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PD Project

This document discusses the design of a petroleum refining plant to process 200,000 barrels of crude oil per day. It begins with an introduction to petroleum, its composition, classification, and the challenges of refining heavy crude oils. The process description explains the key units: desalting, furnace, and distillation column. Material and energy balances are performed for the heater and distillation column. Heat exchanger design and distillation column design sections size the major equipment. An economic evaluation assesses plant costs, profitability, and payback period.

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Umer Aizaz
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0% found this document useful (0 votes)
68 views70 pages

PD Project

This document discusses the design of a petroleum refining plant to process 200,000 barrels of crude oil per day. It begins with an introduction to petroleum, its composition, classification, and the challenges of refining heavy crude oils. The process description explains the key units: desalting, furnace, and distillation column. Material and energy balances are performed for the heater and distillation column. Heat exchanger design and distillation column design sections size the major equipment. An economic evaluation assesses plant costs, profitability, and payback period.

Uploaded by

Umer Aizaz
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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DISTILLATION OF 200,000 BARRELS OF CRUDE OIL

SESSON: 2015-2019
SUBMITTED BY

WHOLE CLASS

PUNJAB INSTITUTE OF CONTEMPORARY SCIENCES


AFFILIATED WITH UNIVERSITY OF THE PUNJAB
DECLARATION FORM

We, declare that the plant design project titled Distillation of 200,000 Barrels of crude oil is
our own work and is not submitted previously, in whole or partial, in respect of our own any
other academic.
ABSTRACT
The overall oil refining industry right now faces solid moves identified with worries about
future feedstock and attributes of oil items. These difficulties favor two principle procedures
for the segment: the primary system is expanding refinement multifaceted nature and
flexibility; the second is incorporating the refining and petrochemical ventures, increasing the
value of the unrefined petroleum while ensure piece of the overall industry to premium oil
items. The two procedures target expanding creation of profoundly determined oil items, all
the while lessening the ecological effects of the refining business. The point of this
investigation is plan a petroleum processing plant to work a 200,000 barrel for every day.

Material equalization, energy balance and a heater configuration are done right now, for the
investigation is done, and furthermore the unit tasks are considered right now.

TABLE OF CONTENT
Contents
INTRODUCTION.........................................................................................................................7
INTRODUCTION:......................................................................................................................8
PETROLEUM..............................................................................................................................8
THE COMPOSITION OF PETROLEUM.........................................................................8
PETROLEUM IN CHEMISTRY..............................................................................................10
PARAFFINS:.............................................................................................................................11
AROMATICS...................................................................................................................12
NAPHTHENES................................................................................................................12
OLEFINS:.........................................................................................................................13
CLASSIFICATION OF PETROLEUM....................................................................................14
API GRAVITY..........................................................................................................................15
FLASH POINT..........................................................................................................................16
REFLUX....................................................................................................................................16
PROCESS DESCRIPTION........................................................................................................17
PROCESS DESCRIPTION.......................................................................................................18
DESALTING:...................................................................................................................18
FURNACE:.......................................................................................................................18
DISTILLATION COLUMN:...........................................................................................19
FLOWSHEET:..................................................................................................................21
MATERIAL BALANCE.............................................................................................................22
HEATER:...................................................................................................................................24
DISTILLATION COLUMN......................................................................................................25
ENERGY BALANCE..................................................................................................................30
HEATER....................................................................................................................................31
DISTILLATION COLUMN......................................................................................................31
HEAT EXCHANGER:..............................................................................................................32
HEAT EXCHANGER DESIGN.................................................................................................38
HEAT EXCHANGER...............................................................................................................39
DISTILLATION COLUMN DESIGN......................................................................................53
ECONOMIC EVALUATION....................................................................................................63
FEASIBILITY STUDY.............................................................................................................64
PLANT COST............................................................................................................................64
COST INDEX............................................................................................................................65
THE COST OF RAW MATERIAL AND PRODUCT.............................................................66
DEPRECIATION.......................................................................................................................67
THE COST OF THE OPERATION..........................................................................................67
CASH FLOW.............................................................................................................................68
PAY- BACK PERIOD...............................................................................................................69
REFERENCES............................................................................................................................70
CHAPTER NO 1
INTRODUCTION
INTRODUCTION:
The demand for crude oil as an energy source is continuously increasing driven by the ever-
growing population and economic development. Globally, over 80 million barrels per day of
crude oil is produced currently out of which about 11 million barrels are classified as heavy
crude oils. It has been well recognized that reservoirs of light conventional crude oils are
decreasing and heavy crude oils are replacing them in the pool of crude oil feedstock in
refineries which process the crude oils into various value-added products such as gasoline,
diesel, liquefied petroleum gas, petrochemical feedstock, etc. The contribution of heavy crude
oils in the crude oil pool is predicted to increase over the years from the current ~10%. An oil
industry expert, Professor Emeritus Peter Odell, suggested that by 2100, the oil industry will
be larger than in 2000 but up to 90% dependent on unconventional crude oils (high-acid
crude oils, heavy crude oils, bitumen, and oil sand. [1]
Heavy crude oil reserves are proven to be abundant, and the active heavy oil-producing
countries include Canada, Venezuela, United States, Mexico, Brazil, Russia, Indonesia,
China, Colombia, Ecuador, Iraq, Kuwait, Saudi Arabia, Chad, and Angola. Heavy oils are
relatively cheaper than light conventional crude oils, and, therefore, they present an economic
opportunity to petroleum refiners to take advantage of their low cost to increase the refiner’s
profit margins. Heavy crude oils represent an important energy resource and require an
unusually high levels of effort and expertise to economically produce and process. But as the
energy demands grow, the economics of heavy oil production and processing will improve.
The production and processing of heavy oils will be influenced by the effectiveness of
available technologies.
Heavy crude oils are defined as any liquid petroleum with an API gravity in the range of 10–
22.3°. The fundamental characteristics of heavy crude oils are high viscosity and density,
chemical complexity, high acidity, high sulfur, increased level of metal and heteroatom
impurities, high asphaltenes content, low American Petroleum Institute (API) gravity, and
low H/C ratio. Due to these unfavorable characteristics, heavy crude oils are termed low-
quality crude oils, and they pose many technological challenges in their production,
transportation, and processing to both the producers and the refiners. Extracting and
processing of heavy crude oil require large amounts of water and energy and can potentially
cause extreme damages to surrounding environment. [2]
PETROLEUM
The Composition of Petroleum
Petroleum contains crude oil only, but in common usage it may contain all liquids, gaseous
and solid hydrocarbons. Under condition of surface temperature and pressure, lighter
hydrocarbons methane, ethane, propane and butane occur as gases, while pentane and heavier
hydrocarbons are in the form of liquids or solids. However in underground oil reservoir the
proportions of gas, liquid and solid depends on surface conditions and on the phase diagram
of the petroleum mixture, oil well produces predominately crude oil, with some natural gas
dissolved in it. Because the underground pressure is higher than surface pressure, some of the
gas will come out of solution and can be recovered as associated gas or solution gas. A gas
well gives predominately natural gas. However, due to higher underground temperature and
pressure than at the surface, the gas may also contain higher hydrocarbons such as pentane,
hexane and heptanes in the gaseous state. At surface these gases will condense out of the gas
to form natural gas condensate, refer as condensate. Condensate is similar in composition to
some volatile light crude oils and resembles to gasoline in appearance. The composition of
light hydrocarbons varies greatly among different oil fields, ranging from as much as 97
percent by weight. The hydrocarbons in crude oil are mostly alkanes, cyclohexane and
various aromatic hydrocarbons, while the other organic compounds contain nitrogen, oxygen
and sulphur and trace amount of metals such as iron, nickel, copper and vanadium.
Proportion of chemical elements varies fairly narrow limits as follow: [3]
Table (1.1) chemical elements of petroleum

Element Percent range

Carbon 83 to 85%

Hydrogen 10 to 14%

Nitrogen 0.1 to 2%

Oxygen 0.05 to 1.5%

Sulphur 0.05 to 6.0%

Metals < 0.1%

Four various kind of hydrocarbon molecule appear in crude oil. The relative percentage of
each varies from oil to oil, determining the properties of each.

Table 1.2 the percentage of hydrocarbons in petroleum


Hydrocarbon Average Range

Alkanes
Paraffin 30% 15 to 60%

Naphthen
es 49% 30 to 60%

Aromati
cs 15% 3 to 30%

Asphalti
c 6% Remained

Petroleum in chemistry:
Petroleum is a mixture of large number of various hydrocarbons; the most commonly found
molecules are paraffin, Naphthenes, aromatics and more complicated chemicals like
asphaltenes. Each petroleum variety has a unique mix of molecules, which define its physical
and chemical properties, like color and viscosity.

PARAFFINS:
Paraffin’s are also called alkanes and have general formula of CnH2n +2, where n is the
number of carbon atoms. Paraffin’s are straight chain and saturated, they are stable and
remain unchanged over a long period of time. Paraffin’s from C1 to C40 usually appeared
in crude oil and represent up to 20% of crude by volume. Example is given below

CH3

H3C CH3
CH3

2, 3-dimethylpentane

H3 C CH3

N-heptane
AROMATICS
Aromatics are significant proportion of petroleum mixture. Aromatics are cyclic but
unsaturated hydrocarbons that begin with benzene molecule and consist of carbon-carbon
double bond. Most commonly found aromatics are benzene and its derivatives with attached
methyl, ethyl, propyl, or higher alkyl groups. This series of aromatics is called alkyl benzene
and have general formula of CnH2n-6. For example:

CH
3

Benzene Toluene

NAPHTHENES
Naphthenes are ring or cyclic saturated hydrocarbons with the general formula of CnH2n.
Cyclopentane and cyclohexane and their derivatives are normally found in crude oils. The
ring with five or six carbon atoms are more stable naphthenic hydrocarbons. The content
of cycloparaffins in crude oil may vary up to 60%. For example

Cyclopentane Cyclohexane Alkylcyclohexane


OLEFINS:
Olefins another class of nonaromatic hydrocarbons but they are unsaturated and have at least
one double bond between carbon-carbon atoms. Compounds with unity double bond are
called mono-Olefins or alkanes. Olefins are uncommon in crude oil due to their reactivity
with hydrogen that makes them saturated; however they can be produced in refineries
through cracking reactions. Example is given below [4]

CH3 CH3

H3C CH3
2, 4-dimethylpentane
CLASSIFICATION OF PETROLEUM

Table 1.4 classification of petroleum

Class of petroleum Composition of 250–300 °C fraction,

wt. %

Par. Naphtha Arom Wax Asph

Paraffinic 46—61 22–32 12–25 1.5–10 0–6

Paraffinic-naphthenic 42–45 38–39 16–20 1–6 0–6

Naphthenic 15–26 61–76 8–13 Trace 0–6

Paraffinic-naphthenic-
27–35 36–47 26–33 0.5–1 0–10
aromatic

Aromatic 0–8 57–78 20–25 0–0.5 0–20


API GRAVITY
API stands for the American Petroleum Institute, the largest oil and natural gas trade
organization in the United States. The API represents about 400 petroleum industry
companies and helps set standards for the processing, refining and distribution of petroleum
products.
One of the most important standards set by the API is the method used to calculate the
petroleum density. This norm is called API gravity. Specific gravity is the ratio of one
substance density to the density of a reference material, usually as water. The API gravity is
somehow similar to the standard specific gravity used in the oil industry, comparing the
density of oil to that of water through a formula designed to ensure measurement accuracy.
Lower dense oil or "light oil" is superior to denser oil because it contains larger amounts of
hydrocarbons that can be converted into gasoline. Petroleum is less dense than water and as
the standard measure for any substance less dense than water, the U.S. government
implemented the Baumé scale in 1916. It refers to the crude, in most instances. The value
used in this scale was 141.5 (as calculated below), but afterwards testing found that the real
value would be 140 due to some error.
The government adjusted the scale to 140 to address the problem but the use of 141.5 had
become so widespread in the oil industry that the API agreed to use the old value of 141.5 to
build the API gravity scale.
The API gravity is measured using the specific gravity of the oil, which is nothing more than
the ratio of its density to that of the water.

[5]
Specific gravity is always set at 60 degrees Fahrenheit for API calculations. API gravity is
calculated as follows:

[6]
Although there are no units for the API values, they are often referred to as degrees. Thus
West Texas Intermediate API gravity is said to be 39.6 degrees. API gravity acts inversely to
density, indicating that the denser oil will be the lower the gravity of its API. An API of 10 is
equal to water, meaning that any oil with an API above 10 floats on water and any oil with an
API below 10 sinks.
The gravity of the API is used to classify oils as light, moderate, heavy, or extra heavy.
Because oil's weight is the greatest determinant of its market value, gravity of the API is of
exceptional importance. For each "weight" the API values are as follows:
 Light API > 31.1
 Medium API 22.3 to 31.1
 Heavy API < 22.3
 Extra Heavy API < 10.0
These are just estimated values as the exact value of gravity of the API varies between light
and heavy oil depending on the area from which oil came.
Since density is a ratio of mass per volume, API can be used to determine how many barrels
of crude oil can be extracted from a given oil's metric tonne. A metric ton of West Texas
Intermediate yields 7.6 barrels (at 42 gallons each), with 39.6 of the API value. [7]
Barrels/metric ton = 1/ [(141.5/ (API + 131.5) x 0.159]
FLASH POINT
Flash point is the lowest temperature at which liquid often petroleum products which
produces vapors in the air near to the surface which will flash or ignite, on exposure to an
open flame. The flash point is generally an indicator of the flammability or combustibility of
the liquid.
The flash point of an oil is the temperature at which the vapor over the oil will flash or
explode abruptly. This temperature is measured by laboratory tests using a system consisting
of a closed cup that contains the oil, heating and stirring equipment, and a special adjustable
flame.
The kind of apparatus used for the middle distillate and fuel oils is called the Pensky Marten
(PM), while the apparatus used in the Kerosene and light distillate case is further cited in this
manual and full descriptions of test methods and procedures are given in ASTM Standards
Part 7, Petroleum Products and Lubricants. [8]
There are other analytical approaches out of the ASTM distillation curve to determine flash
points. The relation of the flash point is as:
Flash point ◦F=0.77 (ASTM 5% ◦F−150◦F)
Representative liquids and their approximate flash points are:
 Automotive gasoline, −43 °C (−45 °F)
 Ethyl alcohol, 13 °C (55 °F)
 Automotive Diesel fuel, 38 °C (100 °F)
 Kerosene, 42–72 °C (108–162 °F) [9]

REFLUX
In normal distillation columns, heat is added to the column from a reboiler and removed in an
overhead condenser. A part of the distillate condensed in overhead condenser is returned to
the column as reflux to aid fractionation. This approach is not feasible in crude distillation
because the overhead temperature is too low for recovery of heat. Also the vapor and liquid
flows in column increase markedly from bottom to top, requiring a very large-diameter
tower. To recover the maximum heat and have uniform vapor and liquid loads in the column,
intermediate refluxes are withdrawn, they exchange heat with incoming crude oil before
entering the furnace and are returned to the plate above in the column. [10]
CHAPTER NO 2
PROCESS DESCRIPTION
PROCESS DESCRIPTION
DESALTING:
Distillation of crude oil is more complicated than distillation of the product, in part because
crude oils contain water, salts and suspended solids. Throughout the refining process, these
contaminates are eliminated to reduce the corrosion, plugging, and fouling of equipment and
to avoid catalyst poisoning throughout processing units.
Most common crude-oil desalination methods are chemical and electrostatic separation, and
both use hot water as an extraction agent. For chemical desalination, water and chemical
surfactant are added to the raw material, which is heated to dissolve or bind salts and other
impurities to the surface, and then placed in a tank for settling. The salts are dissolved in the
wash water and the oil and water phases separated in a settling vessel either by adding
chemicals to aid crack the emulsion or by creating a high-potential electrical field in the
settling vessel to more easily mix the droplets of salt water.

In the process both Alternating and Direct current fields may be used to facilitate
coalescence, and potentials from 12,000 to 35,000 volts are used. 90 to 95% efficiencies are
obtained for single-stage desalination systems and two-stage processes reach 99% or better
efficiency. If the brine's pH reaches 7, emulsions can be formed due to the presence of
sodium naphthenate and sodium sulfide. With most crude oils aiming the pH below 8.0 is
desirable. Effective dehydration is obtained in electrical desalters when handled within a pH
range of 6 to 8, with the best dehydration obtained at a pH close to 6.

The pH value is regulated by either using another source of water, or by adding acid to the
inlet or recycled water. The crude oil feedstock is heated to 65-180 ° C to minimize viscosity
and surface tension in order to blend and isolate the water more easily.

FURNACE:
Fuel flows into the burner, and the air generated by an air blower is burnt. In a particular
furnace, there may be more than one burner that can be arranged in cells which heat a specific
set of tubes.
Burners can also be mounted on the floor, mounted on the wall or mounted on the roof
according to design. The flames heat up the pipe, and in effect in the first portion of the
furnace, known as the radiant section or firebox, which heats the fluid inside. The heating
fluid passes through the tubes and is then heated up to the temperature needed. The
combustion gases are known as flue gas. After the flue gas exits the firebox, most furnace
designs have a portion of convection where more heat is extracted through the flue gas stack
before venting into the atmosphere. This heated fluid is then circulated around the entire plant
to heat exchangers to be used anywhere heat is needed instead of directly heating the product
line as the product or material may be volatile or sensitive to cracking at the temperature of
the furnace.
DISTILLATION COLUMN:
Distillation is based on the fact that in the components which have lower boiling points the
vapor of a boiling mixture would be richer. So, the condensate will contain the more toxic
components as this vapor is cooled and condensed. At the same time, more of the less volatile
elements will appear in the initial mixture. For the separation of a mixture of substances with
small variations in boiling points, fractional distillation is useful and the most important step
in the refining process. Distillation will lead to over 50 per cent of the operating costs of the
plant.

The separation of crude oil into different fractions or straight-run cuts by distillation in
atmospheric and vacuum towers is needed in the refining process. The key fractions or "cuts"
obtained have different boiling point ranges and can be categorized into gases, light
distillates, middle distillates, gas oils, and residual in order to decrease volatility.

The desalted, crude feedstock is preheated using process heat recovered. The feedstock then
flows into a direct-fired crude charge heater then into the vertical distillation column just
above the lower part of the column, at the pressure slightly above the bottom of the vertical
distillation column and at pressure slightly above the atmosphere and the temperatures
ranging from 340-370 ° C (there may be excessive thermal cracking above those
temperatures). All but the heaviest amounts burst into the vapor.

 The temperature is lowered as the hot vapor rises in the tower.


 From the bottom heavy fuel oil or asphalt waste is obtained.

The various major products, including lubricating oil, heating oil, kerosene, diesel, and non-
condensed gases (which condense at lower temperatures) are drawn off at successively higher
points in the tower. Via or with the help of the heat exchange with product and reflux streams
the temperature of crude oil is increased to about 288 ° C. It is then heated in a furnace to
about 399 ° C, and charged to the atmospheric fractionator’s flash region. The temperature of
the furnace discharge is sufficiently high from 343 to 399 ° C to enable vaporization of all
products extracted above the flash zone plus around 10-20% of the bottom component.
Reflux is given by condensing the overhead vapors at the tower and returning a portion of the
liquid to the tower's roof. Increasing side stream products removed from the tower can
decrease the amount of reflux below the draw-off level. Maximum reflux and fractionation is
obtained by removing all heat at the top of the tower, but this results in an inverted cone-like
liquid charge that requires a very large diameter at the top of the tower. To reduce the tower's
upper diameter and even the liquid charge over the tower's length, intermediate heat-removal
streams are used to generate reflux below the sidestream removal points. To do this, liquid is
drained from the tower, cooled by the heat exchanger, returned to the tower or, preferably, a
part of the cooled side stream may be returned to the tower. The cold stream condenses the
lower vapors, and thus increases the reflux below that level. While the crude oil distillation
towers usually do not use reboilers, multiple trays are typically inserted below the flash zone
and steam is added below the bottom tray to extract any residual gas oil in the flash zone
from the liquid and to create a high-flash point bottom.

Figure 2.1

The atmospheric fractionator typically contains 30-50 fractionation trays. Complex mixtures
in crude oils are fairly easy to separate, and typically five to eight trays are required for each
side stream product plus the same number above and below the feed plate. Thus, 30-42 trays
are used that would allow a crude oil atmospheric fractionation tower along with four liquid
side-stream draw offs. The fluid side-stream extracted from the tower will produce low-
boiling components that will lowers the flashpoint. Such “light ends” are stripped from each
side stream in a separate small stripping tower that includes 4-10 steam trays placed
underneath bottom tray. The steam and stripped light ends are diffused back into the vapor
zone of the atmospheric fractionator just above the corresponding side-draw tray. On the
atmospheric tower the overhead condenser condenses the pentane and-heavier portion of the
vapors that come from the top of the stack. That is the light gasoline part of the overhead that
includes some propane and butanes, and basically all the higher-boiling elements in the
tower. Some of this condensate is returned as reflux to the top of the tower, and the remaining
is sent to the stabilization portion of the refinery gas plant where the butanes and propane are
isolated from the LSR gasoline. [11]
FLOWSHEET:

Figure 2.2
CHAPTER NO 3
MATERIAL BALANCE
MATERIAL BALANCE:
Material balance on Desalter unit:

Basis: 200000 barrel per day refinery unit=31800000KG per day


The specific gravity of the crude oil from table specification temperature 15.7 ℃ is 0.8418
𝑆𝐺𝑜𝑖𝑙=𝜌𝑜𝑖𝑙/𝜌𝐻2𝑜
𝜌𝑜𝑖𝑙=𝑆𝐺𝑜𝑖𝑙× 𝜌𝐻2𝑂=0.8418 ×1000 𝐾/𝑔𝑚3
𝜌𝑜𝑖𝑙=841.8 𝐾/𝑔𝑚3
𝑉𝑜𝑖𝑙= 𝑚𝑜𝑖𝑙/𝜌𝑜𝑖𝑙= (31800000 𝐾𝑔/𝑑𝑎𝑦) / (841.8 𝐾𝑔/𝑚3)
𝑉𝑜𝑖𝑙=37776 𝑚3/𝑑𝑎𝑦
𝐴𝑃𝐼 𝑔𝑟𝑎𝑣𝑖𝑡𝑦 = (141.5/𝑆𝐺)−131.5
= (141.5/0.8418)−131.5=36.5921

(200000 barrel/day of feed


crude
97 % of crude)
Water 7% of feed
brine 5.91%
Brine 94%

Feed:
Crude 97% = 194000barrel/day
Water 1% = 2000 barrel/day
Salt 2% = 400 barrel/day
Water added = 14000 barrel/day
1st stage removal
Brine = 94% = 3760 barrel/day
2nd stage
=236.4 barrel/day
Water total = 2000+14000 = 16000 barrel/day
Consumed= for 1:2 ratio
4000 required = 8000 barrel/day
So
Water in crude product = 16000-8000 = 8000 barrel/day

Input Output
Crude oil = 200000 barrel/day Crude + water= 202000 barrel/day
Water = 14000 barrel/day Brine = 12000 barrel/day

Heater:
The heater is used to raise the temperature. So material entering and leaving the heater is
same.

150*C 345*C

1325000kg/hr 1325000 kg/hr


Distillation Column:
The calculation of the density for the product with the percent of the oil is done as following:
ρproduct
S.G=
ρ water

Kg Kg
ρ LPG =S⋅GLPG × ρwater =0.67×1000 3
=670 3
m m
Kg m3 Kg
m LPG =ρLPG × VLPG =670 3 ×.528.864 =354338.88
m day day
Kg Kg
ρ LN =S ⋅GLN ×ρ water =0.74×1000 3 =740 3
m m
3
Kg m Kg
m L,N =ρ L,N × VL,N =740 3 ×2266.56 =1677254.4
m day day
Kg Kg
ρ H,N =s. G H,N ×ρ water =0.78×1000 3 =780 3
m m
3
Kg m Kg
m H,N =ρ H.N × VH,N =780 3 ×5704.176 =4449257.28
m day day
Kg Kg
ρ Ker =S. GKer × ρwater =0.79×1000 3 =790 3
m m
3
Kg m Kg
m Ker = ρKer × V Ker =790 3 ×2077.68 =1641367.2
m day day
Kg Kg
ρ Diest =s. GDiesl × ρwater =0.84×1000 3 =840 3
m m

Kg m3 Kg
m Diesl =ρ Diesl × VDiesl =840 3
×4533.12 =3807820.8
m day day
Kg Kg
ρ residum =S.Gresidum × ρwater =0.90×1000 3 =900 3
m m
Kg m3 Kg
m residum = ρresidum × V residum =900 3 ×22612.7136 =20351442.24
m day day
PRODUCT Percent Volume S.G Density Mass M.W
Volume product

LPG 1.4 528.86 0.67 670 354338


LN 15.1 5704.174 0.73 740 4499257 100
HN 6 2266.56 0.78 780 1677254 150
Kerosene 5.5 2077.68 0.79 790 1641367 165
Diesel 12 4533.22 0.84 840 3807820 215
Residue 60 22612.7 0.90 900 20351442 320

m total =528864+5704176+2266560+2077680+4533120+22612713.6
Kg
=37723113.6
day

Kg 1 m 3 m3
37723113.6 × =37723.1136
day 1000Kg day
3
m Kg Kg
m= Voil × ρoil =37723.1136 ×841.8 3 =31755317.03
day m day
barrel
V.total=199718.975
day

Output Input
200000 199718.975
Material balance about stripper of heavy naphtha
Percent reflux in top tower is constant (6%)
The input amount for strippers towers (H.N) and steam =
𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻.𝑁 𝑡𝑜𝑡𝑎(𝑡𝑜𝑡𝑎𝑙 𝑝𝑒𝑟𝑐𝑒𝑛𝑡%−𝑝𝑒𝑟𝑐𝑒𝑛𝑡 𝑟𝑒𝑓𝑙𝑢𝑥)×100
2266560𝐾𝑔𝑑𝑎𝑦(100−6)×100=2411234.043𝐾𝑔𝑑𝑎𝑦
The percent of reflux at the top of the column (H.N) and steam= (H.N) Input to strippers–
(input without reflux)
2411234.043𝐾𝑔𝑑𝑎𝑦−2266560𝐾𝑔𝑑𝑎𝑦=144674.0426𝐾𝑔𝑑𝑎𝑦 𝑇ℎ𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 𝑏𝑦 𝑔𝑎𝑙𝑙𝑜𝑛 𝑢𝑛𝑖𝑡
(𝑔𝑎𝑙):=144674.0426𝐾𝑔𝑑𝑎𝑦 ×1 𝑙𝑖𝑡𝑒𝑟1 𝐾𝑔 ×1 𝑔𝑎𝑙3.785412 𝑙𝑖𝑡𝑒𝑟=38218.83658𝑔𝑎𝑙𝑑𝑎𝑦
The amount steam injected to stripper will be stander for (H.N)

