(13750)(1.0)-58.84 16
ts =0.108 in
Head is Toroispherical since operating pressure is less than 150 psig.
Solving for Toroispherical Head thickness:
1.104PD
th = + C
2eS-0.2P
1.104 × 58.84×21.228 1
th = +
2(13750)(1.0)-0.2× 58.84 16
th = 0.11266 in
For depth of toroispherical head
d = .25D
d=.25(21.228) = 5.307 in
d= 0.1348 m
Solving for Reactor Length (Lr);
Lr = Lb + d
Lr = 9.975 m + 0.1348 m
Lr = 10.1098 m
Specification Summary:
Equipment Oxidation Reactor
Materials of Construction Carbon steel (S42; Graded A)
Temperature 513 K
Mass 30608.74947 kg/shift
Pressure: 4.5 atm
Bed Length: 10 m
Bed Diameter: 0.7 m
Nominal Shell Thickness: 3/16 in.
Nominal Head Thickness: 3/16 in.
Corrosion Allowance: 1/16
Depth of Head 0.17333976 m
Specification Illustration:
Equipment: Flash Drum
Equipment Code: FD-01
Type: Vertical Gas-Liquid separator with Mesh Eliminator and Vortex Breaker
Data and Assumptions:
1. 99.9999% separation for gas and liquid phase
2. 2 batch/shift
3. Surge time is 10 minutes
Design Requirements:
1. Separator Diameter
2. Separator Height
3. Liquid Height
4. Mist Eliminator Thickness
Operating Parameters:
Operating temperature = 313 K
Operating Pressure = 1.00 atm
Solving for superficial velocity (ν);
Physical properties:
Density of Vapor, ρv = 1.098519665 kg/m3
Density of Liquid, ρL= 1016.99552 kg/m3
From Table 6.9, Chemical Process Engineering Design and Economics by Silla;
ρL-ρv
ν =kv√
ρv
kv = 0.107 m/s (With mist eliminator)
1016.99552 − 1.098519665
ν = 0.107 m/s √
1.098519665
ν = 3.25 m/s
Solving for Cross-sectional Area (A);
Volumetric Flowrate, Vv
2481.369637 20264.39411
( 1016.99552 + 1.098519665) 1 hour
Vv= ×
2 3600 seconds
Vv= 2.5624 m3/s
Solving for Cross- sectional area of Separator (As)
2.5624 m3/s
As=
3.25 m/s
As= 0.78884 m2
Solving for Separator Diameter (Ds)
4 × 0.78884 m2
Ds= √ = 1.0019 m
3.1416
Use Step 8 on Table 7.1 Chemical Process Engineering Design and Economics by Silla, D is
greater than 30 in (0.762 m), round off the diameter to 4 ft (1.2192 m).
Liquid phase surge time (ts) = 5 min
3.1416 × 1.21922
Actual Cross-sectional Area= = 1.167 m2
4
Solving for Liquid height in Separator (Ls);
2481.369637 kg 1 m3
Liquid Volume (Lv) = ×
3600 sec 1016.99552 kg
Liquid Volume (Lv) = 0.000677 m3/s
m3 60 sec
0.000677 s
× 10 min × 1 min
Liquid Height (HL) =
1.167 m2
Liquid Height (HL) = 0.34846 m
From Chemical Process Engineering Design and Economics by Silla
Settling Length (HS) = 1.5D
Settling Length (HS) = 1.5 × 1.005 m = 1.5075 m
Mist eliminator thickness (MT) = 0.152 mφ
Vapor Space (VS) = 0.305 m
For depth of toroispherical head
d = .25D
d=.25(1.005 m)
d= 0.25125 m
Solving for Total Separator Height (H):
H = HL + HS + MT + VS + d
H = 0.34846 m + 1.5075 m +0.152 m +0.305 m + 0.25125 m
H = 2.564 m
Solving for internal pressure;
PAbs =ρgh+Patm
PAbs =(560.71 × 9.81× 2.564) + 202650 Pa
PAbs =216753.47 Pa = 31.45 psi
φ Typical height for mist eliminator according to Silla is 6 in or 0.152 m
For allowable working stress:
S=Su×Fm×Fa×Fr×Fs
Where:
S= allowable working stress
Su= Ultimate tensile strength
Fm= Material Factor
Fa= Radiograph factor
Fr= Stress relieving factor
Fs= Allowable factor for safety
Su = 55000 psi
S=55000×1.0×1.0×0.25
S=13750 psi
Solving for Shell thickness:
PD
ts = +C
2Se-P
Where:
ts = shell thickness
P = working pressure
D = diameter
S = allowable stress
e = efficiency
C = corrosion allowance; (min C = 1/16)
(31.45 )(72) 1
ts = +
2(13750)(1.0)-31.45 16
ts =0.1449 in
Head is Toroispherical since operating pressure is less than 150 psig.
Solving for Toroispherical Head thickness:
1.104PD
th = + C
2eS-0.2P
1.104 × 31.45×72 1
th = +
2(13750)(1.0)-0.2× 31.45 16
th = 0.1534 in
Design Specification:
Equipment Code FD-01
Materials of Construction Carbon steel (S42; Graded A)
Temperature 313.15 K
Mass 30608.74947 kg/shift
Pressure: 1 atm
Height: 2.6 m
Diameter: 1.2192 m or 6 ft
Shell Thickness: 0.1449 in
Head Thickness: 0.1534 in
Nominal Shell Thickness: 3/16 in.
Nominal Head Thickness: 3/16 in.
Liquid Height 0.35 m
Mist eliminator Thickness 0.152 m or 6 in
Design Illustration:
