CH4250 - Process Engineering

(Jan - May 2021)

Final Project Report
Group 18 (Shashank V, Pranav Kamesh S, J Mahesh, RA Keerthan)
Change from Deliverable 3: STYCOL Number of Stages reduced from 50 to 30 & Feed Stage changed to 15.
Reason: To reduce height of column. No changes to styrene purity or rate of production caused due to this change.

Section-1

Analysis of Existing Technologies for Styrene

Production

Introduction

Styrene is a derivative of benzene with formula C6H5CH=CH2 and has the above structure
Styrene is also referred to as ethenylbenzene, vinylbenzene and phenylethene. It is an
oily, colourless liquid with a sweat smell and evaporates easily.
Styrene monomer has its application in production of polymers or co-polymers of
different types which are used to manufacture food containers, fiberglass, medical
devices, paper coatings and toys. Styrene also serves as an intermediate raw material for
many different polymers. Owing to its applications, there is an increased demand for
styrene.
Styrene can be produced using the following four technologies:
1. from catalytic dehydrogenation of ethylbenzene
2. from ethylbenzene hydroperoxide
3. from toluene and methanol
4. from butadiene
In the following sections, we will review the above four technologies along with a
preliminary economic analysis. Finally, we conclude by choosing the optimal technology
based on profit, safety and environment friendliness.
 Technology 1

Production of Ethylbenzene using Mobil Badger process

followed by Catalytic Dehydrogenation of EthylBenzene

The direct dehydrogenation of Ethylbenzene to Styrene accounts for 85% of commercial

Styrene production, making it the most widely used technique for Styrene production.
The reaction is carried out in the vapour phase with steam over a catalyst primarily
consisting of iron oxide. The reaction is endothermic, and can be accomplished both
adiabatically and isothermally.

Raw Materials:
● Benzene
● Ethylene
● Shell 105 catalyst for Ethylbenzene dehydrogenation
● ZSM-5 catalyst for Alkylation [39]

Process Pipeline:
This technology comprises of 2 subprocesses
1. Production of Ethylbenzene from Benzene and Ethylene using Mobil Badger vapour
phase process
2. Production of Styrene from Ethylbenzene using Catalytic Dehydrogenation

Ethylbenzene Production [39]

1. Fresh and recycled Benzene are vapourised and preheated to a desired
temperature, and fed to a multi-stage fixed bed reactor along with Ethylene.
2. Ethylene is distributed to the individual stages of the reactor and Alkylation occurs
at 350-450 C and in a pressure range of 0.69 - 2.76 MPa
3. The Poly Ethyl Benzene stream from the distillation section is mixed with the
Benzene and fed to the trans-alkylator to form additional Ethylbenzene.
4. The combined reactor effluent, consisting of excess Benzene, Ethylbenzene,
poly-ethyl benzenes, and trace impurities, is distilled in the benzene column.
Benzene is condensed in the overhead for recycling to the reactors.
5. The main reactions involved in the Mobil-Badger process are given below:
 6. The major side reaction involved is the formation of diethyl Benzene:
C6H5CH2CH3 + C2H4 ⇄ CH3CH2C6H5CH2CH3

Styrene Production [14]

Fig 2 : Catalytic Dehydrogenation of Ethylbenzene to Styrene

 1. Liquid Ethylbenzene stream is preheated from 25 °C to around 250 °C.
2. The vapors obtained are then sent to another pressurized vessel operating also
under isobaric condition, at which superheated steam is injected in order to
increase the temperature of the vapor mixture to that of the reaction condition
(600 °C).
3. The ethyl-benzene catalytic dehydrogenation takes place in a vertical cylindrical
shell and tube reactor which operates isothermally. The reacting gaseous mixture
flows inside the tubes over the Shell 105 catalyst bed, while superheated steam is
injected in the reactor’s shell to maintain the reaction temperature in the
requested range (580 - 610 °C).
4. The hot gaseous effluent from the Reactor, which presents a temperature near 600
°C and a pressure of 3.5 bar, is pressurized to 6.0 bar using pressure regulating
valves. The mixture is then cooled to 50 °C via two coolers, which use cooling
water as its utility.
5. A three phase LLV separator operating at 50 oC and 5 bar is used for separation. A
gaseous mixture primarily composed of hydrogen, methane and ethylene is
obtained at the top of the LLV Separator. A liquid stream containing water and
certain traces of styrene, benzene and ethylene is obtained at the bottom of this
equipment (wastewater stream). The middle stream (useful stream) contains
mainly styrene and is sent to the Distillation Column No. 1 in order to recover
both the benzene and toluene present in it.
6. Benzene and Toluene are obtained at the top of the Distillation Column No. 1. A
styrene-rich stream is obtained at the column’s bottom, which is sent to the
Distillation Column No. 2 to carry out the final purification step. At the Styrene
Column, the styrene is obtained at the bottom stream with a purity of about 99.5
%. The stream obtained at the top, consisting mainly of Ethylbenzene, Benzene
and Toluene, is recycled back to the process.

Reactions:
The application of high temperatures during the reaction step permits the catalytic
dehydrogenation of ethyl-benzene to be the predominant reaction, with a selectivity of
about 95% [40] while the rest of the reactions involved totalize about 4%.

For production of ethylbenzene:

The main reactions involved in the Mobil-Badger process are given below:

The major side reaction involved is the formation of diethyl Benzene:

C6H5CH2CH3 + C2H4 ⇄ CH3CH2C6H5CH2CH3
For the Dehydrogenation process:
The main reaction is given below. Ethyl Benzene is dehydrogenated to produce Styrene
and Hydrogen gas.

Toluene is one of the major by-products and is thought to be formed from Styrene and
Ethylbenzene by the following side-reactions.
C6H5CH=CH2 + 2H2 ⇄ C6H5CH3 + CH4
C6H5CH2CH3 + H2 ⇄ C6H5CH3 + CH4
C6H5CH=CH2 ⇄ C6H5CH3 + C
Benzene is another by-product that is formed from Ethyl Benzene in the catalytic
Reactor.
C6H5CH2CH3 ⇄ C6H6 + C2H4

Material balance:
Given capacity of the plant = 700 TPD of styrene = 6721.075 kmol styrene/day
Composition of product = 99.5% pure styrene [14]
Required Flow Rate of product = 700000/0.995 kg/day = 703517.587 kg/day
= 6754.849 kmol/day

Conversion of Ethylbenzene (EB) is between 50 to 70 wt % and yield of styrene is

between 88 to 95 mol% [38]. Assuming conversion to be 60 mol% and yield to be 90
mol%, we get
Required Flow Rate of EB = 6754.849 / (0.6*0.9) = 12508.98 kmol/day
Conversion of ethylene to EB = 99 mol %
Benzene to Ethylene ratio = 18 :1 wt ratio = 6.46:1 mol ratio [15]
Yield of EB = 98.5 mol %
Required Flow rate of Ethylene = 12508.98 / (0.99 * 0.985) kmol/day = 12827.75
kmol/day
Required Flow rate of Benzene = 6.46 * 12827.75 kmol/day= 82867.265 kmol/day
Here most of the unreacted Benzene is recycled back. So Benzene in output is Zero.

Economic analysis:
Ethylene price = 75.5 Rs/kg [9] , Benzene price = 50 Rs/litre [10]
EB price = 250 Rs/kg [20], Cost of styrene = 76.2 Rs/kg [12]

Raw materials and product Cost table:

Input Output Net Net Price Cost
Chemical (kg/day) (kg/day) (kg/day) (ton/yr) (Rs/ton) (Rs/yr)
Benzene 877297.06 0 877297.06 320213.4269 57077.6255 182770220
 7 83
977794932
359177
Ethylene 3591.77 355585.23 129788.609 75337.5 7
Ethylbenz 483972206
ene 0 530380.5 530380.5 193588.8825 250000 25
194553030
Styrene 0 700000 700000 255500 76146 00
H2 +
minor
byproduct
s 0 2501.79 2501.79 913.15335 - -
Total cost of raw materials = 2805.49 crore Rs/yr

The composition of Shell 105 catalyst (%w/%w) is 93% Fe2O3, 5% Cr2O and 2% KOH. As
we could not find any resource for the cost of Shell 105 catalyst, we approximate it to be
slightly higher than the total cost of Fe2O3, Cr2O and KOH (because of processing costs).
Cost of Fe2O3=2133.33 Rs/kg [21], Cost of Cr2O=780 Rs/kg [22], Cost of KOH=50 Rs/kg
[23]
Total cost = 0.93*2133.33 + 0.05*780 + 0.02*50 = 2024 Rs/Kg
Assuming processing cost to be 30% of cost of total cost,
Approximated per kg cost of Shell 105 = 2631.2 Rs/kg
From [1], we have 0.33 lb/hr. Fluid = 1 lb cat.
Flow rate of EB = 12508.98 kmol/day = 12508.98*106*2.204/24 lb-EB/hr
= 121766.58 lb-EB/hr
Amount of catalyst required = 121766.58/0.33 lb-cat. = 167418.17 kg-cat.
Approximated cost of Shell 105 = 440510688.8 Rs
Approximate average lifespan of Shell 105 = 3 yrs [24]
⇒ Cost per yr of Shell 105 = 44,05,10,688.8/3 = 14.68 crore Rs/yr

Cost of ZSM-5 catalyst for alkylation = 500 Rs/kg [37]

Ethylene Weight Hourly Space Velocity (WHSV) = (2 lb/hr)/lb-cat
⇒ Amount of catalyst required = (12827.75*28*0.5/24) kg-cat = 7482.854 kg-cat
Lifespan of ZSM-5 catalyst = 50 h [41] = (50/24)/365 yrs = 0.0057 yr
Cost of ZSM-5 = 175.2*7482.854*500 = 65.55 crore Rs/yr

Distance from Vizag chemical plant to Styrene plant = 50 kms [16,17]

Capacity of goods train = around 65 ton per carriage [26]
Number of carriages in goods train = around 50 [27]
⇒ Total capacity of goods train = 3250 tons
Number of goods train required for Benzene transport = 320213.42/3250 = 99 per yr
Number of goods train required for ethylene transport = 129788.61/3250 = 40 per yr
⇒ Total number of goods train required = 139 per yr
Approximate cost per train = 1612500 Rs/train [25]
⇒ Transportation cost = 139*1612500 = 224137500 Rs/yr = 22.41 crores Rs/yr
Total cost = cost of raw materials + catalyst cost + transportation cost
= 2805.49 + 14.68 + 65.55 + 22.41 = 2908.13 crore Rs/yr
Total Revenue = 6785.25 crore Rs/yr
Profit = 3877.12 crore Rs/yr
Return On Investment (ROI) = Profit * 100 / Total cost = 133.32 %

Technology 2

Styrene-Propylene Oxide Process [38]

Styrene can be produced by the catalytic epoxidation of propylene with ethylbenzene
hydroperoxide using a silica-supported titanium catalyst. In this method, styrene is
“co-produced” with propylene oxide. About 15% of the world’s styrene production is
carried through this process.

Raw materials:
● Ethylbenzene (Produced from Benzene and Ethylene - Refer to the Ethylbenzene
production section in Technology-1)
● Oxygen (from air)
● Propylene
● Hydrogen
● Titanium (or) Silicon dioxide catalyst
● Al2O3 catalyst

Process pipeline:
1. Ethylbenzene (EB) is oxidized by air at 130 oC and 0.2 MPa to produce
ethylbenzene hydroperoxide (EBHP), alpha-methylbenzyl alcohol (MBA) and
acetophenone (ACP).
2. EHBP is then made to react with propylene at 110 oC and 4 MPa in presence of a
titanium or silicon dioxide catalyst to form additional MBA and propylene oxide
(PO).
3. ACP is also hydrogenated to produce more MBA in liquid phase at 90 to 150 oC and
8 MPa.
4. In the final step, MBA is dehydrated at 250 oC and low pressure over Al2O3 catalyst
to produce styrene monomer.
Reactions:
Main reactions:

Side reactions:
Material Balance:
Given capacity of plant = 700 TPD of styrene = 6721.075 kmol styrene / day

Ratio of Styrene to PO produced = 2.5:1 (mole) [38]

Conversion of Ethyl Benzene is held to 13% to minimize by-products.
Ethylbenzene Hydroperoxide (EBHP) is assumed to convert completely to Propylene
Oxide (PO) and alpha-methyl Benzyl Alcohol (MBA), while approximately 90% of the
Acetophenone (ACP) produced is hydrogenated, with 92% selectivity to MBA.

Let the amount of EBHP formed (due to oxidation reaction) = x kmol/day

Let the amount of MBA and ACP formed (due to oxidation reaction) = y kmol/day
⇒ x+2y = 13 (Since conversion of EB = 13%, assuming 100 kmol/day EB feed) … (1)

During the formation of propylene oxide, since EBHP is nearly completely converted,
Amount of PO formed = x kmol/day
Amount of MBA (overall) = x+y kmol/day

During the hydrogenation of ACP to MBA,

Amount of MBA (overall) = x+y+(0.9*0.92y) kmol/day
Amount of ACP (remaining) = 0.1y kmol/day

During dehydration of MBA,

Amount of styrene formed = x+y+(0.9*0.92y) kmol/day
⇒ (x+1.818y) = 2.5x … (2)
Solving (1) and (2), we get, x = 4.905 kmol/day, y = 4.047 kmol/day
⇒ Amount of Styrene produced = 12.262 kmol/day
Since the actual Styrene target = 6721.075 kmol/day,
Scaling factor = 6721.075/12.262 = 548.122
⇒ Amount of Propylene feed=4.905*548.122 kmol/day=2688.539 kmol/day
Fresh Ethyl Benzene feed=13*548.122 kmol/day = 7125.589 kmol/day
Oxygen feed = 3.5(assumed)*13*548.122 kmol/day = 24939.562 kmol/day
Hydrogen feed = 0.9*4.047*548.122 kmol/day = 1996.425 kmol/day
Required Flow rate of Ethylene = 7125.589/ (0.99 * 0.985) kmol/day = 7307.172
kmol/day
Required Flow rate of Benzene = 6.46 * 7307.172 kmol/day = 47204.33 kmol/day
Economic analysis:
Cost of Hydrogen = Rs 67.5/kg [31], Cost of Propylene Oxide = Rs 212892.5/ton [32]
Cost of Oxygen = Rs 107692.3077/ton [33], Cost of Propylene = Rs 84523.94/ton[34]
Cost of styrene = 76.2 Rs/kg [12]
Catalyst - For MBA dehydration- Al2O3
For ACP hydrogenation - ZnO + CuO
EBHP + Propylene epoxidation - Ti catalyst

Cost table for raw materials and products:

Input Output Net Net Price
Chemical (Kg/day) (Kg/day) (Kg/day)
(ton/yr) (Rs/ton) Cost (Rs/yr)
499741.6
182405.68 57077.625
3681937.827
Benzene 3182196.212 158 98 57 10411283663
202554.8
73932.504
204600.816
Ethylene 2046.00816 078 86 75337.5 5569890085
Propylene 156144.0
56992.568
Oxide 0 156144.023 23 41 212892.5 12133290370
Styrene 0 700000 700000 255500 76146 19455303000
3439284.
1255338.7
Air 3439284.36 0 36 91 0 0
113133.7
41293.808
Propylene 113133.7211 0 211 21 84523.94 3490315367
26652.27
9728.0787
Acetophenone 0 26652.27055 055 52 - -
1457.3902
Hydrogen 3992.85 0 3992.85 5 67500 98373841.88
Other 3375911. 1232207.5
By-products 0 3375911.061 061 37 - -

Total cost of raw materials = 1956.98 crore Rs/yr

Total revenue =3158.85 crore Rs/yr
Profit = 1201.87 crore Rs/yr
ROI = 61.41 %
Even without catalyst and transportation cost, the ROI is less than technology 1. Hence,
actual ROI will be even lower.
 Technology 3

Styrene from Toluene and Methanol [2]

Raw materials:
● Toluene
● Methanol
● Metal oxide catalyst

Process pipeline:
1. Saturated vapour of feed toluene and methanol is mixed at 570 kPa.
2. The mixture is superheated in an interchanger and fired heater.
3. The resultant stream is fed to a catalytic reactor where toluene and methanol is
converted to styrene, ethylbenzene, water and hydrogen.
4. Heat is recovered from the reactor effluent in an interchanger before the effluent is
condensed with cooling tower water and cooled to 38 oC.

Reactions:
Main reaction:
C7H8 + CH3OH → C6H5CH=CH2 + H2O + H2
Side reaction:
C7H8 + CH3OH → C8H10 + H2O
Material Balance:
Given capacity of plant = 700 TPD of styrene = 6721.075 kmol styrene / day

Conversion of toluene = 71 mol%

Yield of styrene: 83 mol%
Major byproduct: Ethylbenzene (EB)
Equal moles of toluene and methanol present in feed
Required amount of toluene = 6721.075/(0.71*0.83) kmol toluene/day
= 11405.18 kmol toluene/day = 1050873.29 kg toluene/day
Required amount of methanol = 11405.18 kmol methanol/day = 365421.97 kg
methanol/day
Amount of H2 formed = Amount of styrene produced = 6721.075 kmol H2/day
= 13442.15 kg H2/day
Amount of H2O formed = 0.71*amount of toluene = 0.71*11405.18 kmol H2O/day
= 8097.67 kmol H2O/day = 145758.06 kg H2O/day

Amount of EB formed = 0.71*0.17*11405.18 kmol EB/day = 1376.61 kmol EB/day

= 145920.15 kg EB/day

Economic analysis:
Cost of toluene = 70 Rs/kg [28], Cost of methanol = 36 Rs/litre [29] = 49.38 Rs/kg
Cost of styrene = 76.2 Rs/kg [12]

Cost table for raw materials and products:

Input Output Net Net Price Cost
Chemical (Kg/day) (Kg/day) (Kg/day) (ton/yr) (Rs/ton) (Rs/yr)
173754.147 309640.11 216748078
Toluene 1022083.221 5 848329.0733 17 70000 22
198619.322 57228.870 276873276
Methanol 355410.7488 1 156791.4267 76 48380 7
194553030
Styrene 0 700000 700000 255500 76146 00
Ethylbenze 53260.905 133152264
ne 0 145920.29 145920.29 85 250000 63
53201.691
H2O 0 145758.06 145758.06 9 - -
4906.3847
H2 0 13442.15 13442.15 5 - -

Total cost of raw materials = 2444.35 crore Rs/yr

Total revenue = 3277.05 crore Rs/yr
Profit = 832.69 crore Rs/yr
ROI = Profit * 100 / total cost of raw material = 34.066 %
Even without catalyst and transportation cost, the ROI is less than technology 1. Hence,
actual ROI would be even lower.

Technology 4

Styrene from Butadiene [30, 38]

This route of styrene production involves production of an intermediary compound
4-vinylcyclohexene-1 (VCH) which is produced by Diels – Alder dimerisation of
1,3-butadiene.

Raw materials:
● 1,3-butadiene
● Oxygen
● Iron nitrosyl halide catalyst

Process pipeline:
1. 1,3-butadiene undergoes Diels-Alder dimerisation to produce VCH.
2. The reaction is exothermic and requires a temperature of 140 oC and a pressure of
4 MPa.
3. The produced VCH is oxidatively dehydrogenated to styrene at a temperature of
around 100 to 300 and pressure of about 5 atm [3].

Reactions:
Main reactions:
2C4H6 → C6H9CH=CH2
C6H9CH=CH2 + O2→ C6H5CH=CH2 + 2H2O

Side reaction:
C6H9CH=CH2 → C8H10 + H2
C6H9CH=CH2 → C6H6 + C2H6

Material Balance:
Given capacity of plant = 700 TPD of styrene = 6721.075 kmol styrene / day
Assuming conversion of butadiene is almost 100%
From [38], we have yield of VCH = 90 mol%
From [30], we have the following

Assuming the reaction is formed using Fe2O3/ZrO2 catalyst, we have

VCH conversion = 34.5 mol%, Selectivity for styrene = 86.3 mol%, Molar ratio of O2 to
VCH = 6

Amount of VCH required = 6721.075/(0.345*0.863) kmol VCH/day

= 22574.01 kmol VCH/day = 2442057.18 kg VCH/day
Amount of O2 required = 6*Amount of VCH = 6*22574.01 kmol O2/day
= 135444.06 kmol O2/day = 4334209.92 kg O2/day

Amount of butadiene required = 2*Amount of VCH = 45148.02 kmol butadiene/day

= 2442056.41 kg butadiene/day
Amount of Ethylbenzene formed = 0.345*0.061*22574.01 kmol EB/day = 475.07 kmol
EB/day
= 50357.43 kg EB/day
Amount of Benzene formed = 0.345*0.042*22574.01 kmol benzene/day
= 327.09 kmol benzene/day = 25549.58 kg benzene/day

Amount of H2O formed = 2*Amount of styrene formed = 13442.15 kmol H2O/day

= 242093.12 kg H2O/day
Amount of H2 formed = Amount of EB formed
= 475.07 kmol H2/day = 950.14 kg H2/day
Amount of C2H6 formed = Amount of benzene formed = 327.09 kmol C2H6/day
= 9835.59 kg C2H6/day
Amount of VCH in product = 0.655*22574.01 kmol VCH/day = 14785.97 kmol VCH/day
= 1599546.94 kg VCH/day

Economic analysis:
Cost of butadiene = 84 Rs/kg[35], Cost of oxygen = 100000 Rs/ton [33]
Cost of styrene = 76.2 Rs/kg [12], Benzene price = 50 Rs/litre [10] = 57077.62 Rs/ton
Cost of VCH = 69 Rs/kg [36]
Cost table of raw materials and products:
Input Output Net Net Price Cost
Chemical (Kg/day) (Kg/day) (Kg/day) (ton/yr) (Rs/ton) (Rs/yr)
2442056. 891350.58 748734495
Butadiene 41 0 2442056.41 97 84000 31
4334209. 49610.420 496104204
Oxygen 92 4198290.96 135918.96 4 100000 0
Vinylcyclohex 583834.63 402845896
ene 0 1599546.94 1599546.94 31 69000 84
194553030
Styrene 0 700000 700000 255500 76146 00
532282916.
Benzene 0 25549.58 25549.58 9325.5967 57077.62557 7
88363.988
H2O 0 242093.12 242093.12 8 - -
H2 0 950.14 950.14 346.8011 - -
3589.9903
C2H6 0 9835.59 9835.59 5 - -

Total cost of raw materials = 7983.44 crore Rs/yr

Total Revenue = 6027.21 crore Rs/yr
Profit = -1956.23 crore Rs/yr
ROI = -24.05 %
A negative profit and ROI indicates that this technology is economically not viable.

Safety and Environmental impact

Technolog Hazardous chemicals based on health, Max operating Max operating
y flammability and instability indices from pressure temperature
[43] [Refer to Appendix]

1 Ethylene, Ethylbenzene, benzene 35 bar 600 oC

2 Propylene oxide, ethylene, ethylbenzene 80 bar 250 oC

hydroperoxide, propylene, benzene,
ethylbenzene

3 Toluene, EB 5.4 bar 495 oC

4 Vinylcyclohexane, butadiene, benzene, ethane 40 bar 300 oC

Based on ROI from the preliminary economic analysis, Technology 1 and Technology 2
seem to be economically more viable. Higher preference is given to the economics of
processes while selecting a single technology. Hence, Technology 4 is rejected. Even
though Technology 3 seems inherently safest, Technology 1 is not far off from
Technology 3 in terms of inherent safety and the very high ROI value of Technology 1
makes it the best candidate for selection, since there is also better scope for investing
more in safety features. Although Technology 2 has a higher ROI than Technology 3 and
Technology 4, it involves many hazardous chemicals and therefore, not safe and not
environmentally benign. Therefore we reject Technology 2. Based on these
considerations, we select Technology 1: Catalytic Dehydrogenation of
EthylBenzene.

Section-2
Process Specifications from Simulation of Selected Process
with Mass Balance

Selected Process consists of the following sub-processes

● Mobil-Badger process for EthylBenzene Production
● Catalytic Dehydrogenation of EthylBenzene for Styrene Production

Ethylbenzene (EB) Production (Key points)[44]:

A two-reactor process is used so that high conversion of the ethylene can be achieved in
the first reactor and conditions are favorable in the second reactor for the reaction of
Diethylbenzene (DEB) back to EB (higher concentration of DEB)

Reason behind recycling Benzene:

The activation energy of the undesirable reaction (Reaction 2) is higher than that of the
desirable reaction. Hence, lower reactor temperatures improve selectivity. In addition,
selectivity is improved by ensuring low concentrations of ethylene in the reactor. This can
be achieved by using a large excess of benzene, but the excess must be
recovered and recycled.

The 2nd reactor (TRANSALK) is able to convert essentially all the DEB formed in the first
reactor back to EB. Thus the DEB is recycled to extinction.

We add two distillation columns to increase the purity of EB.

 Purity of EB in input to COL-1: 50.11 wt%
Purity of EB in input to COL-2: 71.23 wt%
Purity of EB in output of COL-2: 99.99 wt%

Both the columns operate under vacuum (at 0.3 atm and 0.1 atm respectively), which
give lower reflux-drum temperatures (52oC, 68oC respectively) and permit the use of
cooling water in the condenser. Reboiler temperatures (103oC, 100oC respectively) permit
the use of low pressure steam (4 atm, 160oC) as the utility.

Styrene Production (Key points)[50]:

We achieve a high purity of Styrene by using the Catalytic Dehydrogenation method for
production.

The LLV Separator - STYCOL, must operate at a low temperature (5 - 10 ºC) and at a
relatively high pressure (10 bar) to ensure the highest yield of Styrene, as Styrene is lost
through the top stream of the column otherwise.

It is also necessary to carry out the distillation process in the distillation column at the
lowest possible pressure, as it is possible that Styrene could polymerise spontaneously at
high temperature and pressure, over 125 C and 6 bar. This should also be done to avoid
the polymerization of the vinyl aromatic chemicals created during the reaction step. The
distillation column is used to purify the styrene obtained to a high percentage.

Feed Specifications
Temperature: 30 C
Pressure: 20.265 bar
Molar Flow rate of Benzene: 295.755 kmol/hr
Molar Flow rate of Ethylene: 295.755 kmol/hr
Total Molar Flow rate: 591.51 kmol/hr
Recycle Streams

Styrene produced (700 TPD)

 Block Analysis

Reactor - ALK

Conversion of Ethylene = 99.4%

Involved Reactions [44]

Reactor - TRANSALK

All the DEB formed in the first reactor (46.3546 kmol/hr) is converted back to EB.

Involved Reactions
Same as the Reactor - ALK reactions.

Reactor - EB2STY
Involved Reactions

Distillation Column - COL1

Profile of Liquid and Vapor flow in kmol/hr vs Number of stages

Condenser Performance Reboiler Performance

Name Value Units Name Value Units
 Temperature 51.64922 C Temperature 103.0095 C
Heat duty -2363561 cal/sec Heat duty 1335975 cal/sec
Distillate rate 555.7425 kmol/hr Bottoms rate 402.388 kmol/hr
Reflux rate 430.1447 kmol/hr Boilup rate 507.9051 kmol/hr
Reflux ratio 0.774 mole basis Boilup ratio 1.262227 mole basis
Distillate to Bottoms to
feed ratio 0.580028 feed ratio 0.419972

Distillation Column 2 - COL2

Condenser Performance Reboiler Performance

Name Value Units Name Value Units
Temperature 67.9059171 C Temperature 100.023718 C
Heat duty -1304968.91 cal/sec Heat duty 1157479 cal/sec
Distillate rate 295.755181 kmol/hr Bottoms rate 106.63282 kmol/hr
Reflux rate 195.494175 kmol/hr Boilup rate 379.835067 kmol/hr
Reflux ratio 0.661 mole basis Boilup ratio 3.56208403 mole basis
Distillate to Bottoms to
feed ratio 0.735 feed ratio 0.265

Profile of Liquid and Vapor flow in kmol/hr vs Number of stages

Distillation Column 3 - STYCOL

Condenser Performance Reboiler Performance

Name Value Units Name Value Units
Temperatu Temperature 198.627359 C
re 94.89 C Heat duty 896052.965 cal/sec
Heat duty -164771.998 cal/sec Bottoms rate 280.848344 kmol/hr
Distillate Boilup rate 400.185903 kmol/hr
rate 25.4536998 kmol/hr
Boilup ratio 1.42491815 mole basis
Reflux rate 51.9297308 kmol/hr
Bottoms to
Reflux feed ratio 0.9169
ratio 2.04016434 mole basis
Distillate
to feed
ratio 0.0831
Profile of Liquid and Vapor flow in kmol/hr vs Number of stages

Purity of EthylBenzene is obtained as 99.999 wt% and Purity of Styrene is obtained as

99.745 wt%
 Effluent Stream analysis

Stream- WASTEWAT

Component ppm in wastewater Admissible ppm (vapor)

Benzene 0.05 1

Ethylene 0.22 Not established (Less toxic)

[3]

Toluene 1.21E-04 200 [5]

Methane 0.06 1000 [6]

Styrene 6.26E-04 50 [4]

Waste to incineration (Stream- TO-INCIN):

The LIQDIST stream from the distillation column is heated to generate vapors and is sent
to incineration along with the streams named GASOUT, VAPDIST, where only CO2 and
H2O are expected to be released into the atmosphere. The wastewater stream, as shown
above, contains lower amounts of the chemicals than the admissible limits.

Luyben’s configuration [44] vs. Mobil-Badger Process [45] for the Production of EB:
● For the same purity of Ethylbenzene produced, Mobil-Badger process requires 3
distillation columns whereas Luyben’s configuration (where both the Alkylator and
Transalkylator are placed in series) requires only 2 and operating conditions
(Temperature and Pressure) are milder in the latter.
 ● Luyben’s configuration also requires the same amount of fresh feed (equimolar
mixture of Benzene and Ethylene) as that of the Mobil-Badger process and hence
doesn’t pose a challenge in this regard.

Figure: Flowsheet of Mobil-Badger process. Note the more severe operating conditions
(pressure and temperature) as compared to Luyben’s flowsheet [44].

Figure: Purity of Ethylbenzene from Mobil-Badger process [45]

 Section-3

Energy and Economic Analysis of Selected Process

Changes made in process flowsheet from Deliverable-2 to

Deliverable-3:
1) Except for one cooler block, all other heaters/coolers using utilities have been
replaced with Heat Exchangers, which achieve the same using process streams
instead of utilities. As evident from the above plots, the saving potential is reduced
from 31.56 % to 20.59 % and the actual total utilities reduced from 4.075E+07
(cal/sec) to 3.112E+07 (cal/sec).
2) COMP-1 compressor was removed and VLL flashing in FLASH3 block was done at 3
bara pressure instead of 10 bara.
3) Styrene formation reactor, an RSTOIC block, was replaced with a more rigorous
RPLUG reactor block with kinetics specified as given in [61].

Energy Analysis

Without heat integration

With Heat integration
 Figure: Utility results
Heat exchanger Area (sqm)

COOLER1 (Cooler using utility) 1851.33050449754

HEATEX1 10.4347890206766

HEATEX2 8.9631460239318

HEATEX3 28.6307680258152

HEATEX4 35.956866025449

HEATEX5 2.0270789801208

HEATEX6 4.0829519755206

HEATEX7 14.856512965587

HEATEX8 0.7795370074356

HEATEX9 0.9692510457294

HEATEX10 14.810817034746

Economic Analysis
Factors:
1. Electricity
2. Utilities - Water and Steam
3. Labour
4. Discount rate (for discounted cash flows - assumed to be 5%)
5. Offsite costs
6. Raw materials costs
7. Transportation cost
Electricity cost
We assume that the plant runs on High Tension lines, at a voltage of 11 kV. [53]
Cost = Rs 5.8/unit
Power Factor = 0.85 [54]
Cost (Rs/kWh) = 5.8*0.85 = 4.93 Rs/kWh
Required power after Heat integration = 516.768 kW
Amount of money required per year = 516.768*4.93 = 2547.66624 Rs/hour =
20381329.92 Rs/year

Cost of Water and Steam

Cost of water in Andhra Pradesh for Industrial purposes = Rs 5.5/1000 gallons [55]
1000 gallons = 3,785.41178 litres (US Gallons)
⇒ Cost of water per cubic metre = (5.5*1000)/3785.41178 = Rs 1.4529/m3

Total usage of water in the plant = 38,134.51 m3/hr. (Summing up the usage column in
figure 1)
Amount required for water per operating year
= 38,134.51*1.4529*8000(oper-hrs/yr) = Rs 44,32,59,158.5/year
Production of Steam requires Furnace oil as fuel. [52]
Cost of generating steam (per unit of energy content) is approximated

Cost of furnace oil = Rs. 38,190/ton [56]

From [52], 4.91 tons/day of Furnace Oil fuel usage generates 75.92 tons/day of Steam.
⇒ 1 ton/day of Furnace oil usage generates 15.4623 tons/day of Steam.

Required amount of steam from Heat integration = 11.9258*(24/2.204) tons/day

= 129.8635 tons/day.
Cost of steam = 1.3 * Cost of required Furnace oil = 1.3*38190 Rs/ton = Rs
49647/ton.[59]
⇒ Cost of steam required for generating 15.4623 tons/day = Rs 49467/day
⇒ Cost of steam required for generating the required 129.8635 tons/day
= Rs 4,16,970.6405/day = Rs 13,89,90,213.5/year.

Total Utilities cost = Electricity cost + Cost of water and steam

= Rs 602630701.9/year
Total Capital cost = Rs 1552852500 (USD converted to INR)
CEPCI value used in ASPEN Plus V11 = CEPCI (2016) = 541.7 [60]
CEPCI(2020) = 596.2 [60]
Total Installed Equipment cost(Onsite) = (12087500 USD)*(75 INR/USD)
*(596.2/541.7)= Rs 99,77,71,021.8
Total Investment = 2.36 * Onsite cost = Rs 235,47,39,611 [57]
(Assumption: Plant Expansion only, as also mentioned in [57])

Fixed Capital = Total Investment/1.3 = Rs 181,13,38,163 [57]

We take the cost of Styrene, Benzene and Ethylene raw materials to be slightly lesser
than the retail price quoted in Deliverable 1, taking the prices to be Rs 60/kg, Rs 40/kg,
Rs 65/kg.

Annual Revenue = Amount of styrene produced per year * Cost of Styrene

= 255500000 kg/yr * 60 Rs/kg = Rs 1533,00,00,000/year
Raw Material costs
Input Output Net Price
Chemical (ton/yr) (ton/yr) (ton/yr) (Rs/kg) Cost (Rs/yr)
Benzene 202517 0 202517 40 8100680000
Ethylene 72731.9 0 72731.9 65 4727573500
Styrene 0 255500 255500 60 15330000000

Total raw material cost = Amount of Benzene consumed per year * Cost of Benzene +
Amount of Ethylene consumed per year * Cost of Ethylene
= 202517 kg/yr *40 Rs/kg + 72731.9 kg/yr *65 Rs/kg = Rs 12828253500/year
Labour:
Assumptions: 3 shifts of operators, each shift has 50 operators involved. Wages are
assumed to be Rs.260/hr/operator [58], and therefore:

Total Labour cost = Rs 50*8(hours per shift)*3(shifts per day)*260*365(days per

year, assuming paid leave) = Rs 11,38,80,000/year

Transportation costs = Rs 22,41,00,000/year (From Deliverable 1)

Total Production costs = 0.025*(Revenue) + 1.03*(Raw Material Costs + Utility

Costs + Transportation Cost) + 0.103*(Fixed Capital) + 2.13*(Labour costs)
[57]
= Rs 1487,70,15,959/year

Net Income = Annual Revenue - Total Production costs

= Rs 45,29,84,041.3/year

Since discount rate = 5%, i = 0.05 and:

C = Net Income = Rs 45,29,84,041.3/year

For PV = Rs 235,47,39,611; we can calculate the value of n as:

n= 6.16 years = Payback period

Process Flow Diagram

The Process Flow Diagram was constructed as per the simulation flowsheet in ASPEN. The
following page contains the PFD for the entire process, starting from the input feed
stream ALKFD and ending at the output product stream STYPDT.
 PRODUCTION OF STYRENE: PROCESS FLOW DIAGRAM

RECYHP PUMP1

HEATEX2

COLD-UTL DIST1
CONDENSER1
REFLUX DRUM 1
HX2HOTIN

RECYHTD

COL1F
ALKFD ALKPDT
COND1PUMP
HEATEX1 ALKFDHTD REFLUX

TRANSALK COL1
ALK DEBRHTD FLH1VAP
HEATEX3 COLD-UTL
COLD-UTL CONDENSER2
RB1FEED
COLD-UTL EBPUMP
REFLUX DRUM

HEATEX5 REBOILER1 FLH1FEED FLASH1 EBPDT

FLH1LIQ
REB1PUMP
COL1BTMS
COND2PUMP
REFLUX
COL2

FLH2VAP
HX6HOTIN RB2FEED
HX4HOTIN HEATEX4

REBOILER2
HX5HOTIN FLH2FEED FLASH2
FLH2LIQ

REB2PUMP

PUMP2
DEB-R-HP

COL2BTMS

HEATEX6

EBOUT

HX8HOTIN

EBHTD

HX3HOTIN

HTR4IN
MIXER2
MIXER1 EB2STY
REACF
EB2STYF

SUPSTEAM

HOTUTL

MX2FD
REAC-O
EB2STREC

HEATEX7

SPLIT1
GASOUT
HX9HOTIN
HX8CLDOU MIXF
TO-INC
COOLER1
FLASH3IN HX8CLDIN
HEATEX8

HX4HOTOU
FLASH3
BTEHTD HX10HTIN

FLH4VAP
COLD-UTL COLD-UTL
WASTEWAT LLVOUT
HEATEX9
CONDENSER VAPDIST
REFLUX DRUM

STYCOLPUMP1

STYCOL LIQDIST FLASH4

REFLUX

FLH4LIQ
FLH4VAP
FLH4FEED
PSEUDOST
RBSTYCOLFEED
REBOILER3 FLASH4
HEATEX10

FLH4LIQ STYCOLPUMP2
STYPDT
 Section-4

Process Design and Sizing of all Equipment in the PFD

List of Equipment

REACTORS:
1. ALK - Alkylator Reactor
2. TRANSALK - Transalkylator Reactor
3. EB2STY - Styrene Production Reactor

ALK TRANSALK EB2STY

Weight of catalyst (tonne) 97.0163 130.4559 307.378

Diameter (m) 5.185 5.7872 4.00

Length (m) 10.37 11.5744 18.55

Volume (m3) 218.9626 304.4537 233

Wall thickness (mm) 27.369 30.232 8.373

Head cover thickness (mm) 26.563 29.613 7.862

Effective outside height of 456.92 509.66 217.646

head (mm)

Additional compensation No No Yes

required?

Type of heat exchange for Cooling jacket Cooling jacket Increase wall
utility thickness/external heat
exchanger

SEPARATORS:
1. COL1 - Distillation Column 1: Removal of Benzene from TRANSALK output
2. COL2 - Distillation Column 2: Extraction of EB from COL1 output
3. STYCOL - Styrene Distillation Column : Extraction of Styrene from EB2STY output
 4. FLASH1:
Flash Column Type Vertical Flash Drum

Diameter 2.2627 m

Height of Column 6.788 m

5. FLASH2:
Flash Column Type Vertical Flash Drum

Diameter 3.3591 m

Height of Column 10.0774 m

6. FLASH3:
Flash Column Type Horizontal Flash Drum

Diameter 3.9224 m

Length of Column 19.612 m

7. FLASH4:
Flash Column Type Vertical Flash Drum

Diameter 0.7905 m

Height of Column 2.3714 m

HEAT EXCHANGERS:
1. HEATEX1 - Process stream Shell & Tube Heat Exchanger-1
2. HEATEX2 - Process stream Shell & Tube Heat Exchanger-2
3. HEATEX3 - Reboiler (Column-1)
4. HEATEX4 - Reboiler (Column-2)
5. HEATEX5 - Process stream Shell & Tube Heat Exchanger-5
6. HEATEX6 - Process stream Shell & Tube Heat Exchanger-6
7. HEATEX7 - Process stream Shell & Tube Heat Exchanger-7
8. HEATEX8 - Process stream Shell & Tube Heat Exchanger-8
9. HEATEX9 - Process stream Shell & Tube Heat Exchanger-9
10. HEATEX10 - Reboiler (Stycol Column)
 11. COOLER1 - Utility (cooling water) cooler
12. COL1COND - Condenser - Column 1
13. COL2COND - Condenser - Column 2
14. STYCOLCOND - Condenser - Stycol Column

PUMPS

Pump Pump Operating Impeller Impeller Efficiency Power Seal

Type RPM Specific type and
Speed size

PUMP1 Centrifug 6000 626.184 Centrifugal 54% 56.86 Mechanical

al , 250 mm kW

PUMP2 Centrifug 7000 405.876 Centrifugal 47% 19.06 Mechanical

al , 250 mm kW

EBPUMP Centrifug 3500 795.909 Centrifugal 50.5% 11.289 Mechanical

al , 200 mm kW

Note:
Process calculations leading to the sizing of the equipment provided in Appendix B.
Specification sheets for the same are given in the following pages. Mechanical Drawings
for the equipment is given Appendix C.
 Project Name 700 TPD Styrene Production
Company Name Project Number 18 Sheet 1 of 1
Address REV DATE BY APVD REV DATE BY APVD

FIXED BED REACTOR

Form XXXXX-YY-ZZ

Owner's Name
Plant Location Visakhapatnam Units English Metric
Case Description
Equipment label Equipment name ALK
Plant section
Process service
Design code BIS Maximum diameter 5.239 m Total height 10.37 m
PROCESS DATA

Bed Number 1 2
Vapor flow direction left to right left to right
Liquid flow direction left to right left to right
Operating temperature ºC 160.85 160.85
Pressure bara 20.265 20.265
Vap flow kg/h 24054.9 -
Vap density kg/m3 31.0638 -
Top of section
Vap dynamic viscosity cs 0.435 -
Liq flow kg/h 7244.67 46611.7
Liq density kg/m3 696.064 718.956
Liq kinetic viscosity cs 0.19227 0.227
Operating temperature ºC 160.85 160.85
Pressure bara 20.265 20.265
Vap flow kg/h - -
Vap density kg/m3 - -
Bottom of section
Vap dynamic viscosity N.s/m2 - -
Liq flow kg/h - 78011.2
Liq density kg/m3 - 722.816
Liq dynamic viscosity cs - 0.241523
Catalyst type ZSM-5 ZSM-5
Catalyst shape Cylindrical Cylindrical
Catalyst particle diameter nm 3 3
Catalyst bed diameter m 5.185 5.185
Catalyst bed depth m 4.435 4.435
Catalyst bed bulk volume m3 93.6451 93.6451
Catalyst bed bulk density kg/m3 740 740
Catalyst bed void fraction 0.3 0.3
LHSV /h 0.048189508 0.492901527
GHSV /h 3.53654003 -
WHSV /h 0.647292255 0.96088767

CONSTRUCTION & MATERIALS

Shell material X04Cr17Ni12Mo2 grade stainless steel

Shell outer diameter m 5.239
Shell thickness mm 27.369
Design temperature ºC 800
Design pressure bara 32
Pipe branch nominal diameter mm 150
Support grid type Ring support with major beams
Distributor type Splash plate VEP distributor
Distributor material Stainless Steel and Mild Steel
Demister type Mesh
Demister material X04Cr17Ni12Mo2 grade stainless steel
Notes
 Project Name 700 TPD Styrene Production
Company Name Project Number 18 Sheet 1 of 1
Address REV DATE BY APVD REV DATE BY APVD

FIXED BED REACTOR

Form XXXXX-YY-ZZ

Owner's Name
Plant Location Visakhapatnam Units English Metric
Case Description
Equipment label Equipment name TRANSALK
Plant section
Process service
Design code BIS Maximum diameter 5.847 m Total height 11.5744 m
PROCESS DATA

Bed Number 1 2 3
Liquid1 flow direction left to right left to right left to right
Liquid2 flow direction left to right left to right left to right
Operating temperature ºC 158.85 158.85 158.85
Pressure bara 19.2518 19.2518 19.2518
Liq1 flow kg/h 26003.73333 26003.73333 26003.73333
Liq1 density kg/m3 722.816 722.816 722.816
Feed section
Liq1 dynamic viscosity cs 0.2415 0.2415 0.2415
Liq2 flow kg/h 4577.8 4577.8 4577.8
Liq2 density kg/m3 756.06 756.06 756.06
Liq2 kinetic viscosity cs 0.2989 0.2989 0.2989
Operating temperature ºC - - 158.85
Pressure bara - - 19.2518
Liq1 flow kg/h - - -
Liq1 density kg/m3 - - -
Outlet section
Liq1 dynamic viscosity N.s/m2 - - -
Liq2 flow kg/h - - 91744.6
Liq2 density kg/m3 - - 728.363
Liq2 dynamic viscosity cs - - 0.2529
Catalyst type ZSM-5 ZSM-5 ZSM-5
Catalyst shape Cylindrical Cylindrical Cylindrical
Catalyst particle diameter nm 3 3 3
Catalyst bed diameter m 5.7872 5.7872 5.7872
Catalyst bed depth m 3.191466667 3.191466667 3.191466667
Catalyst bed bulk volume m3 83.94846667 83.94846667 83.94846667
Catalyst bed bulk density kg/m3 740 740 740
Catalyst bed void fraction 0.3 0.3 0.3
LHSV /h 0.354493967 0.059662274 0.413724648
GHSV /h - - -
WHSV /h 0.657875357 0.657875357 2.631501428

CONSTRUCTION & MATERIALS

Shell material X04Cr17Ni12Mo2 grade stainless steel

Shell outer diameter m 5.847
Shell thickness mm 30.232
Design temperature ºC 800
Design pressure bara 32
Pipe branch nominal diameter mm 150
Support grid type Ring support with major beams
Distributor type Splash plate VEP distributor
Distributor material Stainless Steel and Mild Steel
Demister type Mesh
Demister material X04Cr17Ni12Mo2 grade stainless steel
Notes
 Project Name 700 TPD Styrene Production
Company Name Project Number 18 Sheet 1 of 1
Address REV DATE BY APVD REV DATE BY APVD

FIXED BED REACTOR

Form XXXXX-YY-ZZ

Owner's Name
Plant Location Visakhapatnam Units English Metric
Case Description
Equipment label EB2STY Equipment name Fixed bed reactor
Plant section
Process service
Design code BIS Inner diameter 4.016 m Total height 18.55 m
PROCESS DATA

Bed Number 1
Vapour1 flow direction left to right
Vapour2 flow direction left to right
Operating temperature ºC 610
Pressure bara 3
Vap1 flow kg/h 10987
Vap1 density kg/m3 1.08521
Feed section
Vap1 dynamic viscosity cs 25.7016
Vap2 flow kg/h -
Vap2 density kg/m3 -
Vap2 kinetic viscosity cs -
Operating temperature ºC 610
Pressure bara 1
Vap1 flow kg/h -
Vap1 density kg/m3 -
Outlet section
Vap1 dynamic viscosity N.s/m2 -
Vap2 flow kg/h 10987
Vap2 density kg/m3 0.3025
Vap2 dynamic viscosity cs 104.734
Catalyst type Shell 105
Catalyst shape Cylindrical
Catalyst particle diameter mm 4.7
Catalyst bed diameter m 4
Catalyst bed depth m 17.55
Catalyst bed bulk volume m3 220.4336
Catalyst bed bulk density kg/m3 2145.27
Catalyst bed void fraction 0.35
LHSV /h -
GHSV /h 434.6309013
WHSV /h 0.357530467

CONSTRUCTION & MATERIALS

Shell material X04Cr19Ni9 grade stainless steel

Shell outer diameter m 4.032746
Shell thickness mm 8.373
Design temperature ºC 1000
Design pressure bara 7
Pipe branch nominal diameter mm 150
Support grid type Ring support with major beams
Distributor type -
Distributor material Stainless Steel and Mild Steel
Demister type Mesh
Demister material X04Cr19Ni9 grade stainless steel
Notes This reaction is dehydrogenation. Therefore, there is only one vapour in feed
SPECIFICATION SHEET
Project Name CH4250 Process Engineering Capstone Design
Project Number: 1
Group Number: 18
Designed by: J Mahesh, CH17B049
VAPOUR LIQUID CONTACTING COLUMN
Plant Location: Visakhapatnam Units: Metric
Case Description: Production of Styrene from Ethyl Benzene
Equipment label: COL1 Equipment name: Distillation Column 1
Plant section: 1
Design code: IS 2825 Maximum diameter: 3.7345 m Total height: 26.4 m
PROCESS DATA

Column Section 1 2
Tray Numbers 1-16 17-32
Total vapor flow kg/h 83656 55032.4
Total liquid flow kg/h 37916.8 100516
Top of section Operating temperature °C 51.73 90.20
Pressure bara 0.304 0.304
Vap density kg/m3 0.9157 1.0528
Vap dynamic viscosity N.s/m2 8.36e-06 8.09e-06
Liq density kg/m3 840.196 800.22
Liq dynamic viscosity N.s/m2 0.00443 0.000326
Liq surface tension dyn/cm 24.5202 21.6953
Bottom of section Operating temperature °C 90.20 103.09
Pressure bara 0.304 0.304
Vap density kg/m3 1.0319 1.06608
Vap dynamic viscosity N.s/m2 8.16e-06 8.09e-06
Liq density kg/m3 805.037 795.87
Liq dynamic viscosity N.s/m2 0.000340 0.000319
Liq surface tension dyn/cm 22.2541 21.3772
Section pressure drop bar 0.25634 0.25634

CONSTRUCTION & MATERIALS

Column Section 1&2

Tray Numbers 1-32
Shell material Carbon Steel R275 (IS 2041 – 2009)
Shell diameter m 3.616
Shell tangent length m 22.4
Shell thickness mm 18.5
Design temperature °C 104
Design pressure bara 0.304
Test pressure bara 0.304
Segregation height overhead m 1
sump m 1
Tray type SIEVE PLATE
Tray material Carbon Steel R275 (IS 2041 – 2009)
No. trays 32
No. liquid passes per tray 1
No. holes/tray total 39344
active 39344
Hole size mm 5
Hole pitch mm 15
Hole area/ active area % 10
Tray thickness mm 5
Tray spacing m 0.6
Weir length m 2.734
Weir height mm 50
Downcomer clearance mm 173.098
Pressure drop per plate bar 0.016
Notes
SPECIFICATION SHEET
Project Name CH4250 Process Engineering Capstone Design
Project Number: 1
Group Number: 18
Designed by: J Mahesh, CH17B049
VAPOUR LIQUID CONTACTING COLUMN
Plant Location: Visakhapatnam Units: Metric
Case Description: Production of Styrene from Ethyl Benzene
Equipment label: COL2 Equipment name: Distillation Column 2
Plant section: 1
Design code: IS 2825 Maximum diameter: 3.877 m Total height: 29.8 m
PROCESS DATA

Column Section 1 2
Tray Numbers 1-19 20-38
Total vapor flow kg/h 52154.7 48250.6
Total liquid flow kg/h 20755 62335
Top of section Operating temperature °C 67.90 72.97
Pressure bara 0.101 0.101
Vap density kg/m3 0.382 0.382
Vap dynamic viscosity N.s/m2 7.38e-06 7.46e-06
Liq density kg/m3 825.816 823.036
Liq dynamic viscosity N.s/m2 0.0004014 0.0004188
Liq surface tension dyn/cm 24.333 24.455
Bottom of section Operating temperature °C 71.19 100.74
Pressure bara 0.101 0.101
Vap density kg/m3 0.000414 0.416
Vap dynamic viscosity N.s/m2 7.46e-06 7.57e-06
Liq density kg/m3 823.864 811.922
Liq dynamic viscosity N.s/m2 0.3818 0.0003929
Liq surface tension dyn/cm 24.440 23.112
Section pressure drop bar 0.215324 0.215324

CONSTRUCTION & MATERIALS

Column Section 1&2

Tray Numbers 1-38
Shell material Carbon Steel R275 (IS 2041 – 2009)
Shell diameter m 3.763
Shell tangent length m 24.8
Shell thickness mm 13.2
Design temperature °C 110
Design pressure bara 0.101
Test pressure bara 0.101
Segregation height overhead m 1
sump m 1
Tray type SIEVE PLATE
Tray material Carbon Steel R275 (IS 2041 – 2009)
No. trays 32
No. liquid passes per tray 1
No. holes/tray total 42758
active 42758
Hole size mm 5
Hole pitch mm 15
Hole area/ active area % 10
Tray thickness mm 5
Tray spacing m 0.6
Weir length m 2.8503
Weir height mm 50
Downcomer clearance mm 199.257
Pressure drop per plate bar 0.0113
Notes
SPECIFICATION SHEET
Project Name CH4250 Process Engineering Capstone Design
Project Number: 1
Group Number: 18
Designed by: J Mahesh, CH17B049
VAPOUR LIQUID CONTACTING COLUMN
Plant Location: Visakhapatnam Units: Metric
Case Description: Production of Styrene from Ethyl Benzene
Equipment label: STYCOL Equipment name: Styrene Distillation Column
Plant section: 1
Design code: IS 2825 Maximum diameter: 1.1475 m Total height: 52.8 m
PROCESS DATA