Amount steam = 0.2268 𝐾𝑔𝑔𝑎𝑙


The amount steam = (H.N) reflux percent ×steam amount =38218.83658𝑔𝑎𝑙𝑑𝑎𝑦
×0.2268𝐾𝑔𝑔𝑎𝑙=8668.032136𝐾𝑔𝑑𝑎𝑦
Total of reflux Amount from steam and (H.N)
= Amount steam + (H.N) reflux at the top column
=8668.032136𝐾𝑔𝑑𝑎𝑦+144674.0426𝐾𝑔𝑑𝑎𝑦=153342.0747𝐾𝑔𝑑𝑎𝑦
The product bottom of (H.N)stripper = input of (H.N)stripper + amount of steam – reflux
amount of steam and (H.N) =2411234.043+8668.032136−153342.0747=2266560𝐾𝑔𝑑𝑎𝑦

Figure 3.1

The Material Balances AboutThe Stripper Of Kerosene (ker):


The percent of reflux at the top of the tower is constant (4%)
The input amount to Kerosene stripper tower= 𝑡𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 (𝑡𝑜𝑡𝑎𝑙 𝑝𝑒𝑟𝑐𝑒𝑛𝑡%
−𝑟𝑒𝑓𝑙𝑢𝑥 𝑝𝑒𝑟𝑐𝑒𝑛𝑡 )×100
2077680𝐾𝑔𝑑𝑎(100−4)×100=2164250𝐾𝑔𝑑𝑎𝑦
The Percent of reflux at the top of the column (Ker) and steam = Input to strippers (Ker) –
(input without reflux)
=2164250𝐾𝑔𝑑𝑎𝑦−2077680𝐾𝑔𝑑𝑎𝑦=86570𝐾𝑔𝑑𝑎𝑦
𝑇ℎ𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 𝑏𝑦 𝑔𝑎𝑙𝑙𝑜𝑛 𝑢𝑛𝑖𝑡 (𝑔𝑎𝑙)=86570𝐾𝑔𝑑𝑎𝑦 ×1𝑙𝑖𝑡𝑒𝑟1𝐾𝑔
×1𝑔𝑎𝑙3.785412𝑙𝑖𝑡𝑒𝑟=22869.37327𝑔𝑎𝑙𝑑𝑎𝑦
The amount steam injected to stripper will be stander for kerosene: 𝑎𝑚𝑜𝑢𝑛𝑡
𝑠𝑡𝑒𝑎𝑚=0.13608𝐾𝑔𝑠𝑡𝑔𝑎𝑙

So the amount steam water necessary to strip = Percent reflux (Ker) × amount steam
=22869.37327𝑔𝑎𝑙𝑑𝑎𝑦 ×0.13608𝑘𝑔𝑠𝑡𝑔𝑎𝑙=3112.064314𝐾𝑔 𝑠𝑡𝑒𝑎𝑚𝑑𝑎𝑦
Total reflux Amount from steam and kerosene = amount steam water + reflux kerosene

=3112.064314𝑘𝑔𝑠𝑡𝑒𝑎𝑚𝑑𝑎𝑦+86570𝐾𝑔𝑑𝑎𝑦=89682.06431𝑘𝑔𝑑𝑎𝑦
The product bottom stripper (Kerosene) =
Input stripper (Ker) + column steam water – amount reflux steam and kerosene
=2164250𝐾𝑔𝑑𝑎𝑦+3112.064314𝐾𝑔𝑠𝑡𝑒𝑎𝑚𝑑𝑎𝑦−89682.06431𝐾𝑔𝑑𝑎𝑦=2077680𝐾𝑔𝑑𝑎𝑦

Figure 3.2

Out put In put


2167362.06431 2167362.06431

Material -Balance about the Stripper of Diesel (diel).


The Percent reflux in top tower is constant (2%)
The input amount to diesel stripper tower (die) and steam

=𝑚𝑎𝑠𝑠 𝑜𝑓 𝑑𝑖𝑒𝑠𝑒𝑙 𝑡𝑜𝑡𝑎𝑙𝑡𝑜𝑡𝑎𝑙 𝑝𝑒𝑟𝑐𝑒𝑛𝑡%−𝑝𝑒𝑟𝑐𝑒𝑛𝑡 𝑟𝑒𝑓𝑙𝑢𝑥 ×100 = 4533120𝑘𝑔𝑑𝑎𝑦100−2


×100=4625632.653𝑘𝑔𝑑𝑎𝑦
The Percent of reflux at the top of column (die) and steam =

Input to stripper (diesel) and steam – input without reflux


=4625632.653𝑘𝑔𝑑𝑎𝑦−4533120𝑘𝑔𝑑𝑎𝑦=92512.65306𝑘𝑔𝑑𝑎𝑦
𝑇ℎ𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 𝑏𝑦 𝑔𝑎𝑙𝑙𝑜𝑛 𝑢𝑛𝑖𝑡 (𝑔𝑎𝑙)=92512.65306𝑘𝑔𝑑𝑎𝑦 ×1𝑙𝑖𝑡𝑒𝑟1𝑘𝑔
×1𝑔𝑎𝑙3.785412𝑙𝑖𝑡𝑒𝑟=24439.25603𝑔𝑎𝑙𝑑𝑎𝑦
The amount steam injected to stripper will be stander for diesel:
𝑎𝑚𝑜𝑢𝑛𝑡 𝑠𝑡𝑒𝑎𝑚=0.02265𝑘𝑔𝑔𝑎𝑙So
amount steam water = percent reflux (diesel) × amount steam 24439.25603𝑔𝑎𝑙𝑑𝑎𝑦
×0.02265𝑘𝑔𝑔𝑎𝑙=553.5491492𝑘𝑔𝑠𝑡𝑒𝑎𝑚𝑑𝑎𝑦
total reflux Amount from steam and diesel = amount steam water + reflux top
=553.5491492+92512.65306=93066.20221𝑘𝑔𝑑𝑎𝑦
The product bottom column diesel= Input stripper (diesel) + amount steam water – amount
reflux Steam and (diesel) =4625632.653+553.5491492−93066.20221=4533120𝑘𝑔𝑑𝑎𝑦

In put Out put


4626186.2021492 4626186.20221
CHAPTER NO 4
ENERGY BALANCE

ENERGY BALANCE:
Energy Balance across Heater
150*C 345*C

1325000kg/hr 1325000 kg/hr


Heater:
As crude oil entering the heater at 150*C and leaving the heater at 345*C.

Cp of crude oil = 2.55KJ/kg*C


Energy required = Q = mCpdt
m= 31800000Kg/day
Q= (31800000) (2.55) (345-150)
Q= 15812550000KJ/day Energy required

Distillation column:
Mass of the crude oil entering the column= 60945 Kg/hr
Temperature of crude oil inlet= 400 C
Heat capacity of crude oil= 2.55 KJ/Kg C
Q= m*Cp*delta T
Q= 58278656.3 KJ/hr
Mass of the naphtha leaving the column= 30472.5 Kg/hr
Temperature outlet= 120 C
Heat capacity naphtha = 2.007 KJ/Kg C
Q= m*Cp*delta T
Q= 5810039.21 KJ/hr
Mass of the kerosene leaving the column= 18283.5 Kg/hr
Temperature outlet= 180 C
Heat capacity kerosene= 2.14 KJ/Kg C
Q= m*Cp*delta T
Q= 6064636.95 KJ/hr
Mass of the diesel leaving the column= 9141.75 Kg/hr
Temperature outlet= 250 C
Heat capacity diesel= 2.3 KJ/Kg C
Q= m*Cp*delta T
Q= 37456524.6 KJ/hr
Mass of the residue leaving the column= 3047.25 Kg/hr
Temperature outlet= 350 C
Heat capacity residue= 2.39 KJ/Kg C
Q= m*Cp*delta T
Q= 8947451.44 KJ/hr

HEAT IN KJ/hr HEAT OUT KJ/hr


58278656.3 58278656.3

HEAT EXCHANGER:
1-Heavy Naphtha heat exchanger
The temperature of crude oil equal 26.67℃
The temperature of heavy naphtha that inlet to the heat exchanger = 141.67℃
The temperature of heavy naphtha that outlet from the heat exchanger = 82.22℃
And by using the total energy equation Q = mcp∆T
Where:
m: the mass of product
cp: specific heat for product
∆T: temperature difference
(mH.N*cpH.N*∆TH.N) = (moil*cpOil*∆TOil)
(5701476*2.007*(141.67-82.22))= (29733489.6*2.55*∆T)
∆T = 680278165.6 / 75820398.48
∆T=8.97℃
T Oil out =T Oil int+8.97
T Oil out =35.64℃
2- Kerosene heat exchanger
The temperature of kerosene that inlet to the heat exchanger =180.56℃
The temperature of kerosene that outlet from the heat exchanger = 40℃
The temperature of crude oil which inlet to the second heat exchanger = 35.64℃
(mke*Cpke*∆T)=(mOil*Cpoil*∆T)
(2077680*2.14*(180.56-40))-(29733489.6*2.55*∆T)
∆T= 624962819.7 / 75820398.48
∆T=8.243℃
TOil out =TOil int+8.243
=35.64+8.243
TOil out =43.88℃
3-1 cold diesel (A) heat exchanger
The temperature of cold diesel that inlet to the heat exchanger = 171.11℃
The temperature of cold diesel that outlet from the heat exchanger =81.11℃
The temperature of crude oil inlet to the heat exchanger = 43.88℃
(mco Die*cpco Die *∆T) = (mOil *cpOil *∆TOil)
(4533120*2.30*(171.11-81.11)) = (29733489.6*2.55*∆T)
∆T = 938355840 / 75820398.48
∆𝑇 = 12.38℃
T Oil out =T Oil in +12.38
=43.88 +12.38
T Oil out=56.26℃
3-2 cold diesel (B) heat exchanger
QDie =mOil*cpoil*∆𝑇
=29733489.6*2.55*∆T
∆T = 12.38℃
TOil out =Toil in+12.38
=56.26+12.38
TOil out=68.64℃
4-1 Heavy Naphth crude oil (A) heat exchanger
The temperature of Heavy Naphtha inlet to the heat exchanger = 175.56℃
The temperature of Heavy Naphtha outlet from the heat exchanger = 97.78℃
The temperature of crude oil inlet to the heat exchanger = 68.64℃
mH.N*cpH.N*∆𝑇= mOil*cpOil*∆𝑇
5701476*2.007*(175.56-97.78)=29733489.6*2.55*∆𝑇
∆T = 890025832.2 / 75820398.48
∆𝑇 = 11.74
TOil out= Toil in+11.74
TOil out =80.38℃
4-2 Heavy Naphtha crude oil heat (B) exchanger
QH.N=mOil *cpOil*∆𝑇
890025832.2=29733489.6*2.55*∆𝑇
∆𝑇 = 11.74℃
T Oil out =80.38+11.74
=92.12℃
5-1 the cold residue (A) heat exchanger
The temperature of cold residue inlet to the heat exchanger = 254.44℃
The temperature of cold residue outlet from the heat exchanger = 161.11℃
The temperature of crude oil inlet to the heat exchanger = 92.12℃
mC.Re*cpC.Re*∆𝑇=mOil *cpOil *∆𝑇
22612713.6*2.39*(254.44-161.11) =29733489.6*2.55*∆𝑇
∆T = 5043962499 / 75820398.48
∆𝑇 = 66.53℃
Toil out =92.12+66.53
=158.65℃
5-2 the cold residue (B) heat exchanger
QC.Re= mOil *cpOil *∆𝑇
5043962499=29733489.6*2.55*∆𝑇
∆𝑇 = 66.53℃
Toil out=158.65+66.53
Toil out=225.18℃
6- Hot Diesel heat exchanger
The temperature of hot diesel inlet to the heat exchanger = 252.22℃
The temperature of hot diesel outlet from the heat exchanger = 182.22℃
The temperature of the crude oil inlet to the heat exchanger = 225.18℃
mH.De*cpH.De*∆𝑇=mOil*cpOil*∆𝑇
4533120*2.30*(252.22-182.22 ) =29733489.6*2.55*∆𝑇
∆T = 729832320 / 75820398.48
∆𝑇 = 9.63℃
TOil out =225.18+9.63
TOil out=234.81℃
7-1 Diesel pumparoulid (A) heat exchanger
The temperature of diesel pump around lid inlet to the heat exchanger = 270.56℃
The temperature of diesel pump around lid outlet from the heat exchanger = 195.56℃
The temperature of diesel pump around lid inlet the to heat exchanger = 234.81℃
mDe.P*cpDe.P*∆𝑇=mOil*cpOil*∆𝑇
4533120*2.30*(270.56-195.56)=29733489.6*2.55*∆𝑇
∆T = 781963200 / 75820398.48
∆𝑇 = 10.3℃
TOil out=234.81+10.3
TOil out=245.12℃
7-2 Diesel pump around lid(B) heat exchanger
QDe.p=mOil*cpOil*∆𝑇
781963200=29733489*2.55*∆𝑇
∆𝑇 = 10.3℃
TOil out=245.12+10.3
TOil out=255.4℃
8- Hot Residue heat exchanger
The temperature of hot residue inlet to the heat exchanger = 356.11℃
The temperature of hot residue outlet from the heat exchanger = 54.44℃
The temperature of crude oil inlet to the heat exchanger = 255.4℃
mH.De*cpH.De*∆𝑇=mOil*cpOil*∆𝑇
22612713.6*2.39*(356.11-254.44) = 29733489.6*2.55*∆𝑇
∆T = 5494692674 / 75820398.48
∆𝑇 = 72.47℃
TOil out =255.4+72.47
TOil out =327.79℃ this is the final temperature of crude oil
THE ENERGY BALANCE ON HEAT EXCHANGER:
Equation:
Q=m*Cp*delta T

Mass flowrate entering the Furnace = 60945.13167Kg/hr

Heat capacity of Crude oil = 2.55KJ/Kg C


Reference temperature= 25C
Temperature of Inlet=40C
Temperature of outlet=400C
Qin Qout
2331151.286 2331151.344
Substitute in the equation:
Mass flowrate leaving the Furnace = 60945.13167
Heat capacity of Crude oil = 2.56KJ/Kg C
Reference temperature = 40C
Temperature of outlet = 400C
Q= m*Cp*delta T Q = 2331151.344 KJ/hr
CHAPTER NO 5
HEAT EXCHANGER DESIGN
HEAT EXCHANGER DESIGN:
HEAT EXCHANGER:
• A heat exchanger is a device used to transfer heat between two or more fluids.

• Heat exchangers are used in both cooling and heating processes.

• The fluids can be single or two phase and, depending on the exchanger type.
• They are widely used in refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries & natural-gas processing etc.
Types of heat exchangers:
The following are the types of heat exchanger:
• Shell & tube heat exchanger

• Plate heat exchanger

• Air cooled heat exchanger

Shell & tube heat exchanger:


• Shell and Tube Heat Exchangers consist of a large number of small tubes which
are located within a cylindrical shell. The tubes are positioned into the cylinder using
a tube bundle or tube stack which can either have fixed tube plates or a floating tube
stack which allows the tube bundle to expand and contract with varying heat
conditions as well as allowing the tube bundle to be easily removed for servicing and
maintenance.

Plate & Frame heat exchanger:


Plate & Frame Heat Exchangers operate in the same way as a shell and tube heat
exchanger, using a series of stacked plates rather than tubes. Plate heat exchangers are usually
brazed depending on the application and fluids being used. Their compact stainless steel
construction makes them an ideal choice for use with refrigerants or in food and beverage
processing. Its application is food processing & petrochemicals industry where copper and
aluminum can’t be used.
Air cooled heat exchanger:
Air Cooled Heat Exchangers are commonly used in vehicles or other mobile applications
where no permanent cool water source is available. Thermex designs and supplies
combination cooling packs which combine an engine jacket water cooler, oil cooler and
charge air cooler into a single unit reducing space requirements and improving efficiency.
Cool air is provided either by a fan or by air flow caused by the movement of the vehicle. Its
application is truck, buses, military vehicles, gas & diesel engines etc.

DESIGN OF SHELL & TUBE HEAT EXCHANGER


• We will use shell and tube heat exchanger because it is widely used in oil refineries
and other chemical processing units as it is suited for high pressure applications.

• As from the name, this type of heat exchanger consists of a shell (a large pressure
vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another
fluid flows over the tubes (through the shell) to transfer heat between the two fluids.

• The set of tubes is called a tube bundle, and may be composed of several types of
tubes.

• There are different variations in the shell and tube heat exchanger. Typically, the ends
of each tube are connected to plenums (sometimes called water boxes) through holes
in tube sheets. The tubes may be straight or bent in the shape of a U, called U-tubes.
Selection of the material:
To be able to transfer heat well, the tube material should have
good thermal conductivity. Because heat is transferred from a hot to a cold side through the
tubes, there is a temperature difference through the width of the tubes. The tube material also
should be compatible with both the shell and tube side fluids for long periods under the
operating conditions (temperatures, pressures, pH, etc.) to minimize deterioration such as
corrosion.
Typically metals, including aluminum, copper alloy, stainless steel, carbon steel,
nonferrous copper alloy, Inconel, nickel, Hastelloy and Titanium and Fluorinated
ethylene propylene (FEP) are also used to produce the tubing material due to their high
resistance to extreme temperatures.
Poor choice of tube material could result in a leak through a tube between the shell and tube
sides causing fluid cross-contamination and possibly loss of pressure.
Design a shell-and-tube exchanger for the following data:
2077680kg/day of kerosene (42°API) leaves the base of a kerosene side stripping column
at 180.56℃ and is to be cooled to 40℃ by exchange with 37723113.6kg/day light crude
oil (34°API) coming from storage at 33.74℃.
The kerosene enters the exchanger at a pressure of 5 bar and the crude oil at 6.5 bar. A
pressure drop of 0.8 bar is permissible on both streams. Allowance should be made for
fouling by including a fouling factor of 0.0003 (𝑊/𝑚2℃)^−1on the crude stream and
0.0002 (𝑊/𝑚2℃)^−1on the kerosene stream.
The following steps are followed to design the shell and tube heat exchanger.
Step 1: Specification
The specification is given as following:

86570kg/h of kerosene (42° API) at 180.56℃ cooled to 40℃, by exchange with


1571796.4kg/h light crude oil (34° API) at 33.74℃.

The kerosene pressure 5 bar, the crude oil pressure 6.5 bar.

Permissible pressure drops of 0.8 bars on both streams.

Fouling factors: crude stream 0.00035(W / m2℃)−1,


Kerosene stream 0.0002(W/m2℃)−1
To complete the specification, the duty (heat transfer rate) and the outlet temperature
of the crude oil needed to be calculated.