Column Section 1 2
Tray Numbers 1-25 25-49
Total vapor flow kg/h 8809.62 31296.4
Total liquid flow kg/h 7083.19 60492.5
Top of section Operating temperature °C 134.64 143.11
Pressure bara 1.013 1.037
Vap density kg/m3 2.464 3.173
Vap dynamic viscosity N.s/m2 9.94e-06 9.07e-06
Liq density kg/m3 863.867 789.317
Liq dynamic viscosity N.s/m2 0.0003492 0.0002294
Liq surface tension dyn/cm 24.764 18.635
Bottom of section Operating temperature °C 142.99 147.73
Pressure bara 1.036 1.063
Vap density kg/m3 2.953 3.278
Vap dynamic viscosity N.s/m2 9.34e-06 9.05e-06
Liq density kg/m3 789.437 784.094
Liq dynamic viscosity N.s/m2 0.0002295 0.0002234
Liq surface tension dyn/cm 18.647 17.993
Section pressure drop bar 0.692 0.692

CONSTRUCTION & MATERIALS

Column Section 1&2

Tray Numbers 1-49
Shell material Carbon Steel R275 (IS 2041 – 2009)
Shell diameter m 1.0475
Shell tangent length m 47.8
Shell thickness mm 16.72
Design temperature °C 162.5
Design pressure bara 1.170
Test pressure bara 1.637
Segregation height overhead m 1
sump m 1
Tray type SIEVE PLATE
Tray material Carbon Steel R275 (IS 2041 – 2009)
No. trays 49
No. liquid passes per tray 1
No. holes/tray total 1251
active 1251
Hole size mm 5
Hole pitch mm 23.72
Hole area/ active area % 4
Tray thickness mm 5
Tray spacing m 0.9
Weir length m 0.771
Weir height mm 50
Downcomer clearance mm 414.78
Pressure drop per plate bar 0.0282
Notes
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX1

6 SURFACE PER UNIT (m2) 47.68 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 109899 31399.5
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 1 0.361
11 Liquid 0 0.639
12 DENSITY @ AVE. COND (kg/cum) 0.33 118
13 VISCOSITY @ AVE. COND (Pa-s) 2.80E-05 3.11E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.046 0.076
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.55 0.41
o
16 TEMPERATURE IN ( C) 544.21 30
17 TEMPERATURE OUT (o C) 490.96 160.85
18 OPERATING PRESSURE (bar) 1.013 20.25
19 NUMBER OF PASSES 1 2
20 PRESSURE DROP (psi) Calc. 5.06 Calc. 0.373
21 HEAT EXCHANGED (kW) 3735.69
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 22.275 (Max(Shell side and tube side); a conservative figure)
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 392 O.D. (in) 0.75 BWG 16 Length (in) 80 Pitch (in) 1
26 SHELL Cr-Mo Steel I.D. (in) 54 N.D. (mm) 1500 NOZZLE I.D. (in) 10
27 SHELL COVER 63.04 mm thickness CHANNEL COVER 62.19 mm thickness
28 TUBESHEET THICKNESS (cm) 11.03 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 54 Thickness (mm) 15.9 Hole Dia. (mm) 19.25
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1410
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 18
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX2

6 SURFACE PER UNIT (m2) 39.7 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 109899 46661.7
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 1 0
11 Liquid 0 1
12 DENSITY @ AVE. COND (kg/cum) 0.33 800
13 VISCOSITY @ AVE. COND (Pa-s) 2.60E-05 4.40E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.04 0.06
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.543 0.45
o
16 TEMPERATURE IN ( C) 490.96 51.94
17 TEMPERATURE OUT (o C) 450.71 160.85
18 OPERATING PRESSURE (bar) 0.9 20.25
19 NUMBER OF PASSES 1 6
20 PRESSURE DROP (psi) Calc. 6.05 Calc. 0.06
21 HEAT EXCHANGED (kW) 2768.85
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 22.275
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 261 O.D. (in) 1.25 BWG 16 Length (in) 60 Pitch (in) 1.5625
26 SHELL Cr-Mo Steel I.D. (in) 54 N.D. (mm) 1500 NOZZLE I.D. (in) 10
27 SHELL COVER 63.04 mm thickness CHANNEL COVER 62.19 mm thickness
28 TUBESHEET THICKNESS (cm) 11.69 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 54 Thickness (mm) 15.9 Hole Dia. (mm) 19.25
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1410
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 18
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX3

6 SURFACE PER UNIT (m2) 612.75 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 99153.2 109899
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 1
11 Liquid 1 0
12 DENSITY @ AVE. COND (kg/cum) 1.06 0.36
13 VISCOSITY @ AVE. COND (Pa-s) 8.07E-06 2.27E-05
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.0097 0.034
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.366 0.515
o
16 TEMPERATURE IN ( C) 100.02 371.76
17 TEMPERATURE OUT (o C) 102.22 286.65
18 OPERATING PRESSURE (bar) 0.303 0.87
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.06 Calc. 2.06
21 HEAT EXCHANGED (kW) 5491.99
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 0.957
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 889 O.D. (in) 2 BWG 8 Length (in) 170 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 100 N.D. (mm) 2600 NOZZLE I.D. (in) 10
27 SHELL COVER 10.89 mm thickness CHANNEL COVER 21.95 mm thickness
28 TUBESHEET THICKNESS (cm) 4.49 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 100 Thickness (mm) 19.1 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 2300
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX4

6 SURFACE PER UNIT (m2) 417.03 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 59684.2 109899
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 1
11 Liquid 1 0
12 DENSITY @ AVE. COND (kg/cum) 0.52 0.41
13 VISCOSITY @ AVE. COND (Pa-s) 7.60E-06 1.96E-05
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.0648 0.028
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.479 0.494
o
16 TEMPERATURE IN ( C) 82.3 286.65
17 TEMPERATURE OUT (o C) 93.44 208.68
18 OPERATING PRESSURE (bar) 0.1 0.87
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.096 Calc. 1.07
21 HEAT EXCHANGED (kW) 4816.81
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 0.957
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 857 O.D. (in) 2 BWG 8 Length (in) 120 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 80 N.D. (mm) 2100 NOZZLE I.D. (in) 10
27 SHELL COVER 34 mm thickness CHANNEL COVER 34 mm thickness
28 TUBESHEET THICKNESS (cm) 3.58 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 80 Thickness (mm) 19.1 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1950
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX5

6 SURFACE PER UNIT (m2) 7.597 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 109899 13733.4
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 1 0
11 Liquid 0 1
12 DENSITY @ AVE. COND (kg/cum) 0.33 815
13 VISCOSITY @ AVE. COND (Pa-s) 2.50E-05 4.05E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0..038 0.064
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.53 0.5
o
16 TEMPERATURE IN ( C) 433.39 94.87
17 TEMPERATURE OUT (o C) 425.7 158.85
18 OPERATING PRESSURE (bar) 0.87 19.25
19 NUMBER OF PASSES 1 8
20 PRESSURE DROP (psi) Calc. 6.655 Calc. 0.0095
21 HEAT EXCHANGED (kW) 520.191
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 21.175
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 500 O.D. (in) 0.75 BWG 16 Length (in) 10 Pitch (in) 1
26 SHELL Cr-Mo Steel I.D. (in) 42.4 N.D. (mm) 1200 NOZZLE I.D. (in) 10
27 SHELL COVER 62 mm thickness CHANNEL COVER 62 mm thickness
28 TUBESHEET THICKNESS (cm) 8.45 FLOATING NO
29 BAFFLES Type NONE Spacing (in) N.A. Thickness (mm) N.A. Hole Dia. (mm) 19.25 (TUBESHEET)
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1090
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX6

6 SURFACE PER UNIT (m2) 10.21 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 109899 31399.6
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 1 0
11 Liquid 0 1
12 DENSITY @ AVE. COND (kg/cum) 0.33 800
13 VISCOSITY @ AVE. COND (Pa-s) 2.50E-05 3.00E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.038 0.06
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.543 0.45
o
16 TEMPERATURE IN ( C) 450.71 68.22
17 TEMPERATURE OUT (o C) 433.39 136
18 OPERATING PRESSURE (bar) 0.87 5.5
19 NUMBER OF PASSES 1 6
20 PRESSURE DROP (psi) Calc. 7.46 Calc. 0.26
21 HEAT EXCHANGED (kW) 1177.91
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 6.05
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 224 O.D. (in) 0.75 BWG 16 Length (in) 30 Pitch (in) 1
26 SHELL Cr-Mo Steel I.D. (in) 49 N.D. (mm) 1300 NOZZLE I.D. (in) 10
27 SHELL COVER 28 mm thickness CHANNEL COVER 28 mm thickness
28 TUBESHEET THICKNESS (cm) 5.22 FLOATING NO
29 BAFFLES Type NONE Spacing (in) N.A Thickness (mm) N.A Hole Dia. (mm) 19.25 (TUBESHEET)
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1240
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX7

6 SURFACE PER UNIT (m2) 48.65 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 109899 31399.6
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 1 0
11 Liquid 0 1
12 DENSITY @ AVE. COND (kg/cum) 0.33 760
13 VISCOSITY @ AVE. COND (Pa-s) 2.50E-05 2.00E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.04 0.06
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.543 0.45
o
16 TEMPERATURE IN ( C) 610 136
17 TEMPERATURE OUT (o C) 544.21 250
18 OPERATING PRESSURE (bar) 0.87 5.5
19 NUMBER OF PASSES 1 8
20 PRESSURE DROP (psi) Calc. 1.29 Calc. 0.07
21 HEAT EXCHANGED (kW) 4726.59
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 6.05
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 640 O.D. (in) 0.75 BWG 16 Length (in) 50 Pitch (in) 1
26 SHELL Cr-Mo Steel I.D. (in) 49 N.D. (mm) 1300 NOZZLE I.D. (in) 10
27 SHELL COVER 28 mm thickness CHANNEL COVER 28 mm thickness
28 TUBESHEET THICKNESS (cm) 5.22 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 49 Thickness (mm) 15.9 Hole Dia. (mm) 19.25
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1240
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm)13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX8

6 SURFACE PER UNIT (m2) 460.48 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 643.33 109899
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 1
11 Liquid 1 0
12 DENSITY @ AVE. COND (kg/cum) 0.276 0.33
13 VISCOSITY @ AVE. COND (Pa-s) 8.72E-06 2.40E-05
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.1 0.038
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 3.17 0.53
o
16 TEMPERATURE IN ( C) 10 425.7
17 TEMPERATURE OUT (o C) 110 422.2
18 OPERATING PRESSURE (bar) 3 0.87
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.006 Calc. 1.66
21 HEAT EXCHANGED (kW) 4726.59
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 3.3
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 947 O.D. (in) 2 BWG 8 Length (in) 120 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 77 N.D. (mm) 2000 NOZZLE I.D. (in) 10
27 SHELL COVER 22 mm thickness CHANNEL COVER 22 mm thickness
28 TUBESHEET THICKNESS (cm) 6.42 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 15.4 Thickness (mm) 15.9 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1770
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX9

6 SURFACE PER UNIT (m2) 18.76 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 1607.88 109899
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 1
11 Liquid 1 0
12 DENSITY @ AVE. COND (kg/cum) 400 0.33
13 VISCOSITY @ AVE. COND (Pa-s) 3.49E-04 2.50E-05
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.073 0.038
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.474 0.528
o
16 TEMPERATURE IN ( C) 85 422.149
17 TEMPERATURE OUT (o C) 160 418.403
18 OPERATING PRESSURE (bar) 1.013 0.87
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 6.53E-05 Calc. 0.29
21 HEAT EXCHANGED (kW) 252.392
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 1.114
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 926 O.D. (in) 2 BWG 8 Length (in) 5 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 65 N.D. (mm) 1700 NOZZLE I.D. (in) 10
27 SHELL COVER 24.5 mm thickness CHANNEL COVER 24.5 mm thickness
28 TUBESHEET THICKNESS (cm) 3.29 FLOATING NO
29 BAFFLES Type NONE Spacing (in) N.A Thickness (mm) N.A Hole Dia. (mm) 51.3 (TUBESHEET)
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1590
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: HEATEX10

6 SURFACE PER UNIT (m2) 138.66 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 60503.9 109899
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 1
11 Liquid 1 0
12 DENSITY @ AVE. COND (kg/cum) 390 0.33
13 VISCOSITY @ AVE. COND (Pa-s) 2.23E-04 2.46E-05
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.063 0.038
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.503 0.528
o
16 TEMPERATURE IN ( C) 147.7 418.4
17 TEMPERATURE OUT (o C) 147.7 371.76
18 OPERATING PRESSURE (bar) 1.06 0.87
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.218 Calc. 0.641
21 HEAT EXCHANGED (kW) 3106.4
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 1.167
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 855 O.D. (in) 2 BWG 8 Length (in) 40 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 69 N.D. (mm) 1800 NOZZLE I.D. (in) 10
27 SHELL COVER 23.5 mm thickness CHANNEL COVER 23.5 mm thickness
28 TUBESHEET THICKNESS (cm) 3.57 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 6.9 Thickness (mm) 9.5 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1590
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: COOLER1

6 SURFACE PER UNIT (m2) 2033.95 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 18316.5 4939491.8
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 1 0
11 Liquid 0 1
12 DENSITY @ AVE. COND (kg/cum) 0.7 1000
13 VISCOSITY @ AVE. COND (Pa-s) 1.00E-05 8.90E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.02 0.36
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.4 1
o
16 TEMPERATURE IN ( C) 208.68 2
17 TEMPERATURE OUT (o C) 10 4
18 OPERATING PRESSURE (bar) 0.87 5
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.182 Calc. 54.62
21 HEAT EXCHANGED (kW) 11534.92
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 5.5
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 2433 O.D. (in) 0.75 BWG 16 Length (in) 550 Pitch (in) 1
26 SHELL Cr-Mo Steel I.D. (in) 58 N.D. (mm) 1500 NOZZLE I.D. (in) 10
27 SHELL COVER 13.5 mm thickness CHANNEL COVER 13.5 mm thickness
28 TUBESHEET THICKNESS (cm) 5.89 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 58 Thickness (mm) 15.9 Hole Dia. (mm) 19.25
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1410
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33 NUMBER OF UNITS = 6 (IN PARALLEL)
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: COL1COND

6 SURFACE PER UNIT (m2) 902.904 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 82689 4192380
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 0
11 Liquid 1 1
12 DENSITY @ AVE. COND (kg/cum) 841.65 1000
13 VISCOSITY @ AVE. COND (Pa-s) 4.45E-04 8.90E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.075 0.363
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.408 1
o
16 TEMPERATURE IN ( C) 50.758 2
17 TEMPERATURE OUT (o C) 50.758 4
18 OPERATING PRESSURE (bar) 1.013 5
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.0042 Calc. 6.96
21 HEAT EXCHANGED (kW) 9790.23
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 5.5
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 445 O.D. (in) 2 BWG 8 Length (in) 500 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 49 N.D. (mm) 1300 NOZZLE I.D. (in) 10
27 SHELL COVER 22.5 mm thickness CHANNEL COVER 22.5 mm thickness
28 TUBESHEET THICKNESS (cm) 5.51 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 49 Thickness (mm) 15.9 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1240
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: COL2COND

6 SURFACE PER UNIT (m2) 390.25 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 52154.8 2339647
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 0
11 Liquid 1 1
12 DENSITY @ AVE. COND (kg/cum) 825.8 1000
13 VISCOSITY @ AVE. COND (Pa-s) 4.01E-04 8.90E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.068 0.363
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.44 1
o
16 TEMPERATURE IN ( C) 67.906 2
17 TEMPERATURE OUT (o C) 67.906 4
18 OPERATING PRESSURE (bar) 1.013 5
19 NUMBER OF PASSES 1 1
20 PRESSURE DROP (psi) Calc. 0.006 Calc. 10.1
21 HEAT EXCHANGED (kW) 5463.64
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 5.5
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 193 O.D. (in) 2 BWG 8 Length (in) 500 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 39 N.D. (mm) 1100 NOZZLE I.D. (in) 8
27 SHELL COVER 55 mm thickness CHANNEL COVER 55 mm thickness
28 TUBESHEET THICKNESS (cm) 4.39 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 39 Thickness (mm) 12.7 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1090
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
Plant Location: Vishakhapatnam Designed by: Shashank V, CH17B119
Case Description: Production of Styrene Project Name CH4250 Process Engineering Capstone Design
Group # 18 Sheet 1
SHELL AND TUBE EXCHANGER DATA SHEET EQUIPMENT: STYCOLCOND

6 SURFACE PER UNIT (m2) 64.01 SHELLS PER UNIT 1 SERIES 1 PARALLEL 1
7 PERFORMANCE OF ONE UNIT SHELL SIDE TUBE SIDE
8 FLUID CIRCULATED (kg/hr) 6652.04 408279.5
9 MOLE FRACTION OF FLUID ENTERING
10 Vapor 0 0
11 Liquid 1 1
12 DENSITY @ AVE. COND (kg/cum) 860 1000
13 VISCOSITY @ AVE. COND (Pa-s) 3.00E-04 8.90E-04
14 THERMAL CONDUCTIVITY (BTU/(hr-ft-F)) 0.073 0.363
15 SPECIFIC HEAT CAPACITY (BTU/(lb-F)) 0.474 1
o
16 TEMPERATURE IN ( C) 85 2
17 TEMPERATURE OUT (o C) 85 4
18 OPERATING PRESSURE (bar) 1.013 5
19 NUMBER OF PASSES 1 6
20 PRESSURE DROP (psi) Calc. 0.096 Calc. 1.07
21 HEAT EXCHANGED (kW) 953.432
22 CONSTRUCTION
23 DESIGN PRESSURE (bar) 5.5
o
24 DESIGN . TEMP. (MAX. METAL TEMP.) ( C) 650
25 TUBES Cr-Mo Steel No. 255 O.D. (in) 2 BWG 8 Length (in) 62 Pitch (in) 2.5
26 SHELL Cr-Mo Steel I.D. (in) 39 N.D. (mm) 1100 NOZZLE I.D. (in) 8
27 SHELL COVER 55 mm thickness CHANNEL COVER 55 mm thickness
28 TUBESHEET THICKNESS (cm) 4.39 FLOATING NO
29 BAFFLES Type 25% cut segmental Spacing (in) 7.8 Thickness (mm) 9.5 Hole Dia. (mm) 51.3
30 SHELL SUPPORTS Saddle Supports No. 2 Width (mm) 1090
31 GASKETS Flat Iron jacketed, Asbestos fill GASKET WIDTH (mm) 13
32 CORROSION ALLOW. Shell Side 6 mm Tube Side 6 mm
33
 DOCUMENT NO. PROJECT : CH4250 Process Engineering Capstone Design
Logo & Name of XXXXXXXXX LOCATION : Vishakhapatnam
Company PUMP XXXXXX For Enquiry 0

PUMP1 DATE ISSUE REV. PREP CHKD APPD

SERVICE / FUNCTION : Benzene Circulation Pump QTY : 1
SUPPLIER : M/S TYPE : CENTRIFUGAL
MODEL NO : *
PROCESS DATA DRIVE : MOTOR
Fluid Benzene Starting 3 Phase, Induction Motor
Composition (wt/wt &) 0.74 Voltage 415+/-10%
Density Max, kg/m3 900 Frequency 50HZ+/-3%
Density at Opr. Temp., kg/m3 841.508 Motor Rating, kW 60
Viscosity at Opr. Temp., cP 0.5 Motor Speed, RPM 6000
Corrosion / Erosion NIL Mounting Foot Mounted
Operating Temp., Nor/Max, °C 50/60 Amb. Temp. °C -
Solid Content , % NIL Protection Class IP-65
Normal Mass Flow Rate, kg/h 46611.7 Installation Out door
Normal Volumetric Flow Rate, m3/hr 55.4 Flame Proof Yes
Min. Volumetric Flow Rate, m3/hr 45 Starting DOL
Max. Volumetric Flow Rate, m3/hr 60 Motor Frame Size -
Available NPSH , mtrs 4.353 Area Classification -
Suction Pressure, kg/cm2g 0.31 Motor Make -
Diff. Pressure, kg/cm2g 20.3545
Diff. Discharge Head, mtrs 241.841
Vapour Pressure , mmHg 268
NPSH Required, mtrs 3

ENGINEERING DATA MATERIAL OF CONSTRUCTION

Design Temperature, °C 121.111 Casing CF8
Design Pressure, kg/cm2g 23.1467 Shaft SS316
Hydrotest Pressure, kg/cm2g - Impeller CF8
Installation Outdoor Coupling -
Suction / Discharge Size, mm 95 Sleeve CF8
Drive / Pump, RPM 6000 Base Frame IS 2062
Coupling Type - Accessories -
Pump Mounting HorIzontal Foundation Bolts MS
Flange Rating - Coupling Guard IS 2062
Design Efficiency, % 54 All Wetted Parts SS316
Sealing Type Single Mechnaical Seal Seal Face Combination -
Impeller Type Centrifugal Seal Flushing Plan -
Impeller Diameter, mm 250 Mechanical Seal Make -
Casing Type Single Volute
Suction / Discharge, m3/hr 55.4
Pump Design Standard IS

REMARKS :
 DOCUMENT NO. PROJECT : CH4250 Process Engineering Capstone Design
Logo & Name of XXXXXXXXX LOCATION : Vishakhapatnam
Company PUMP XXXXXX For Enquiry 0

PUMP2 DATE ISSUE REV. PREP CHKD APPD

SERVICE / FUNCTION : Diethyl Benzene Circulation Pump QTY : 1
SUPPLIER : M/S TYPE : CENTRIFUGAL
MODEL NO : *
PROCESS DATA DRIVE : MOTOR
Fluid Diethyl Benzene Starting 3 Phase, Induction Motor
Composition (wt/wt &) 0.84 Voltage 415+/-10%
Density Max, kg/m3 900 Frequency 50HZ+/-3%
Density at Opr. Temp., kg/m3 815.321 Motor Rating, kW 25
Viscosity at Opr. Temp., cP 0.5 Motor Speed, RPM 7000
Corrosion / Erosion NIL Mounting Foot Mounted
Operating Temp., Nor/Max, °C 93 / 120 Amb. Temp. °C -
Solid Content , % NIL Protection Class IP-65
Normal Mass Flow Rate, kg/h 13733.4 Installation Out door
Normal Volumetric Flow Rate, m3/hr 16.8 Flame Proof Yes
Min. Volumetric Flow Rate, m3/hr 10 Starting DOL
Max. Volumetric Flow Rate, m3/hr 25 Motor Frame Size -
Available NPSH , mtrs 5.3 Area Classification -
Suction Pressure, kg/cm2g 0.10 Motor Make -
Diff. Pressure, kg/cm2g 19.528
Diff. Discharge Head, mtrs 239.67
Vapour Pressure , mmHg 58
NPSH Required, mtrs 3

ENGINEERING DATA MATERIAL OF CONSTRUCTION

Design Temperature, °C 122.645 Casing CF8
Design Pressure, kg/cm2g 22.113 Shaft SS316
Hydrotest Pressure, kg/cm2g - Impeller CF8
Installation Outdoor Coupling -
Suction / Discharge Size, mm 55 Sleeve CF8
Drive / Pump, RPM 7000 Base Frame IS 2062
Coupling Type - Accessories -
Pump Mounting Horizontal Foundation Bolts MS
Flange Rating - Coupling Guard IS 2062
Design Efficiency, % 47 All Wetted Parts SS316
Sealing Type Single Mechnaical Seal Seal Face Combination -
Impeller Type Centrifugal Seal Flushing Plan -
Impeller Diameter, mm 250 Mechanical Seal Make -
Casing Type Single Volute
Suction / Discharge, m3/hr 16.8441
Pump Design Standard IS

REMARKS :
 DOCUMENT NO. PROJECT : CH4250 Process Engineering Capstone Design
Logo & Name of XXXXXXXXX LOCATION : Vishakhapatnam
Company PUMP XXXXXX For Enquiry 0

EBPUMP DATE ISSUE REV. PREP CHKD APPD

SERVICE / FUNCTION : EthylBenzene Circulation Pump QTY : 1
SUPPLIER : M/S TYPE : CENTRIFUGAL
MODEL NO : *
PROCESS DATA DRIVE : MOTOR
Fluid EthylBenzene Starting 3 Phase, Induction Motor
Composition (wt/wt &) 0.999 Voltage 415+/-10%
Density Max, kg/m3 900 Frequency 50HZ+/-3%
Density at Opr. Temp., kg/m3 825.816 Motor Rating, kW 20
Viscosity at Opr. Temp., cP 0.5 Motor Speed, RPM 3500
Corrosion / Erosion NIL Mounting Foot Mounted
Operating Temp., Nor/Max, °C 67.9 / 90 Amb. Temp. °C -
Solid Content , % NIL Protection Class IP-65
Normal Mass Flow Rate, kg/h 31399.6 Installation Out door
Normal Volumetric Flow Rate, m3/hr 38.0 Flame Proof Yes
Min. Volumetric Flow Rate, m3/hr 25 Starting DOL
Max. Volumetric Flow Rate, m3/hr 50 Motor Frame Size -
Available NPSH , mtrs 4.934 Area Classification -
Suction Pressure, kg/cm2g 0.10 Motor Make -
Diff. Pressure, kg/cm2g 5.5051
Diff. Discharge Head, mtrs 66.6628
Vapour Pressure , mmHg 80
NPSH Required, mtrs 3

ENGINEERING DATA MATERIAL OF CONSTRUCTION

Design Temperature, °C 121.111 Casing CF8
Design Pressure, kg/cm2g 6.3329 Shaft SS316
Hydrotest Pressure, kg/cm2g - Impeller CF8
Installation Outdoor Coupling -
Suction / Discharge Size, mm 80 Sleeve CF8
Drive / Pump, RPM 3500 Base Frame IS 2062
Coupling Type - Accessories -
Pump Mounting Horzontal Foundation Bolts MS
Flange Rating - Coupling Guard IS 2062
Design Efficiency, % 50.5 All Wetted Parts SS316
Sealing Type Single Mechnaical Seal Seal Face Combination -
Impeller Type Centrifugal Seal Flushing Plan -
Impeller Diameter, mm 200 Mechanical Seal Make -
Casing Type Single Volute
Suction / Discharge 38.0225
Pump Design Standard IS

REMARKS :
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 APPENDIX
Appendix A
A1. Table of NFPA indices for the chemicals involved in all
technologies [43]
Sum (For
Final list of
ease of hazardous
Health Flammability Instabilit interpret chemicals
Index Index y Index ability) Comments (Sum>4)
Technology-1
Ethylbenzene 2 3 0 5
Benzene 2 3 0 5
Ethylene,
Ethylbenzene,
Ethylene 2 4 2 8 benzene
Highly flammable,
Diethylbenzene NA NA NA NA PAC1=10 ppm
Hydrogen 0 4 0 4

Technology-2
Ethylbenzene 2 3 0 5
Propylene 1 4 1 6
Propylene oxide,
ethylene,
ethylbenzene
hydroperoxide,
propylene,
benzene,
Propylene oxide 3 4 2 9 ethylbenzene
Benzene 2 3 0 5
Ethylene 2 4 2 8
Acetophenone 2 2 0 4
alpha-Methylbenz
yl Alcohol 2 2 0 4
*Due to lack of available
information, it is assumed
that it is similar physically
and chemically to Cumene
Hydroperoxide. Unstable.
Ethylbenzene Possesses oxidizing
Hydroperoxide 1* 2* 4* 7* properties. Readily capable
 of detonation or explosive
decomposition or explosive
reaction at normal
temperatures and
pressures.
Hydrogen 0 4 0 4

Technology-3
Toluene,
Toluene 2 3 0 5 Ethylbenzene
Methanol 1 3 0 4
Ethylbenzene 2 3 0 5
hydrogen 0 4 0 4

Technology-4
Vinylcyclohexene
, Butadiene,
Butadiene 2 4 2 8 Benzene, Ethane
Vinylcyclohexene 2 3 2 7
Benzene 2 3 0 5
Ethane 1 4 0 5
Hydrogen 0 4 0 4
APPENDIX B
B1: Calculations for Reactor Equipment
The reactions that are present in production of ethylbenzene are:
𝐶6 𝐻6 + 𝐶2 𝐻4 → 𝐶8 𝐻10 − (𝑑4𝑟1)
𝐶8 𝐻10 + 𝐶2 𝐻4 → 𝐶10 𝐻14 − (𝑑4𝑟2)
𝐶10 𝐻14 + 𝐶6 𝐻6 → 2𝐶8 𝐻10 − (𝑑4𝑟3)

Two reactors are used in ethylbenzene production namely ALK and TRANSALK. In
ASPEN simulation, we used an isothermal CSTR for modelling ALK and TRANSALK.
Both ALK and TRANSALK reactors are isothermal catalytic packed-bed reactors
[76].

ALK: Reactor
The ALK reactor (abbreviation for alkylation) is where most of the
ethylbenzene production takes place. The bed operates at 160.85 𝑜 𝐶
[Appendix-Fig.3] and the reaction is carried out in the presence of ZSM-5
catalyst [76]. The input to ALK is a mixture of vapor and liquid. Referring
to [64], we select a fixed bed reactor for modelling mixed phase solid
catalyzed reactions.

The input to ALK is ALKFDHTD and HX2HOTIN (a recycle). Only reactions

(1) and (2) are dominant as negligible diethylbenzene is present in both
ALKFDHTD and HX2HOTIN. The limiting reactant is Ethylene in both the
reactions and therefore, we define conversion based on ethylene.

In terms of catalyst weight, the differential form of material balance is given

by:
𝑑𝑋𝐸 𝑘𝑚𝑜𝑙
𝐹𝐸𝑜 = −𝑟𝐸 − (𝑑4𝑟4)
𝑑𝑊 𝑘𝑔 𝑐𝑎𝑡 − ℎ
Where

𝐹𝐸𝑜 is the inlet molar flow rate of ethylene. [Appendix-Fig.2]

𝑊 is the amount of catalyst

𝑋𝐸 is the conversion of ethylene

−𝑟𝐸 is the rate of consumption of ethylene

The kinetics for reactions (1) and (2) are obtained from [65]. The kinetics
are listed below:

Reaction (d4r1):
𝑘𝑟 𝐶𝐸 𝑘𝑚𝑜𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒
−𝑟1 =
1 + 𝑘𝐸𝐵 𝐶𝐸𝐵 𝑘𝑔 𝑐𝑎𝑡 − ℎ
−6.344 × 104
𝑘𝑟 = 0.69 × 106 exp ( )
𝑅𝑇

−3.933 × 103
𝑘𝐸𝐵 = −1.5202 × 10−2 exp ( )
𝑅𝑇

Reaction (d4r2):
−4.703 × 104 𝑘𝑚𝑜𝑙 𝐸𝐵
−𝑟2 = 2.8 × 10−2 exp ( ) 𝐶𝐸𝐵 𝐶𝐸
𝑅𝑇 𝑘𝑔 𝑐𝑎𝑡 − ℎ

Therefore, the rate of consumption of ethylene can be written as

−𝑟𝐸 = −𝑟1 − 𝑟2

−6.344 × 104
0.69 × 106 exp ( ) 𝐶𝐸
𝑅𝑇
−𝑟𝐸 =
−3.933 × 103
1 − 1.5202 × 10−2 exp ( 𝑅𝑇 ) 𝐶𝐸𝐵
−4.703 × 104
+ 2.8 × 10−2 exp ( ) 𝐶𝐸𝐵 𝐶𝐸
𝑅𝑇

Substituting the above rate equation in equation (4) will give:

−6.344 × 104
𝑑𝑋𝐸 0.69 × 106 exp ( 𝑅𝑇 ) 𝐶𝐸
𝐹𝐸𝑜 =
𝑑𝑊 −3.933 × 103
1 − 1.5202 × 10−2 exp ( 𝑅𝑇 ) 𝐶𝐸𝐵
−4.703 × 104
+ 2.8 × 10−2 exp ( ) 𝐶𝐸𝐵 𝐶𝐸
𝑅𝑇

Assuming 95% selectivity of ethylene for reaction (d4r1),

𝐶𝐸 = 𝐶𝐸0 (1 − 𝑋𝐸 )

𝐶𝐸𝐵 = 𝐶𝐸𝐵0 + 0.95𝐶𝐸0 𝑋𝐸 − 0.05𝐶𝐸0 𝑋𝐸

Hence the material balance can be written completely in terms of

conversion and is reported below.
 −6.344 × 104
𝑑𝑋𝐸 0.69 × 106 exp ( 𝑅𝑇 ) 𝐶𝐸0 (1 − 𝑋𝐸 )
𝐹𝐸𝑜 =
𝑑𝑊 −3.933 × 103
1 − 1.5202 × 10−2 exp ( 𝑅𝑇 ) (𝐶𝐸𝐵0 + 0.95𝐶𝐸0 𝑋𝐸 − 0.05𝐶𝐸0 𝑋𝐸 )
4
−4.703 × 10
+ 2.8 × 10−2 exp ( ) (𝐶𝐸𝐵0 + 0.95𝐶𝐸0 𝑋𝐸 − 0.05𝐶𝐸0 𝑋𝐸 𝐶𝐸0 (1
𝑅𝑇
− 𝑋𝐸 )

Numerically integrating the above equation with the integration limits as

𝑋𝐸 = 0 at 𝑊 = 0 and 𝑋𝐸 = 0.9954 (desired conversion from ASPEN
simulation) at 𝑊 = 𝑊. The numerical integration is carried out using
𝑖𝑛𝑡𝑒𝑔𝑟𝑎𝑙 routine in 𝑀𝐴𝑇𝐿𝐴𝐵. The result of integration is
𝑊 = 97.018 𝑡𝑜𝑛𝑛𝑒

The solid volume of the catalyst can be calculated as:

𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡
𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 =
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡
𝑘𝑔
Where density of zeolite catalyst = 740 𝑚3
[66]

97018.323
=> 𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = = 131.1031 𝑚3
740
Next, we find out the bulk volume of the catalyst which is defined as:
𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡
𝑏𝑢𝑙𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 =
1 − 𝑣𝑜𝑖𝑑 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛

Where void fraction of zeolite catalyst = 0.3 [67]

=> 𝑏𝑢𝑙𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 187.2902 𝑚3

We distribute the catalyst onto two beds [71], with 0.5 𝑚 being the gap
between the two beds and inlet & outlet of the reactor.

Therefore, the volume of reactor can be approximated as:

𝜋 2 𝜋 𝜋
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 = 𝐷 𝐿 = 187.2902 + 0.5 × 𝐷 2 + 2 × 0.5 × 𝐷 2
4 4 4
The reactor length to diameter ratio for non-adiabatic reactor is
recommended to be in the range 1 to 3 [70]. By choosing 𝐿/𝐷 ratio to be
2 and solving for diameter, we get
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝐷 = 5.1850 𝑚; 𝐿𝑒𝑛𝑔𝑡ℎ 𝐿 = 10.37 𝑚

Therefore, the reactor volume 𝑉 is

𝜋 2
𝑉= 𝐷 𝐿 = 218.9626 𝑚3
4
Shell shape and material:

The shape of the shell is cylindrical. The operating temperature and

pressure of ALK is 160.85 °𝐶 and 20.265 bar [Appendix-Fig.3] respectively.
The material of choice must withstand the operating temperature, higher
 yield strength along with high resistance to corrosion. Taking these factors
into consideration, we choose stainless steel of grade (according to IS [78])
𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2 to construct the cylindrical shell. The maximum
temperature that 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2 can withstand is around 870 °𝐶.