The mean temperature of the kerosene =180.56+40= 110.28℃

2
At this temperature the specific heat capacity of 42◦ API kerosene is 2.14 kJ/kg℃
86570
𝑄𝑘𝑒𝑟= 3600 ×2.14(180.56−40)=7233.365969𝑘𝑊

As a first trial take the mean temperature of the crude oil as equal to the inlet
temperature, 33.74℃; specific heat capacity at this temperature = 2.55 kJ/kg
℃. An energy balance gives:

1571796.4
×2.55(𝑡2−33.74)=1509.4
3600

𝑡2=35.09℃so the stream mean temperature =(33.74+35.09)/2 =34.415℃


The specific heat at this temperature is 2.05 kJ/kg℃
Step 2: collect Physical Properties
Kersone Inle Me out
t an let
Temperat 180. 110 40 ℃
ure 56 .8
Specific 2.72 2.4 2.2 kJ/kg
Heat 7 6 ℃

Thermal 0.13 . . W/m


conducti 0 132 135 ℃
vity
Density 690 730 770 kg/m
3

viscosity .22 .43 .80 mN


sm−2

Crude Out Me inl


oil let an et
Temperat 37.1 35. 33. ℃
ure 79 45 74
Specific 2.09 2.0 2.0 kJ/kg
heat 5 1 ℃

Thermal 0.13 0.1 0.1 W/m


conducti 3 34 35 ℃
vity
Density 800 820 84 kg/m
3
0

viscosity 2.4 3.2 4.3 mNs

Step 3: Overall coefficient


For an exchange of this type the overall coefficient will be in the range 300 to
500𝑊/𝑚2 ℃, between heavy oils and steams; so start with 300 𝑊/𝑚2 ℃

Step 4: Exchanger type and dimensions

An even Number of tube passes is usually the preferred arrangement, as these positions the
inlet and outlet nozzles at the same end of the exchanger, which simplifies the paperwork.
Start with one shell and two tube passes
( T 1−t2 ) −(T 2−t 1)
∆ T lm=
(T 1−t 2)
ln
(T 2−t 1)

( 180.56−35.09 ) −(40−33.74)
∆ T lm=
(180−35)
ln
( 40−33.74)

= 44.253° C

(T 1−T 2 )
R=
t 2−t 1

(180.56−40)
R=
35.09−33.74

R = 104.11

(t 2−t 1 )
S=
T 1−t 1

(35−33.74)
S=
180.5−33.74

S = 0.0096
From figure temperature correction factor one shell pass two or more even tube
passes = 0.75, which is acceptable.
So, ∆ = 0.75 × 44.253 = 33.18975℃

Step 5: Heat Transfer Area

Q=UA ∆T m

𝐴𝑜 =1509.4×103 /300×33.18975
= 151.593 𝑚2

Step 6: Layout and tube size


Using a split-ring floating head exchanger for efficiency and ease of cleaning
Neither fluid is corrosive, nor is the operating pressure not high, so plain carbon steel can
be used for the shell and tubes. The crude is dirtier than the kerosene, so put the crude
through the tubes and the kerosene in the shell.

Use 19.05 mm (3/4 inch) outside diameter, 14.83 mm inside diameter, 5 m Long tubes on
a triangular 23.81 mm pitch.

Step 7: Number of tubes


Area of one tube (neglecting thickness of tube sheets) = 𝜋 ×19.05×10−3×5=0.2992 𝑚2
Number of tubes = Area of heat transfer / Area of one tube =151.593 /0.2992 = 506.66
So, for 2 passes, tubes per pass = 325 tubes
Check the tube-side velocity at this stage to see if it looks reasonable.
Tube cross-sectional area = 𝜋 × 4 × (14.83×10−3) ×2=0.0001727 𝑚2
So area per pass =325×0.0001727 = 0.05612 𝑚2
Volumetric flow = 1571796.43600×1820 = 0.5325 𝑚3/𝑠
Tube-side velocity, Ut = Qoil/Area of tube one pass =0.5325/0.05612 = 9.4877 m/s
The velocity is satisfactory, between 3 to 5 m/s, but may be a little low. This will show up
when the pressure drop is calculated.

Step 8: Bundle and shell diameter


The following table would help us for the calculations of the tube arrangement.

From the table, we have for 2 tube passes, K1=0.249, Nt=2.207

So, D𝑏 = 19.05 × (506.66/0.249)1/2.207 = 601.17 𝑚𝑚 (0.601 𝑚)


Shell-bundle clearances

For a split-ring floating head exchanger the typical shell clearance from Figure is 63 mm, so
the shell inside diameter, 𝐷𝑠 = 601.17+63 = 664.17𝑚𝑚

Step 9: Tube-side heat transfer coefficient

𝑅𝑒 =

= 820 × 9.4877 × 14.83 × 10−3 / 3.2 × 10–3 = 0.03605 × (0.03605 /1000=3605)

𝑃𝑟 =
= 2.05 × 103×3.2×10−3/ 0.134 = 48.96
𝐿/𝑑𝑖 = 5000 / 14.83 = 337

From Figure, so reading is 𝑗ℎ=3.2×10−3

𝑁𝑢 = 3.2 × 10−3 × (0.03605) × (48.96)0.33 = 0.0004166 × (0.4166)


ℎ𝑖 = 0.4166 × (0.134/14.83×10−3) = 3.76(376) 𝑊/𝑚2 ℃

This is clearly too low if U is to be 300 W/m2℃. The tube-side velocity did look low, so
increase the number of tube passes to 4. This will halve the cross-sectional area in each pass
and double the velocity.

New
U𝑡 =2×9.4877=18.9754 𝑚/𝑠
And
𝑅𝑒 = 2 × 0.03605 = 0.0721
𝑗ℎ=3.2×10−3
ℎ𝑖 = (0.13414.83×10−3) × 3.8×10−3 × (0.0721) × (48.96) × 0.33
= 8939 𝑊/𝑚2 ℃
As a first trial take the baffle spacing = 𝐷𝑠/5, say 150 mm. This spacing should give good
heat transfer without too high a pressure drop.

23.81−19.05
As= ×679 ×135.8=18433.89m m 2=0.01843 m2
23.81

1.10
de= (23.812−0.917 ×19.052 )=13.52 mm
19.05

86570 1
Volumetric flow-rate on shell-side = × =0.0329 m 3 /s
3600 1730

q 0.0329 m
Shell−side velocity = = =1.785
As 0.01843 s

730 × 1.620× 13.52×10−3 4


ℜ= −3
=37183.14=(3.718 ×10 )
0.43 × 10

2.14 ×103 ×0.43 ×10−3


Pr= =6.97
0.132

Use segmental baffles with a 25% cut. This should give a reasonable heat transfer coefficient
without too large a pressure drop.
From Book ,h=4.52 ×10−3.

Neglecting the viscosity correction

0.132
hs=( × 103 )× 4.52× 10−3 ×37183.14 × 6.970.33=3114 W /m 2 ℃
13.52

Step 11: Overall coefficient


The overall coefficient calculation from this relation:

1 1 19.05
19.05 ×10−3 ln ( 19.05
14.83 ) 1
= (
Uo 8939
+ 0.00035
14.83)(
+ ) 2× 55
+
3266
+ 0.0002

Uo=863.93 W /m2 ℃

This is above the initial estimate of 300 𝑊/𝑚2 ℃. The number of tubes could possibly be
reduced, but first check the pressure drops.

Step 12: Pressure drop Tube-side


651 tubes, 4 passes, tube inside diameter 14.83 mm,=9.487 m/s,

ℜ=7.2× 103, From Figure (3),so reading, jf =5 × 10−3 .


Figure 1 (Tube-side friction factors)

5000 820 ×9.487 2


(
ΔPt=4 8 ×5 ×10 −3
( 14.83 ) )
+ 2.5 [
2
]

820 × 902
¿ 4 ( 13.5+ 2.5 ) [ 2 ]
23596 N /m 2 ,2.3 ¯¿

Summary of the proposed design:


 Split ring, floating head, 1 shell pass, and 4 tube passes.

 360 carbon steel tubes, 5 m long, 19.05 mm out diameter, 14.83 mm inside diameter,
triangular pitch, Pitch 23.18 mm.

 Heat transfer area 107.7 𝑚2 (based on outside diameter).

 Shell inside diameter 597 mm (600 mm), baffle spacing 140 mm, 25% cut.

 Tube-side coefficient 680𝑊/𝑚2 ℃

 Shell-side coefficient 1366𝑊/𝑚2 ℃

 Dirt/Fouling factors:

 Tube-side (crude oil) 0.00035 (𝑊/𝑚2 ℃)^−1


 Shell-side (kerosene) 0.0002 (𝑊/𝑚2 ℃)^−1
 Pressure drops:

 Tube-side, estimated 0.40 bar, +0.1 for nozzles; specified 0.8 bar overall.
 Shell-side, estimated 0.45 bar, +0.1 for nozzles; specified 0.8 bar overall.
CHAPTER NO 6
DISTILLATION COLUMN DESIGN
DISTILLATION COLUMN:
Step: 1. Determine Process Operation Variables
 Assumed feed rate, composition, purity of distillate and bottoms, and the quality of
the feed are known.
 Perform overall material and component balances to determine the compositions of
the distillate and bottoms.
F*ZF=XD*D+XB*B
F=D+B
Where:
F=Feed rate of input stream
ZF=Composition of light component in feed
XD=Mole Fraction of light in distillate
XB=Mole Fraction of light in Bottom
D=Total distillate amount
B=Total bottom amount
Note*If more than two components, these values are the light-key and heavy-key component.