Shell wall thickness:

From Section 3 of [77], we have the following formula for minimum

thickness of a cylindrical shell:
𝑃𝑖 𝑑𝑖
𝑡= + 𝐶 − (d5r1)
2𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 𝜂𝑗 − 𝑃𝑖

Where

𝑡: wall thickness (mm)

𝑃𝑖 : Design pressure (MPa). Taken as 3.2 MPa > operating pressure

2 MPa

𝑑𝑖 : Internal diameter of the reactor (mm)

𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 : Allowable tensile stress for the reactor material (MPa)

𝜂𝑗 : Longitudinal joints efficiency. Taken as 85%.

𝐶: Corrosion allowance (mm). Taken as 1 mm

The ultimate tensile strength of 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2 grade stainless steel is

558 MPa [79] at 204°𝐶.

Appendix-Fig.8: Table for ultimate tensile strength of 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2 grade SS

From Appendix-Fig.8, assuming that the ultimate tensile at 204°𝐶 is similar

to that at 160.85°𝐶, with a safety factor of 1.5, the allowable tensile stress
(𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 ) is equal to
558
𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 = = 372 𝑀𝑃𝑎
1.5
Using this, we have the minimum wall thickness to be:
 3.2 × 5185
𝑡= +1
2 × 372 × 0.85 − 3.2
=> 𝑡 = 27.369 𝑚𝑚

Doomed ends:

We use a semi-ellipsoidal doomed end with ratio of major to minor axis as

2:1 [77]. We choose the same material used for shell, that is stainless steel
of grade 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2.

The minimum thickness is calculated as:

𝐾𝑓 𝑃𝑖 𝑑𝑖
𝑡ℎ = + 𝐶 − (d5r2)
2𝜎𝑎𝑙𝑙 𝜂𝑗 − 0.2𝑃𝑖

Where,

𝑡ℎ : Head thickness (mm)

2+𝑘𝑖2
𝐾𝑓 : Stress intensification factor and is calculated as 𝐾𝑓 = . 𝑘𝑖 is
6
defined as the ratio of major to minor axis of ellipsoidal head. For
2:1 semi-ellipsoidal end, 𝑘𝑖 is 2 and therefore, 𝐾𝑓 = 1.

𝐶: Corrosion allowance (mm).

As reactor head is less susceptible to corrosion, 𝐶 is taken as 0.3 mm.

By using these, we calculate 𝑡ℎ as

1 × 3.2 × 5185
𝑡ℎ = + 0.3
2 × 372 × 0.85 − 0.2 × 3.2
𝑡ℎ = 26.563 𝑚𝑚

The effective outside height of the semi-ellipsoidal end is found by using

𝐷𝑜 𝑟0
ℎ𝑒 = √ − (d5r7)
2

Where

𝐷𝑜 : Outside diameter of the shell (mm)

𝑟𝑜 : Corner radius. Can be computed as min (𝐷𝑜 , 3𝑡ℎ ) (mm)

By using this formula, we have ℎ𝑒 = 456.92 𝑚𝑚

Design of shell openings:

We design the openings using area of compensation method. The minimum

area required for compensation according to [77] is
𝐴 = 𝑑 × 𝑡𝑟 − (d5r3)

Where
 𝑑: internal diameter of the branch plus twice the corrosion allowance
(mm)

𝑡𝑟 : minimum thickness of shell by putting 𝑐 = 0 and 𝜂𝑗 = 1 in Eq.1

(mm).

Branch internal diameter calculation:

As the internal diameter of the vessel is more than 900 𝑚𝑚 for our
case, we use two circular openings with an area of 150 × 100 𝑚𝑚 each.
The diameter of the opening can be calculated as
2
𝐷𝑜𝑝
𝜋 = 150 × 100
4
=> 𝐷𝑜𝑝 = 138.233 𝑚𝑚

The nominal 𝐷𝑜𝑝 is taken as 150 𝑚𝑚 [Appendix-Fig.10]

 Appendix-Fig.10: Branch Nominal sizes available from [77]

By using the calculated 𝐷𝑜𝑝 , we find 𝑑 as

𝑑 = 𝐷𝑜𝑝 + 2𝑐 = 140.233 𝑚𝑚

𝑡𝑟 = 22.397 𝑚𝑚

Therefore,
𝐴 = 3185.643 𝑚𝑚2

Next, we calculate the following areas:

𝐴𝑠 = 𝑑(𝑡 − 𝑡𝑟 − 𝑐) − (d5r4)
𝐴𝑜 = 2𝐻1 (𝑡 − 𝑡𝑟 − 𝑐) − (d5r5)
𝐴𝑖 = 2𝐻2 (𝑡 − 2𝑐) − (d5r6)

Where

𝐴𝑠 : Area of portion of shell which is effective as compensation (𝑚𝑚2 )

𝐴𝑜 : Area of portion of branch pipe external to vessel which is effective

as compensation (𝑚𝑚2 )

𝐴𝑖 : Are of portion of branch pipe inside vessel which is effective

compensation (𝑚𝑚2 )

𝑡: Actual thickness of shell (mm)

𝑡𝑟 : minimum thickness of shell by putting 𝑐 = 0 and 𝜂𝑗 = 1 in Eq.1

(mm)

𝐻1 : Height of effective compensation in branch wall external to vessel.

Taken as √𝑑(𝑡 − 𝑐) (mm)

𝐻2 : Height of any portion of branch pipe projecting inside vessel.

Taken as √𝑑(𝑡 − 2𝑐) (mm)

𝑐: corrosion allowance (mm). Taken as 1 mm.

𝑑: internal diameter of the branch plus twice the corrosion allowance

(mm)
 When 𝐴 < 𝐴𝑠 + 𝐴𝑜 + 𝐴𝑖 , no additional compensation is required.

By using the above formulas, we get the following results

𝐴𝑠 = 595.887 𝑚𝑚2 ; 𝐴𝑜 = 483.151 𝑚𝑚2 ; 𝐴𝑖 = 3026.461 𝑚𝑚2

𝐴𝑠 + 𝐴𝑜 + 𝐴𝑖 = 4105.5 𝑚𝑚2 > 𝐴

Therefore, no additional compensation is required.

Feasibility of cooling jacket:

The reaction is an isothermal exothermic reaction that takes place at

160.85 𝑜 𝐶. For a similar reactor system, [75] used an overall heat transfer
coefficient as 850 𝑊/𝑚2 𝑘. We use water as the cold utility which enters at
25 𝑜 𝐶 and exits at 120 𝑜 𝐶. The flow of cold utility inside the reactor is
assumed to be similar to flow inside a one shell pass-two tube pass reactor.
We use F-LMTD to model the heat exchange. The overall heat transfer is
defined as
𝑄 = 𝑈𝐴Δ𝑇𝐿𝑀𝑇𝐷 𝐹

Where

𝑈: Overall heat transfer coefficient (850 𝑊/𝑚2 𝑘)

𝐴: Area of heat exchange (𝑚2 )

Δ𝑇𝐿𝑀𝑇𝐷 : Logarithmic mean temperature difference

𝐹: Temperature correction factor obtained from Appendix-Fig.1

Appendix-Fig.1: F-LMTD correlation chart

120−25
Temperature effectiveness 𝑆 = 160.85−25 = 0.699
160.85−160.85
Heat capacity rate ratio 𝑅 = 120−25
=0

From the F-LMTD chart, we get 𝐹 = 0.96

 (160.85 − 120) − (160.85 − 25)
Δ𝑇𝐿𝑀𝑇𝐷 = = 79 𝑜 𝐶
160.85 − 120
ln ( )
160.85 − 25
|𝑄| = 10427.6 𝑘𝑊 [Appendix-Fig.3]

=> 10427.6 × 103 = 850 × 𝐴ℎ𝑒𝑥 × 79 × 0.96

𝐴ℎ𝑒𝑥 = 161.758 𝑚2

Surface area of reactor:

𝑑𝑜𝑢𝑡𝑒𝑟 = 𝑑𝑖 + 2𝑡 = 5.239 𝑚
𝐿 = 10.37 𝑚

=> 𝐴𝑟𝑒𝑎𝑐 = 170.615 𝑚2

Since 𝐴𝑟𝑒𝑎𝑐 > 𝐴ℎ𝑒𝑥 , we can use a cooling jacket around the reactor.

TRANSALK: Reactor
The TRANSALK reactor (abbreviation for transalkylation) is where
diethylbenzene is reacted with benzene to get converted to ethylbenzene.
The bed operates at 158.85 𝑜 𝐶 and the reaction is carried out in the presence
of ZSM-5 catalyst. The input to TRANSALK is liquid. Referring to [64], we
select a fixed bed reactor for modelling liquid phase solid catalyzed
reactions.

The input to TRANSALK is ALKPDT and DEBRHTD. Only reaction (d4r3) is

dominant as negligible ethylene is present in both ALKPDT and DEBRHTD.
The limiting reactant is diethylbenzene in both the reactions and therefore,
we define conversion based on diethylbenzene.

The material balance equation based on catalyst weight will give

𝑑𝑋𝐷𝐸𝐵 𝑘𝑚𝑜𝑙
𝐹𝐷𝐸𝐵𝑜 = −𝑟𝐷𝐸𝐵
𝑑𝑊 𝑘𝑔 𝑐𝑎𝑡 − ℎ

Where the subscript 𝐷𝐸𝐵 refers to the specific quantity (as defined in
Eq.(d4r4)) with respect to diethylbenzene. 𝐹𝐷𝐸𝐵0 is obtained from
[Appendix-Fig.4].
 Appendix-Fig.4: TRANSALK stream results

From [65], the kinetics of reaction (d4r3) is obtained as

5.928 × 104 𝐶𝐷𝐸𝐵 𝐶𝐵1.0218 𝑘𝑚𝑜𝑙 𝑏𝑒𝑛𝑧𝑒𝑛𝑒

−𝑟𝐷𝐸𝐵 = 2.378 × 104 𝑒𝑥𝑝 (− ) −6
𝑅×𝑇 (3
1 + × 10 𝐶𝐵 ) 𝑘𝑔 𝑐𝑎𝑡 − ℎ

𝐶𝐷𝐸𝐵 = 𝐶𝐷𝐸𝐵 0 (1 − 𝑋𝐷𝐸𝐵 ) ; 𝐶𝐵 = 𝐶𝐵 0 − 𝐶𝐷𝐸𝐵0 𝑋𝐷𝐸𝐵

Like we did in ALK calculation, we numerically integrate the material

balance differential equation with the limits as 𝑋𝐷𝐸𝐵 = 0 when 𝑊 = 0 and
𝑋𝐷𝐸𝐵 = 0.998 when 𝑊 = 𝑊. By doing so, we get
𝑊 = 130.4559 𝑡𝑜𝑛𝑛𝑒

Like we did in ALK calculation, solid volume and bulk volume of the ZSM-5
catalyst were computed using density and void fraction
130455.915
𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = = 176.2918 𝑚3
740
207.073
𝑏𝑢𝑙𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = = 251.8454 𝑚3
1 − 0.3
By referring to [71], we use three packed beds for TRANSALK with a
spacing of 0.5 𝑚 between the beds and between the bed and inlet & outlet,
𝜋 2 𝜋 𝜋
𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝐷 𝐿 = 251.8454 + 2 × 0.5 × 𝐷 2 + 2 × 0.5 × 𝐷 2
4 4 4
Using the same aspect ratio (=2) as that of ALK, we solve the above
equation to get
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝐷 = 5.7872 𝑚 ; 𝐿𝑒𝑛𝑔𝑡ℎ 𝐿 = 11.5744 𝑚

=> 𝑟𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = 304.4537 𝑚3

Shell shape and material:

The shape of the shell is cylindrical. The operating temperature and

pressure of TRANSALK is 158.85 °𝐶 and 19.25 bar [Appendix-Fig.5]
respectively. The material of choice must withstand the operating
temperature, higher yield strength along with high resistance to corrosion.
 Taking these factors into consideration, we choose stainless steel of grade
(according to IS [78]) 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2 to construct the cylindrical shell. The
maximum temperature that 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2 can withstand is around 870 °𝐶.

Appendix-Fig.5: TRANSALK net heat duty

Shell wall thickness:

From Eq.(d5r1), we get the thickness as:

=> 𝑡 = 30.232 𝑚𝑚

Doomed ends:

We use a semi-ellipsoidal doomed end with ratio of major to minor axis as

2:1 [77]. We choose the same material used for shell, that is stainless steel
of grade 𝑋04𝐶𝑟17𝑁𝑖12𝑀𝑜2.

By using Eq.(d5r2), we calculate 𝑡ℎ as

𝑡ℎ = 29.613 𝑚𝑚

The effective outside height of the semi-ellipsoidal end is calculated from

Eq.(d5r7) as
ℎ𝑒 = 509.66 𝑚𝑚

Design of shell openings:

Like in ALK, we have two circular openings of area 150 × 100 𝑚𝑚. We design
each of those openings using area of compensation method. We compute
the areas given in Eq.(d5r3) to Eq.(d5r6). By doing so, we get

𝐴 = 3555.633 𝑚𝑚2 ; 𝐴𝑠 = 635.095 𝑚𝑚2 ; 𝐴𝑜 = 542.171 𝑚𝑚2 ; 𝐴𝑖 = 3552.897 𝑚𝑚2

𝐴𝑠 + 𝐴𝑜 + 𝐴𝑖 = 4730.165 𝑚𝑚2 > 𝐴

Therefore, no additional compensation is required.

Cooling of TRANSALK:

The reaction is an isothermal exothermic reaction that takes place at

158.85 𝑜 𝐶. We use water as the cold utility. The inlet temperature of cold
utility is 25 𝑜 𝐶 and outlet temperature of cold utility is 120 𝑜 𝐶. Like we did in
ALK, we again assume that the flow of cold utility on heat exchanging
surface of the reactor is similar to the flow one shell two pass heat
 exchanger. The overall heat transfer coefficient is 850 𝑊/𝑚2 𝑘 [75] and we
use the F-LMTD model.
(158.85 − 120) − (158.85 − 25)
Δ𝑇𝐿𝑀𝑇𝐷 = = 76.797 𝑜 𝐶
158.85 − 120
ln ( )
158.85 − 25
𝐹 = 0.96 (calculated from Appendix-Fig.1 correlation)

|𝑄| = 263.059 𝑘𝑊 [Appendix-Fig.5]

=> 263.059 × 103 = 850 × 𝐴ℎ𝑒𝑥 × 76.797 × 0.96

𝐴ℎ𝑒𝑥 = 4.08 𝑚2

Surface area of reactor:

𝑑𝑜𝑢𝑡𝑒𝑟 = 𝑑𝑖𝑛𝑛𝑒𝑟 + 2𝑡 = 5.847 𝑚
𝐿 = 11.5744 𝑚

=> 𝐴𝑟𝑒𝑎𝑐 = 212.525 𝑚2

Since 𝐴𝑟𝑒𝑎𝑐 > 𝐴ℎ𝑒𝑥 , we can use a cooling jacket around the reactor.

EB2STY: Reactor
The reactions that are present in production of styrene are:
𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 → 𝐶6 𝐻5 𝐶𝐻𝐶𝐻2 + 𝐻2 − (𝑑4𝑟7)
𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 → 𝐶6 𝐻6 + 𝐶2 𝐻4 − (𝑑4𝑟8)
𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 + 𝐻2 → 𝐶6 𝐻5 𝐶𝐻3 + 𝐶𝐻4 − (𝑑4𝑟9)

The EB2STY reactor block is responsible for the production of styrene from
ethylbenzene. EB2STY is an isothermal catalytic packed-bed reactor [76].

The reaction is carried out in the presence of Shell 105 [76] and the bed
operates at 610 𝑜 𝐶 [Appendix-Fig.7]. The input to EB2STY is a gaseous
mixture. Referring to [77], we select a fixed bed reactor for modelling gas
phase solid catalyzed reactions.
The input to EB2STY is EB2STYF. Reaction (d4r7) is the dominant reaction
whereas reactions (d4r8) and (d4r9) are side reactions. The kinetics
associated with these reactions are obtained from [10, 11] and are as
follows:
−0.909 × 105 𝑝𝑆𝑇𝑌 𝑝𝐻2 𝑘𝑚𝑜𝑙
𝑟7 = 8.32 × 103 𝑒𝑥𝑝 ( ) (𝑝𝐸𝐵 − )
𝑅𝑇 𝑘𝐸𝐵 𝑘𝑔 𝑐𝑎𝑡 − 𝑠

−2.8 × 105 𝑘𝑚𝑜𝑙

𝑟8 = 4.29 × 108 𝑒𝑥𝑝 ( ) 𝑝𝐸𝐵
𝑅𝑇 𝑘𝑔 𝑐𝑎𝑡 − 𝑠

3
−0.915 × 105 𝑘𝑚𝑜𝑙
𝑟9 = 6.13 × 10 exp ( ) 𝑝𝐸𝐵 𝑝𝐻2
𝑅𝑇 𝑘𝑔 𝑐𝑎𝑡 − 𝑠

Where 𝑝𝐸𝐵 , 𝑝𝑆𝑇𝑌 and 𝑝𝐻2 are partial pressures (in bar) of ethylbenzene,
styrene and hydrogen respectively.𝑘𝐸𝐵 in 𝑟7 is defined as
12275 − 126.267𝑇 − 0.002194𝑇 2
𝑘𝐸𝐵 = exp ( ) 𝑏𝑎𝑟
𝑅𝑇

Ethylbenzene acts as the limiting reactant. Therefore, we write the material

balance equation with respect to the amount of ethylbenzene present. The
material balance equation is written as:
𝑑𝐹𝐸𝐵
= −𝜌𝑐 𝑟𝐸𝐵 − (d4r10)
𝑑𝑉
Where

𝐹𝐸𝐵 : Flowrate of ethylbenzene, initial value obtained from

[Appendix-Fig.6]

𝜌𝑐 : Density of catalyst = 2145.27 𝑘𝑔/𝑚3 [72]

−𝑟𝐸𝐵 : Rate of consumption of ethylbenzene

Being a gaseous flow reactor and since the rate expression is based on
partial pressure, we account for pressure drop using ergun equation as
follows:

𝑑𝑃 𝜇𝑔 𝑉𝑠 (1 − 𝜖)2 𝜌𝑔 𝑉𝑠2 (1 − 𝜖)
= −10−5 [150 + 1.75 ] − (d4r11)
𝑑𝑙 𝜙𝑠2 𝐷𝑝2 𝜖 3 𝜙𝑠 𝐷𝑝 𝜖 3

Where

𝑃: Total pressure (bar)

𝑙: Length of the reactor (m)

𝐷𝑝 : Diameter of catalyst particle (mm)

𝜙𝑠 : Sphericity of particle

𝜌𝑔 : Gas mixture density (𝑘𝑔/𝑚3 )

𝑉𝑠 : Superficial gas velocity (m/s)

 𝜇𝑔 : Viscosity of gas mixture (cP)

𝜖: Bed porosity

Appendix-Fig.6: EB2STY stream results

From [72], the following catalyst properties were obtained

𝐷𝑝 = 4.7 𝑚𝑚 ; 𝜖 = 0.35

The viscosity of gas mixture in catalyst bed can be calculated using

Chapman-Enskog theory which states:
𝜇𝑔 = 3.6 × 10−4 (−10.035 + 0.25191𝑇 − 0.000037932𝑇 2 )

Gas mixture density 𝜌𝑔 is calculated assuming ideal gas [72]

𝑝𝐸𝐵 𝑀𝐸𝐵 + 𝑝𝑆𝑇𝑌 𝑀𝑆𝑇𝑌 + 𝑝𝐻2 𝑀𝐻2
𝜌𝑔 =
𝑅𝑇
Where 𝑀𝐸𝐵 , 𝑀𝑆𝑇𝑌 and 𝑀𝐻2 are molecular weights of ethylbenzene, styrene
and hydrogen respectively.
𝐹
The partial pressures can be related to molar flow rates through 𝑝𝑖 = 𝑃 𝐹 𝑖
𝑇

In Eq.(d4r11), 𝑑𝑙 is rewritten interms of 𝑑𝑉 using an length-to-diameter

ratio of 4.6. Once Eq.(d4r10) and Eq.(d4r11) are with respect to the reactor
volume 𝑉, they are solved simultaneously using Runge-Kutte-Gill fourth
order method with a step size of 1 𝑚3 . The initial condition is set as when
𝑉 = 0, 𝐹𝐸𝐵 = 𝐹𝐸𝐵0 = 295.7 𝑘𝑚𝑜𝑙/ℎ𝑟 and 𝑃 = 𝑃0 = 3 𝑏𝑎𝑟. The solver is stopped
once the conversion of ethylbenzene reaches 99.83%
 Conversion of ethylbenzene to styrene vs Volume
120

100
Conversion (%)

80

60

40

20

0
0
8
16
24
32
40
48
56
64
72
80
88
96
104
112
120
128
136
144
152
160
168
176
184
192
200
208
216
224
232
Volume (m3)

For a conversion of 99.83 %, we require a reactor of volume 233 𝑚3 .

The pressure at the exit of reactor was estimated to be 0.6 𝑏𝑎𝑟.

As we assumed the aspect ratio to be 4.6, we get

𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝐷 = 4 𝑚; 𝐿𝑒𝑛𝑔𝑡ℎ 𝐿 = 18.55 𝑚

The amount of catalyst required can be calculated by reversing the method

that we used to calculate the reactor volume of ALK and TRANSALK. But
unlike ALK and TRANSALK, the catalyst is not split into two part but rather
kept as one single part. Assuming that the space between catalyst bed and
reactor inlet & outlet is 0.5 m, we get
𝜋 2
𝑅𝑒𝑎𝑐𝑡𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑏𝑢𝑙𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 + 2 × 0.5 × 𝐷
4
=> 𝑏𝑢𝑙𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 233 − 12.5664 = 220.4336 𝑚3
𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 𝑏𝑢𝑙𝑘 𝑣𝑜𝑙𝑢𝑚𝑒 × (1 − 𝜖) = 220.4336 × (1 − 0.35)
=> 𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 143.2819 𝑚3
𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 × 𝑠𝑜𝑙𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 = 2145.27 × 143.2819
=> 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 = 307. 378 𝑡𝑜𝑛𝑛𝑒

Shell shape and material:

The shape of the shell is cylindrical. The operating temperature and

pressure of EB2STY is 610 °𝐶 [Appendix-Fig.7]. The material of choice must
withstand the operating temperature, higher yield strength along with high
resistance to corrosion. Taking these factors into consideration, we choose
stainless steel of grade (according to IS [78]) 𝑋04𝐶𝑟19𝑁𝑖9 to construct the
cylindrical shell. The maximum temperature that 𝑋04𝐶𝑟19𝑁𝑖9 can withstand
is around 1000 °𝐶.
 Appendix-Fig.7: EB2STY net heat duty

Shell wall thickness:

The ultimate tensile stress for stainless steel of grade 𝑋04𝐶𝑟19𝑁𝑖9 at 610°𝐶
is 326.831 𝑀𝑃𝑎 (By interpolation from Appendix-Fig.9 [80]). Taking a safety
factor of 1.5, we have
326.831
𝜎𝑎𝑙𝑙𝑜𝑤𝑒𝑑 = = 217.887 𝑀𝑃𝑎
1.5
The design pressure is taken as 0.7 MPa as the operating pressure is
between 1 to 3 bar.

Using this and plugging values into Eq.(d5r1), we get the thickness as:
=> 𝑡 = 8.373 𝑚𝑚

Appendix-Fig.9: Table for ultimate tensile strength of 𝑋04𝐶𝑟19𝑁𝑖9 grade SS

Doomed ends:

We use a semi-ellipsoidal doomed end with ratio of major to minor axis as

2:1 [77]. We choose the same material used for shell, that is stainless steel
of grade 𝑋07𝐶𝑟18𝑁𝑖9 .

By using Eq.(d5r2), we calculate 𝑡ℎ as

𝑡ℎ = 7.862 𝑚𝑚

The effective outside height of the semi-ellipsoidal end is calculated from

Eq.(d5r7) as
 ℎ𝑒 = 217.646 𝑚𝑚

Design of shell openings:

Like in ALK, we have two circular openings of area 150 × 100 𝑚𝑚. We design
each of those openings using area of compensation method. We compute
the areas given in Eq.(d5r3) to Eq.(d5r6). By doing so, we get
𝐴 = 915.361 𝑚𝑚2 ; 𝐴𝑠 = 140.678 𝑚𝑚2 ; 𝐴𝑜 = 60.315 𝑚𝑚2 ; 𝐴𝑖 = 381.086 𝑚𝑚2

𝐴𝑠 + 𝐴𝑜 + 𝐴𝑖 = 582.080 𝑚𝑚2 < 𝐴

Therefore, additional compensation of 333.281 𝑚𝑚2 is required.

Heating of EB2STY

The reaction is an isothermal endothermic reaction that takes place at 610 𝑜 𝐶

[Appendix-Fig.7]. We use hot oil as the hot utility. The inlet temperature of
hot utility is 900 𝑜 𝐶 and outlet temperature of hot utility is 880 𝑜 𝐶. Like we
did in ALK, we again assume that the flow of hot utility on heat exchanging
surface of the reactor is similar to the flow one shell two pass heat
exchanger. The overall heat transfer coefficient is 200 𝑊/𝑚2 𝐶 [81] and we
use the F-LMTD model. Since the cold stream is isothermal (note that the
reaction is endothermic), 𝑆 = 0, 𝑅 = ∞ and 𝐹 = 1
(900 − 610) − (880 − 610)
Δ𝑇𝐿𝑀𝑇𝐷 = = 279.88 𝑜 𝐶
900 − 610
ln ( )
880 − 610
|𝑄| = 17107.6 𝑘𝑊 [Appendix-Fig.7]

=> 17107.6 × 103 = 200 × 𝐴ℎ𝑒𝑥 × 279.88 × 1

𝐴ℎ𝑒𝑥 = 305.622 𝑚2

Surface area of reactor:

𝑑𝑜𝑢𝑡𝑒𝑟 = 𝑑𝑖𝑛𝑛𝑒𝑟 + 2𝑡 = 4.016 𝑚
𝐿 = 18.55 𝑚

=> 𝐴𝑟𝑒𝑎𝑐 = 233.96𝑚2

Since 𝐴𝑟𝑒𝑎𝑐 < 𝐴ℎ𝑒𝑥 , we can’t directly configure a heating jacket around the
surface of the reactor. One way is to increase the thickness of the reactor
wall to provide enough heat exchanger area. By keeping 1% extra margin
for heat exchange area, the required area of surface of reactor for heat
exchange = 1.01 × 305.622 = 320.903 𝑚2.
320.903 = 𝜋(4 + 2𝑡𝑛𝑒𝑤 )18.55
=> 𝑡𝑛𝑒𝑤 = 0.7533 𝑚

Other way to provide heat exchange in such a scenario is by adding an

external heat exchanging unit as recommended in [75].
B2: Calculations for Separator Equipment
The major class of equipment used for separations in the production of Styrene
are the Distillation Columns, modelled as RadFrac Blocks in Aspen Plus. There is
a total of 3 Distillation Columns in the PFD, and 4 Flash Drums.

B2a: Separator Equipment Sizing

COL1: Distillation Column

The COL1 Distillation Column processes the output from the TRANSALK
reactor through stream COL1F and produces Distillate output through stream
DIST1 and Bottoms output through COL1BTMS stream. Through Aspen
Simulation, by targeting the required output purity of Ethyl Benzene, the
stream data is obtained:
Stream Data:

Column Design Specifications:

Condenser Type Total Condenser

Molar Reflux Ratio 0.774

Number of Stages 20

Feed Stage 10, Fed Above Stage

Based on the above considerations, the Column is designed as a Plate Column
with Sieve plates, chosen for their economic advantage, wide operating range,
and ability to operate at high Vapour flow rates.

A Plate Column is designed, with Sieve Plates, for above specs, between stages
2-19:

Flow Rates:

Feed Rate 𝐹 = 958.131 kmol/h

Distillate Rate 𝐷 = 555.743 kmol/h

Bottoms Rate 𝐵 = 402.388 kmol/h

The feed enters as 496.774 kmol/h Liquid feed and 461.357 kmol/h Vapor Feed.
∴ 𝑉𝑎𝑝𝑜𝑢𝑟 𝑅𝑎𝑡𝑒 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑 𝑉 = 𝐷(1 + 𝑅) = 555.743(1 + 0.774) = 985.888 𝑘𝑚𝑜𝑙/ℎ
𝑉𝑎𝑝𝑜𝑢𝑟 𝑅𝑎𝑡𝑒 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑 𝑉 ′ = 𝐷(1 + 𝑅) − 𝐹𝑣 = 985.888 − 461.357 = 524.531 𝑘𝑚𝑜𝑙/ℎ
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑, 𝐿 = 𝑅𝐷 = 0.774 × 555.743 = 430.145 𝑘𝑚𝑜𝑙/ℎ
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑, 𝐿′ = 𝑅𝐷 + 𝐹 = 430.145 + 496.774 = 926.919 𝑘𝑚𝑜𝑙/ℎ

Physical Properties:

Assuming column efficiency of 60%, ignoring reboiler:

20
Number of real stages = = 34
0.6

Assuming pressure drop per plate is 100 mm water.

Column pressure drop = 100 × 10−3 × 1000 × 9.81 × 34 = 33354 𝑃𝑎

Top Tray Properties:

Temperature = 51.732°𝐶

𝑉𝑎𝑝𝑜𝑢𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.91575 𝑘𝑔/𝑚3

𝐿𝑖𝑞𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 840.196 𝑘𝑔/𝑚3

𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 24.5203 𝑚𝑁/𝑚
𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑊𝑒𝑖𝑔ℎ𝑡 = 84.854 𝑔/𝑚𝑜𝑙

Bottom Tray Properties:

Temperature = 103.086 °𝐶

𝑉𝑎𝑝𝑜𝑢𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 1.06608 𝑘𝑔/𝑚3

𝐿𝑖𝑞𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 795.87 𝑘𝑔/𝑚3

𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 21.3772 𝑚𝑁/𝑚
𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑊𝑒𝑖𝑔ℎ𝑡 = 113.035 𝑔/𝑚𝑜𝑙

Column Diameter:
Neglecting changes in molar flow rate due to differences in molecular weight
between vapour and liquid:

𝐿′ 𝜌𝐺 926.919 1.066
𝐹𝐿𝑉 𝑏𝑜𝑡𝑡𝑜𝑚 = √ = √ = 0.06468
𝐺′ 𝜌𝐿 524.531 795.87

𝐿 𝜌𝐺 430.145 0.9158
𝐹𝐿𝑉 𝑡𝑜𝑝 = √ = √ = 0.01440
𝐺 𝜌𝐿 985.888 840.196

Taking plate spacing as 0.6 m.

Assuming a nonfoaming system, with hole size less than 6.5mm, weir height less
than 15% of the plate spacing, and assuming hole-active area as 10%.

Using the correlation between 𝐹𝐿𝑉 and 𝐾1 [Ref 64, Figure 17.34],

Bottom 𝐾1 = 0.12.

Top 𝐾1 = 0.105

After correcting for Surface Tension,

21.3772 0.2
𝐵𝑜𝑡𝑡𝑜𝑚 𝐾1 = 0.12 × ( ) = 0.1216
20
24.5203 0.2
𝑇𝑜𝑝 𝐾1 = 0.105 × ( ) = 0.1102
20
(𝜌𝐿 −𝜌𝑉 )
Bottom 𝑢𝑓 = 𝐾1 × √ 𝜌𝑉
= 3.3205 𝑚/𝑠

(𝜌𝐿 −𝜌𝑉 )
Top 𝑢𝑓 = 𝐾1 × √ 𝜌𝑉
= 3.3375 𝑚/𝑠

Designing for 85% flooding at maximum flow rate:

Bottom 𝑢𝑚𝑎𝑥 = 3.3375 × 0.85 = 2.8224 𝑚/𝑠

Top 𝑢𝑚𝑎𝑥 = 3.3205 × 0.85 = 2.8369 𝑚/𝑠

Maximum volumetric flow rate:

𝐺′×𝑚𝑤 524.531×113.035
Bottom 𝑄𝑚 = = = 15.449 𝑚3 /𝑠
𝜌𝐺 ×3600 1.06608×3600

𝐺×𝑚𝑤 985.888×84.854
Top 𝑄𝑚 = 𝜌 = = 25.376 𝑚3 /𝑠
𝐺 ×3600 0.91575×3600

Taking downcomer area as 12% of total:

Column cross-sectional area:

𝑄𝑚 1 21.01 1
Bottom = 𝑢𝑚𝑎𝑥
× 0.88 = 3.249 × 0.88 = 6.220 𝑚2

𝑄𝑚 1 240.808 1
Top = 𝑢𝑚𝑎𝑥
× 0.88 = 6.3504
× 0.88 = 10.1647 𝑚2

Column diameter:
 𝐴×4 6.467×4
Bottom = √ 𝜋
=√ 𝜋
= 2.8142 𝑚

𝐴×4 37.92×4
Top = √ 𝜋
=√ 𝜋
= 3.598 𝑚

Hence the column diameter is taken as the larger of the two, 3.598 m, and the
perforated area of the plates below the feed are reduced accordingly.

Provisional Plate Design:

Column Diameter = 3.598 m

Column Area 𝐴𝐶 = 10.165 m2

Downcomer Area (at 12%) 𝐴𝐷 = 0.12 × 𝐴𝐶 = 0.12 × 10.165 = 1.220 𝑚2

Net Area 𝐴𝑁 = 𝐴𝐶 − 𝐴𝐷 = 10.165 − 1.220 = 8.9449 𝑚2

Active Area 𝐴𝐴 = 𝐴𝐶 − 2𝐴𝐷 = 7.7251 𝑚2

Hole Area, taking 10% of 𝐴𝐴 as first trial 𝐴𝐻 = 0.10𝐴𝐴 = 0.7725 𝑚2

Weir Length, using the correlation between downcomer area and weir length
[Ref 64, Figure 17.39]:
𝑙𝑤 = 0.76 × 3.598 = 2.7341 𝑚

Taking: 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 = 50 𝑚𝑚, 𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑑ℎ = 5 𝑚𝑚, 𝑃𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 5 𝑚𝑚

Checking for Weeping:

𝐿′ × 𝑚𝑤 926.919 × 113.035
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑖𝑞𝑢𝑖𝑑 𝑅𝑎𝑡𝑒 𝑚𝑚𝑎𝑥 = = = 29.10 𝑘𝑔/𝑠
3600 3600
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑖𝑞𝑢𝑖𝑑 𝑅𝑎𝑡𝑒 𝑎𝑡 70% 𝑡𝑢𝑟𝑛𝑑𝑜𝑤𝑛 𝑚0.7 = 0.7 × 29.10 = 20.37 𝑘𝑔/𝑠

Height of Weir Liquid Crest ℎ𝑜𝑤 :

2/3
𝑚𝑚𝑎𝑥 2/3 29.1
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = [ ] =( ) = 0.05634 𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 𝑙𝑤 796.222 × 2.734
2/3
𝑚0.7 2/3 20.37
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = [ ] =( ) = 0.04442 𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 𝑙𝑤 796.222 × 2.734

At minimum rate, ℎ𝑤 + ℎ𝑜𝑤 = 50 + 27.4 = 74.4212 𝑚𝑚

From the Weep-point Correlation [Ref 64, Figure 17.37], 𝐾2 = 30.85

𝐾2 −0.90(25.4−𝑑ℎ ) 30.85−0.90(25.4−5)
Minimum velocity through hole 𝑢ℎ (𝑚𝑖𝑛) = 0.5 = =
𝜌𝑉 1.0660.5
13.068 𝑚/𝑠
𝑄𝑉 ×0.7 15.449×0.7
Actual minimum vapour velocity = 𝐴𝐻
= 0.7725
= 13.9985 𝑚/𝑠

Since actual minimum velocity is higher than the weep point velocity, weeping
will not occur even at minimum operating rate.