Step 2. Determine the Minimum Reflux Ratio


This graphical approach is determined using the McCabe-Thiele Method for binary
Mixtures. The ratio of reflux flow to distillate flow is called the reflux ratio.
Assumptions:
The following assumptions are implied when using this method (McCabe,
1993):
a. Constant Molal Overflow. The molar flow rates of the vapor and liquid are nearly constant
in each section of the column. This also ensures the operating lines are straight lines.
b. Heat Effects are negligible. For example, heat losses to and from the column are small and
neglected
c. For every mole of vapor condensed, another mole of liquid is vaporized.
d. The liquid and vapor leaving the tray is in equilibrium with the vapor and liquid entering
the tray.
Procedure:
If an equilibrium curve is not given, draw a y-x diagram (y representing the vapor phase and
x the liquid). The equilibrium curve can be obtained by relating the relative volatility to the
composition of the liquid.
y = a*x/(1+x(a-1))
This shows the bubble-point and dew point of a binary mixture at constant pressure. An
equilibrium line describes the compositions of the liquid and vapor in equilibrium at a fixed
pressure. The equilibrium line crossing the forty-five degree line is an indication of an
azeotropic mixture. An azeotrope is a liquid
Mixture which when vaporized produces the same composition as the liquid. If the mixture is
azeotropic, then more advanced types of separation must be considered.

Forty Five Degree Line


1. Draw the diagonal line connecting the points (0.0, 0.0) to (1.0, 1.0).This is your forty-five
degree line.
 Feed Line (q-Line)
2. The feed line can be constructed by locating the point on the forty five degree line that
corresponds to the feed composition. This point can be extended with a slope of q/ (q-1)
where q is the feed
Quality. The feed line can be directly plotted through the following equation:
y=q/(q-1)X - ZF/(q-1)
Upper Operating Line
3. Draw the operating line for the enriching section. First find the desired top product
composition (on the x-axis) and locate the corresponding point on the forty-five degree line.
Connect this
Point to the point where the equilibrium cure and the feed line intersect. This is the upper
operating line. The y intercept of this line is equal to XD/(R+1). The following equation can
be used to
Determine the minimum reflux:

Rmin= (XD/yintercept ) – 1
Lower Operating Line
T4. Draw the operating line for the stripping section. First find the desired bottom product
composition (on the x-axis) and locate the
Corresponding point on the forty-five degree line. Draw a line from this point to the
intersection of the equilibrium curve and the feed line. This is your lower operating line. The
slope of this line is equal to (Vbmin+1)/Vbmin where Vb is the boilup ratio. The boilup ratio
is the fractional amount of liquid that is boiled back into the column to the amount of liquid
leaving.

Physical property data


D = 354338.8Kg/day
80% LPG 20% water
5 Kmol
V D=6442.
day
Kmol
L D=3937
day

Bottom Product

B = 20351442.4Kg/day
Residue 60% vaccum gas oil 40%
Kmol
LB =48843
day

Kmol
V B =18417
day
Kg
Density data ( )
m3

LPG (Vapour) = 0.35


Water = 988
Residue =900
Vaccum gas oil= 2.7
Column Diameter

2.7
F LV bottom=2.65
√ 900

= 0.145

0.35
F LV top=0.61
√ 988
= 0.01148

Taken tray spacing 0.5


From figure
Base K1 = 7.8 ×10−2
Top K1 = 9.0×10−2
Correction for surface tension

67 0.2 −2
base K 1=( ) × 7.8× 10
20
= 9.93×10−3

34 0.2 −2
top K 1=( ) × 9.0 ×10
20
= 9.98×10−3
Flooding velocity

ρ L− ρV
Base U f =K 1
√ ρV

900−2.7
Base U f =9.93 ×10−2
√ 2.7
= 1.81m/s
988−0.35
top U f =9.98 ×10−2
√ 0.35
= 5.30 m/s

Design for 85% flooding velocity at maximum rate


m
base u v =1.81 ×0.85=1.53
s
m
topu v =5.3 ×0.85=4.5
s
Maximum volumetric flow rate

18417.5× 442
Base = =34.89 m 3 /¿s
2.7× 86400

6442.5 × 44
Top = = =11.84 m 3 /¿s
11.84 × 86400

Net Area required


34.89
Bottom = =22.84 m 2
1.53
11.84
Top = =2.63m2
4.5
We take down comer area as 12% of total

Column cross sectional area


22.8
Base = =25.9 m 2
0.88
2.63
Top = =2.9 m2
0.88
Column diameter

25.9× 4
base=
√ 3.1428
=5.7 m

2.9 × 4
top=
√ 3.1428
=3.69 m
Provisional plate design:
From the outside and inside diameter that comes from Standard Pipe Size (BS 1600), we can
consider the values of following parameters:
Column diameter = Dc = 0.85 m
Column area = Ac = 0.56 m2
Let us assume the downcomer area to be 12 %.
Downcomer area = Ad = 0.12 * 0.56 = 0.06 m2
Net area = An = Ac - Ad = 0.56 - 0.06 = 0.05 m2
Active area= Aa = Ac - 2Ad = 0.56 - 0.12 = 0.44 m2

Let us assume hole area Ah to be 10 per cent Aa as trial = 0.44*10% = 0.044 m2

Weir length from Figure the following figure = 0.86 * 0.85 = 0.73 m
We can assume:

Weir height = 50 mm
Hole diameter = 5 mm
Plate thickness = 5 mm

Check weeping:

Maximum liquid rate = (854 *18/3600) =4.27 kg/s

Since the turndown ratio assumed to be 70%.


Using the equation:
how = 750 * [Lw / pL * lw ]2/3
where,
Lw = Maximum liquid rate
pL = Density of liquid
lw = weir length
Maximum how = 750 * (4.27 / 954* 0.06)2/3 = 28 mm liquid
Minimum how = 750 * (2.31 / 954*0.60)2/3 = 21 mm liquid

At minimum rate,
hw + how = 50 +21 =71 mm

From Figure

At the value of hw + how = 71, the value of K2 = 30.5


K2 = 30.5
Using the equation:
Uh(min) = [ K2 – 0.90 * ( 25.4 – dh) / (density of vapor)1/2 ]
Uh(min) = 30.5-0.90 * (25.4-5) / (0.72)1/2 = 14 m/s

Actual minimum vapor velocity = minimum vapor rate / Ah


Where Ah is the hole area.

= 0.7 *1.13 /0.038= 20.8 m/s

Here 0.7 was the turndown ratio.


So minimum operating rate will be well above weep point.
Plate pressure drop:
Dry plate pressure drop:
Maximum vapor velocity through holes:
Uh= Maximum volumetric flow rate/ hole area
Uh= 1.16/0.038 = 30.5 m/s
From Fig 11.34 from book
For plate thickness/ hole diameter =1
Ah/Ap ≈ Ah/Aa = 0.1 x 100
Then go to Fig 11.34 to find the value of Co
Co= 0.83
Now using Eq 11.88
Dry plate pressure drop =hd= 51 x { Uh/ Co}2 x ρ v/ρ L
hd= 45 mm liquid
For residual head Eq 11.89
hr = 12.5x103/ ρ L = 13.5 mm liquid

Total plate pressure drop;


ht= hd+ hr+(hw+how) = 135 mm liquid

Downcomer liquid backup


Downcomer pressure loss

Take hap= weir height(hw)-10 = 40mm

Area under apron, Aap = weir length x hap = 0.027 m2

If Aap is less tha downcomer area Ad, we will use Aap in Eq 11.92

hdc= 166x{Lwd/ρ LAm}2

Am=Ad ≈ Aap

Lwd= liquid flow rate in downcomer

hdc= 5.7 mm say 6 mm

Backup in down comer by Eq 11.91

hb= (hw+how)+ht+hdc = 210 mm or 0 .21 m

if hb is less than 0.5x( plate spacing +weir length), then value of hb is acceptable.
Check Residence time by Eq 11.95

tr= Adx hbxρ L/ Lwd = 3.2 seconds

At least 3 seconds of residence time is recommended.


CHAPTER NO 7
ECONOMIC EVALUATION

COSTING:
FEASIBILITY STUDY:
A feasibility study is an examination of how effectively a task or project can be completed,
representing factors that influence it, for example, and financial, innovative, legitimate and
scheduling factors. Project manager use feasibility studies to decide potential positive and
negative results of an undertaking before contributing a lot of time and cash into it. A
feasibility study plans to unbiasedly and soundly reveal the qualities and shortcomings of a
current business or proposed venture, opportunity and dangers present in the earth, the assets
required to bring through, and at last the possibilities for progress. In its most straightforward
terms, the two criteria to pass judgment on feasibility are cost required and incentive to be
achieved. An all-around structured feasibility study ought to give a verifiable foundation of
the business or venture, a depiction of the item or administration, bookkeeping explanations,
subtleties of the activities and the executives, advertising exploration and arrangements,
money related information, legitimate necessities and assessment commitments. By and
large, feasibility considers go before specialized advancement and undertaking execution. A
feasibility study assesses the undertaking's potential for progress; along these lines, saw
objectivity is a significant factor in the believability of the investigation for potential financial
specialists and loaning organizations. It should subsequently be led with a goal, fair way to
deal with give data whereupon choices can be based. A feasibility study tests the
reasonability of a thought, an extend or even another business. The objective of a feasibility
study is to put accentuation on potential issues that could happen if a venture is sought after
and decide whether, after every single critical factor are thought of, the task ought to be
sought after. Feasibility study concentrates likewise permit a business to address where and
how it will work, potential impediments, rivalry and the subsidizing expected to get the
business ready for action.

PLANT COST:
It is often compulsory to suggest the cost of a piece of plant when no cost data are available
for the specific size of operational capacity involved. Good result can be obtained by using
the logarithm relationship known as the six-tenth-factor-rule, if the new piece of plant is same
to another capacity for which cost data are available. According to rule, if cost of a given
piece at one capacity is known, the cost of a same unit with X times the capacity of the first is
approximately (X)*m times the cost of the initial unit.
Cost of plant B = cost of plant A ¿
m= (𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑦𝑒𝑎𝑟−𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑦𝑒𝑎𝑟)/ 100
In this project there are a comparison the prices of PARCO that have capacity of 20000 barrel
per day with a plant have capacity 200000 barrel per day. The cost of plant B must be
converting from original year (1965) to present year (2020) depending upon the cost index to
obtain fixed cost. And cost of plant A = 1.35*108$, and m=0. 27
200000
Cost of plant B =1.35*108( ¿= 2.4*108
20000

COST INDEX
Most cost data which are available for quick use in a preliminary or pre design estimate are
based on conditions at some time in the past. Because cost may change considerably with
time due to changes in economic conditions, few methods must be used for updating cost data
applicable at a past date to costs that are representative of conditions at a later time; this can
be achieved by the use of cost indexes. Index value is merely an index value for a given point
in time showing the cost at that time relative to certain base time. If the cost is known in past
at some point the equivalent cost at the present time can be determined by multiplying the
original cost by the ratio of present index value to the index value applicable when the
original cost was obtained. Cost indexes can be only used to give a general estimate, but no
index can take into account all factors such as special technological advancements or local
conditions. The common indexes fairly permit only accurate estimate if the time duration
involved is less than ten years.

Present cost= original cost*(index value at present time/ index value at time original cost was
obtained

Cost index at present time (2020) = (1090)

Cost index at original time (1965) = (800)


Present cost in 2018 = 2.4*108 (1090/800)
Fixed cost = present cost = 3. 27*108$
Assume the variable cost is 60% of fixed cost
Variable cost = 0.6 * fixed cost = 1.9*10 8$
Total cost = fixed cost +variable cost = 5.03*10 8
THE COST OF RAW MATERIAL AND PRODUCT:
Let us assume the price of the raw material to be equal 15 $/m3.

Raw Material Cost Per m3 Flowrate in m3/hr


Crude oil 15 $ 1324.89

The cost of the Raw-Material = (Flowrate for the Raw-Material-1* Price of Raw-Material-1 +
Flowrate for the Raw-Material-2* Price of Raw-Material-2)
The cost of Raw-Material /year = [(1324.89*15)] * 348 = 6915925 $/year

The table listed below briefs the cost of products with respect to their flowrates. The cost of the
products has been used for the year 2020. Let us assume the price to be 40 $.

Products Cost $/m3 Flowrates in m3/day

Naptha 40 2262.65
Kerosene 40 2077.68
Diesel 40 4533.12
Residue 40 22612.45

The cost of the products = (Flowrate for the product-1* Price of the product-1 + Flowrate of
product-2 * Price of product-2+ Flowrate for the product-3* Price of the product-3 + Flowrate of
product-4 * Price of product-4)

Let us assume the working hours for the units is 8352 hr/year, which is equal to 348 days/year
The cost of the products/ day = [(2262.65*40) + (2077.68*40) + (4533.12*40) +
(22612.45*40)]*348
= 438280944 $/year
DEPRECIATION
Depreciation is an auditing technique of allocating and ascribing the cost of a tangible
(touchable) assets over its useful life.
Businesses usually depreciate long-term assets for both tax and auditing purposes.
For tax purposes, businesses can subtract the cost of the tangible assets they buy as business
expenditures.
However, businesses must depreciate these assets in accordance with IRS rules about how and
when the subtraction may be taken.
Assume 30 years depreciation time period and the installation has no recovery value
Depreciation=total cost (C)/life period (n)
Depreciation= 5.03 x 108/30 = 1.7 x 107 $/year

THE COST OF THE OPERATION


The cost of operation is the business strategy implemented in many companies to gain a huge
market.
Cost of operation is the cost acquired in completing one operation.
It may be a conversion of inputs into the outputs or labor costs etc.
If the cost of operation is less than it is convenient to maintain cost leadership and gain the
market with competitive advantage.
Operating cost = Raw material (RM) + utilities (util) + operation labor + others
RM + DEP = 90% from production cost
Production cost=RM+DEP/0.9
Production cost=1.13 x 108 +1.7 x 107 /0.9 = 1.44 x 108 $/year
Util + Labor = 0.1 x production cost
Util + Labor = 0.1x 1.44 x 108 = 1.44 x 107 $/year
Operating cost =1.44 x 108 + 1.44 x 107 = 1.59 x 108 $/year
CASH FLOW
Cash flow is the net amount of cash and cash-equivalents moving into and out of a business.
Positive cash flow indicates that a company's liquid assets are increasing, enabling it to settle
debts, reinvest in its business, return money to shareholders, pay expenses and provide a buffer
against future financial challenges. Negative cash flow indicates that a company's liquid assets
are decreasing. Net cash flow is distinguished from net income, which includes accounts
receivable and other items for which payment has not actually been received. Cash flow is used
to assess the quality of a company's income, that is, how liquid it is, which can indicate whether
the company is positioned to remain solvent.
Cash flows are often transformed into measures that give information e.g. on a company's value
and situation:
 To determine a project's rate of return or value. The time of cash flows into and out of
projects are used as inputs in financial models such as internal rate of return and net
present value.
 To determine problems with a business's liquidity. Being profitable does not necessarily
mean being liquid. A company can fail because of a shortage of cash even while
profitable.
 As an alternative measure of a business's profits when it is believed that accrual
accounting concepts do not represent economic realities. For instance, a company may be
notionally profitable but generating little operational cash (as may be the case for a
company that barters its products rather than selling for cash). In such a case, the
company may be deriving additional operating cash by issuing shares or raising
additional debt finance.
 Cash flow can be used to evaluate the 'quality' of income generated by accrual
accounting. When net income is composed of large non-cash items it is considered low
quality.
 To evaluate the risks within a financial product, e.g., matching cash requirements,
evaluating default risk, re-investment requirements, etc.

Cash flow = Net profit Prices $/year


Years 1-30
Income 5.65*108
Operating -1.59*108
Depreciation -1.7*107
The net profit =3.88*108
PAY- BACK PERIOD
Payback period is the time in which the initial cash outflow of an investment is expected to be
recovered from the cash inflows generated by the investment. It is one of the simplest investment
appraisal techniques
Formula
The formula to calculate payback period of a project depends on whether the cash flow per
period from the project is even or uneven. In case they are even, the formula to calculate payback
period is:
Pay−back period=Total cost cash flow
Pay−back period=5.03∗1083.88∗108=1.297 𝑦𝑒𝑎𝑟
Advantages of Payback Period are:
1. Payback period is very simple to calculate.
2. It can be a measure of risk inherent in a project. Since cash flows that occur later in a project's
life are considered more uncertain, payback period provides an indication of how certain the
project cash inflows are.
3. For companies facing liquidity problems, it provides a good ranking of projects that would
return money early.
Disadvantages of Payback Period are:
1. Payback period does not take into account the time value of money which is a serious
drawback since it can lead to wrong decisions. A variation of payback method that attempts to
remove this drawback is called discounted method.
2. It does not take into account, the cash flows that occur after the payback period.
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(3)-Peach leaf, Jaeger Products, Inc., Houston, Texas, http://www.jaeger.com,2016
(4)-http://www.ogj.com/seb/2016
(5)-Brix Jacobsen -Department Head, Structural and Fluid Mechanics, R&T- book: The
Centrifugal Pump, RESEARCH AND TECHNOLOGY, www.grundfos.com, 2006
(6)-Paresh Girdhar B. Eng. (Mech Eng.), Practical Centrifugal Pumps -Design, Operation and
Maintenance, www.integra-india.com, 2005 (7)-Himmelblau, David M. Basic Principles and
Calculations in Chemical Engineering (2nd ed.). Prentice Hall. (1967).
(7)-Surinder Park ash, Refining Processes Handbook, United States of America,
http://www.gulfpp.com, 2003
(8)-Klaus D. Timmerhaus, Professors of Chemical Engineering University of Colorado, Plant
Design And Economics For Chemical Engineers, 1991
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(10)-David S. J. “Stan” Jones & Peter R. Puja, Handbook of Petroleum Processing, University of
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