Plate Pressure Drop:

Dry plate drop:
𝑄𝑉 15.449
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ ℎ𝑜𝑙𝑒𝑠: 𝑢ℎ = = = 19.998 𝑚/𝑠
𝐴𝐻 0.7725

From Correlation between Orifice Coefficient and perforated area [Ref 64, Figure
𝐴𝐻
17.42], with 𝐴𝑃
≈ 0.1, plate thickness / plate diameter = 1, we obtain 𝐶0 = 0.84

𝑢ℎ 2 𝜌𝐺 19.998 2 1.066
ℎ𝑑 = 51 [ ] = 51 [ ] = 38.719 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝐶0 𝜌𝐿 0.84 795.87
12.5×103 12.5×103
Residual Head ℎ𝑟 = = = 15.70 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 795.87

Total plate pressure drop ℎ𝑡 = ℎ𝑑 + ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑟 = 104.482 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

Downcomer Liquid Backup

ℎ𝑎𝑝 = ℎ𝑤 − 10 = 40𝑚𝑚

Area under apron, 𝐴𝑎𝑝 = 𝑙𝑤 × ℎ𝑎𝑝 × 10−3 = 0.10936 𝑚2

𝑚
Downcomer head loss ℎ𝑑𝑐 = 166 [𝜌 𝑚𝑎𝑥
𝐴
] = 18.56 𝑚𝑚
𝐿 𝑎𝑝

1
Backup in downcomer ℎ𝑏𝑐 = ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑡 + ℎ𝑑𝑐 = 173.098 𝑚𝑚 < 2 (0.6 + 𝑙𝑤 )

Hence plate spacing of 0.6m is acceptable.

Residence Time:
𝐴𝐷 ℎ𝑏𝑐 𝜌𝐿
𝑡𝑟 = = 5.774 𝑠 > 3 𝑠
𝑚𝑚𝑎𝑥

Entrainment:
𝑄𝑉 15.45
𝑢𝑣 = = = 1.727 𝑚/𝑠
𝐴𝑁 8.9449
𝑢 1.727
Percent flooding 𝑓% = 𝑢𝑣 = 3.32
= 52.01%
𝑓

From Entrainment Correlation with 𝐹𝐿𝑉 [Ref 64, Figure 17.36], Ψ = 1.5 × 10−2 , well
below 0.1

Thus, the percent flooding is well below the design figure of 85% and
entrainment will not occur.

Number of Holes:
2
𝜋𝑑ℎ
Area of one hole = 𝑎𝐻 = 4
= 1.964 × 105 𝑚2
𝐴𝐻
Number of holes = 𝑎𝐻
= 39344

Height of Tower:
Given 32 plates, with 0.6 m spacing between them, a height of 22.8 m is
obtained. Adding a 0.5 m manhole at feed stage, a manhole every 10 trays in
the column, 1 m height at top of column, and a skirt of height 3 m, the total
height obtained is 26.4 m.

Final Column Specifications:

Column Diameter 3.5975 m

Tower Height 26.4 m

Cross-Sectional Area 10.165 sqm

Number of Plates 32

Plate Type Sieve

Downcomer Area 1.220 sqm(12%)

Total Hole Area 0.7725 sqm

Hole Diameter 5 mm

Total Number of Holes 39344

Weir Height 50 mm

Weir Length 2.734 m

Plate Spacing 0.6 m

Plate thickness 5 mm

Turn-down (ratio of lowest to highest 70%

flowrate)

Reflux Drum:

The Reflux Drum was sized such that fifteen minutes of accumulation would
result in the vessel becoming half-full. Given the volumetric Reflux Rate of
724.02 l/min, the resultant volume of the Reflux Drum is 21720.64 L.

Using an L/D aspect ratio of 3 for a horizontal vessel:

𝑉𝑜𝑙𝑢𝑚𝑒 = 21.72064 𝑚3 = 3𝜋𝐷 2 𝐿 = 3𝜋𝐷 3

𝐷 = 1.321 𝑚, 𝐿 = 3.9627 𝑚
COL2: Distillation Column

The COL2 Distillation Column processes the bottoms output from COL1
through stream COL1BTMS, and produces Distillate output through stream
EBPDT and Bottoms output through COL2BTMS stream. Through Aspen
Simulations, the stream data is obtained:
Stream Data:

Column Design Specifications:

Condenser Type Total Condenser

Molar Reflux Ratio 0.661

Number of Stages 24

Feed Stage 15, Fed Above Stage

Based on the above considerations, the Column is designed as a Plate Column
with Sieve plates, chosen for their economic advantage, wide operating range,
and ability to operate at high Vapour flow rates.

A Plate Column is designed, with Sieve Plates, for above specs, between stages
2-23:

Flow Rates:

Feed Rate 𝐹 = 402.388 kmol/h

Distillate Rate 𝐷 = 295.755 kmol/h

Bottoms Rate 𝐵 = 106.633 kmol/h

The feed enters as 338.11 kmol/h Liquid feed and 64.2771 kmol/h Vapor Feed.
∴ 𝑉𝑎𝑝𝑜𝑢𝑟 𝑅𝑎𝑡𝑒 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑 𝑉 = 𝐷(1 + 𝑅) = 295.755(1 + 0.661) = 491.250 𝑘𝑚𝑜𝑙/ℎ
𝑉𝑎𝑝𝑜𝑢𝑟 𝑅𝑎𝑡𝑒 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑 𝑉 ′ = 𝐷(1 + 𝑅) − 𝐹𝑣 = 491.250 − 64.2771 = 426.972 𝑘𝑚𝑜𝑙/ℎ
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑, 𝐿 = 𝑅𝐷 = 0.661 × 295.755 = 195.494 𝑘𝑚𝑜𝑙/ℎ
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑, 𝐿′ = 𝑅𝐷 + 𝐹 = 195.494 + 402.388 = 597.881 𝑘𝑚𝑜𝑙/ℎ

Physical Properties:

Assuming column efficiency of 60%, ignoring reboiler:

24
Number of real stages = 0.6
= 40

Assuming pressure drop per plate is 100 mm water.

Column pressure drop = 100 × 10−3 × 1000 × 9.81 × 40 = 39240 𝑃𝑎

Top Tray Properties:

Temperature = 67.9059°𝐶

𝑉𝑎𝑝𝑜𝑢𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.381517 𝑘𝑔/𝑚3

𝐿𝑖𝑞𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 825.816 𝑘𝑔/𝑚3

𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 24.3334 𝑚𝑁/𝑚
𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑊𝑒𝑖𝑔ℎ𝑡 = 106.1676 𝑔/𝑚𝑜𝑙

Bottom Tray Properties:

Temperature = 100.742 °𝐶

𝑉𝑎𝑝𝑜𝑢𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.416325 𝑘𝑔/𝑚3

𝐿𝑖𝑞𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 811.921 𝑘𝑔/𝑚3

𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 23.1119 𝑚𝑁/𝑚
𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑊𝑒𝑖𝑔ℎ𝑡 = 132.0839 𝑔/𝑚𝑜𝑙

Column Diameter:
Neglecting changes in molar flow rate due to differences in molecular weight
between vapour and liquid:

𝐿′ 𝜌𝐺
𝐹𝐿𝑉 𝑏𝑜𝑡𝑡𝑜𝑚 = √ = 0.03171
𝐺′ 𝜌𝐿

𝐿 𝜌𝐺
𝐹𝐿𝑉 𝑡𝑜𝑝 = √ = 0.008554
𝐺 𝜌𝐿

Taking plate spacing as 0.6 m.

Assuming a nonfoaming system, with hole size less than 6.5mm, weir height less
than 15% of the plate spacing, and assuming hole-active area as 10%.

Using the correlation between 𝐹𝐿𝑉 and 𝐾1 [Ref 64, Figure 17.34],

Bottom 𝐾1 = 0.11.

Top 𝐾1 = 0.095

After correcting for Surface Tension,

23.1119 0.2
𝐵𝑜𝑡𝑡𝑜𝑚 𝐾1 = 0.11 × ( ) = 0.1132
20
24.3334 0.2
𝑇𝑜𝑝 𝐾1 = 0.095 × ( ) = 0.0988
20
(𝜌𝐿 −𝜌𝑉 )
Bottom 𝑢𝑓 = 𝐾1 × √ 𝜌𝑉
= 4.999 𝑚/𝑠

(𝜌𝐿 −𝜌𝑉 )
Top 𝑢𝑓 = 𝐾1 × √ = 4.596 𝑚/𝑠
𝜌𝑉

Designing for 85% flooding at maximum flow rate:

Bottom 𝑢𝑚𝑎𝑥 = 𝑢𝑓 × 0.85 = 4.2491 𝑚/𝑠

Top 𝑢𝑚𝑎𝑥 = 𝑢𝑓 × 0.85 = 3.9063 𝑚/𝑠

Maximum volumetric flow rate:

𝐺′×𝑚𝑤
Bottom 𝑄𝑚 = = 37.628 𝑚3 /𝑠
𝜌𝐺 ×3600

𝐺×𝑚𝑤
Top 𝑄𝑚 = 𝜌 = 37.973 𝑚3 /𝑠
𝐺 ×3600

Taking downcomer area as 12% of total:

Column cross-sectional area:

𝑄𝑚 1
Bottom = 𝑢𝑚𝑎𝑥
× 0.88 = 10.063 𝑚2

𝑄𝑚 1
Top = 𝑢𝑚𝑎𝑥
× 0.88 = 11.0467 𝑚2

Column diameter:
 𝐴×4 6.467×4
Bottom = √ 𝜋
=√ 𝜋
= 3.5795 𝑚

𝐴×4 37.92×4
Top = √ 𝜋
=√ 𝜋
= 3.7503 𝑚

Hence the column diameter is taken as the larger of the two, 3.7503 m, and the
perforated area of the plates below the feed are reduced accordingly.

Provisional Plate Design:

Column Diameter = 3.7503 m

Column Area 𝐴𝐶 = 11.0467 m2

Downcomer Area (at 12%) 𝐴𝐷 = 0.12 × 𝐴𝐶 = 1.3256 𝑚2

Net Area 𝐴𝑁 = 𝐴𝐶 − 𝐴𝐷 = 10.165 − 1.220 = 9.7211 𝑚2

Active Area 𝐴𝐴 = 𝐴𝐶 − 2𝐴𝐷 = 8.3955 𝑚2

Hole Area, taking 10% of 𝐴𝐴 as first trial 𝐴𝐻 = 0.10𝐴𝐴 = 0.839550 𝑚2

Weir Length, using the correlation between downcomer area and weir length
[Ref 64, Figure 17.39]:
𝑙𝑤 = 0.76 × 𝑑 = 2.8503 𝑚

Taking: 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 = 50 𝑚𝑚, 𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑑ℎ = 5 𝑚𝑚, 𝑃𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 5 𝑚𝑚

Checking for Weeping:

𝐿′ × 𝑚𝑤
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑖𝑞𝑢𝑖𝑑 𝑅𝑎𝑡𝑒 𝑚𝑚𝑎𝑥 = = 21.936 𝑘𝑔/𝑠
3600
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑖𝑞𝑢𝑖𝑑 𝑅𝑎𝑡𝑒 𝑎𝑡 70% 𝑡𝑢𝑟𝑛𝑑𝑜𝑤𝑛 𝑚0.7 = 0.7 × 𝑚𝑚𝑎𝑥 = 15.3554 𝑘𝑔/𝑠

Height of Weir Liquid Crest ℎ𝑜𝑤 :

𝑚𝑚𝑎𝑥 2/3
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = [ ] = 0.04479 𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 𝑙𝑤
𝑚0.7 2/3
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = [ ] = 0.03531 𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 𝑙𝑤

At minimum rate, ℎ𝑤 + ℎ𝑜𝑤 = 85.3108 𝑚𝑚

From the Weep-point Correlation [Ref 64, Figure 17.37], 𝐾2 = 30.8

𝐾2 −0.90(25.4−𝑑ℎ )
Minimum velocity through hole 𝑢ℎ (𝑚𝑖𝑛) = 0.5
𝜌𝑉
= 2.3451 𝑚/𝑠

𝑄𝑉 ×0.7
Actual minimum vapour velocity = 𝐴𝐻
= 31.374 𝑚/𝑠

Since actual minimum velocity is higher than the weep point velocity, weeping
will not occur even at minimum operating conditions.

Plate Pressure Drop:

Dry plate drop:
𝑄𝑉
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ ℎ𝑜𝑙𝑒𝑠: 𝑢ℎ = = 44.8195 𝑚/𝑠
𝐴𝐻

From Correlation between Orifice Coefficient and perforated area [Ref 64, Figure
𝐴
17.42], with 𝐻 ≈ 0.1, plate thickness / plate diameter = 1, we obtain 𝐶0 = 0.84
𝐴𝑃

𝑢ℎ 2 𝜌𝐺
ℎ𝑑 = 51 [ ] = 74.75 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝐶0 𝜌𝐿
12.5×103
Residual Head ℎ𝑟 = 𝜌𝐿
= 15.40 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

Total plate pressure drop ℎ𝑡 = ℎ𝑑 + ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑟 = 139.89 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

Downcomer Liquid Backup

ℎ𝑎𝑝 = ℎ𝑤 − 10 = 40𝑚𝑚

Area under apron, 𝐴𝑎𝑝 = 𝑙𝑤 × ℎ𝑎𝑝 × 10−3 = 0.11401 𝑚2

𝑚𝑚𝑎𝑥
Downcomer head loss ℎ𝑑𝑐 = 166 [ ] = 9.3221 𝑚𝑚
𝜌𝐿 𝐴𝑎𝑝

1
Backup in downcomer ℎ𝑏𝑐 = ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑡 + ℎ𝑑𝑐 = 199.257 𝑚𝑚 < 2 (0.6 + 𝑙𝑤 ) 𝑚

Hence plate spacing of 0.6m is acceptable.

Residence Time:
𝐴𝐷 ℎ𝑏𝑐 𝜌𝐿
𝑡𝑟 = = 9.7764 𝑠 > 3 𝑠
𝑚𝑚𝑎𝑥

Entrainment:
𝑄𝑉
𝑢𝑣 = = 3.8708 𝑚/𝑠
𝐴𝑁
𝑢
Percent flooding 𝑓% = 𝑢𝑣 = 77.43%
𝑓

From Entrainment Correlation with 𝐹𝐿𝑉 [Ref 64, Figure 17.36], Ψ = 5.5 × 10−2 , well
below 0.1

Thus, the percent flooding is below the design figure of 85% and entrainment
will not occur.

Number of Holes:
2
𝜋𝑑ℎ
Area of one hole = 𝑎𝐻 = 4
= 1.964 × 105 𝑚2
𝐴𝐻
Number of holes = 𝑎𝐻
= 42758

Height of Tower:

Given 38 plates, with 0.6 m spacing between them, a height of 22.8 m is

obtained. Adding a 0.5 m manhole at feed stage, a manhole every 10 trays in
the column, 1 m height at top of column, and a skirt of height 4 m, the total
height obtained is 29.8 m.

Final Column Specifications:

Column Diameter 3.7503 m

Tower Height 29.8 m
Cross-Sectional Area 11.0467 sqm
Number of Plates 38
Plate Type Sieve
Downcomer Area 1.3256 sqm (12%)
Total Hole Area 0.8395 sqm
Hole Diameter 5 mm
Total Number of Holes 42758
Weir Height 50 mm
Weir Length 2.8503 m
Plate Spacing 0.6 m
Plate Material Mild Steel
Downcomer Material Mild Steel
Plate thickness 5 mm
Turn-down 70%
Reflux Drum:

The Reflux Drum was sized such that fifteen minutes of accumulation would
result in the vessel becoming half-full. Given the volumetric Reflux Rate of
418.881 l/min, the resultant volume of the Reflux Drum is 12566.44 L.

Using an L/D aspect ratio of 3 for a horizontal vessel:

𝑉𝑜𝑙𝑢𝑚𝑒 = 12.566 𝑚3 = 3𝜋𝐷 2 𝐿 = 3𝜋𝐷 3

𝐷 = 1.101 𝑚, 𝐿 = 3.302 𝑚
STYCOL: Distillation Column

The STYCOL Distillation Column is used to produce the final product Styrene
of the target purity. It takes in input through stream LLVOUT, and produces
output through streams STYPDT, LIQDIST & VAPDIST. Through Aspen
Simulation, the stream data is obtained:
Stream Data:

Column Design Specifications:

Condenser Type Partial (Vapour/Liquid) Condenser

Molar Reflux Ratio 2.5

Number of Stages 30

Feed Stage 15, Fed Above Stage

Based on the above considerations, the Column is designed as a Plate Column

with Sieve plates, chosen for their economic advantage, wide operating range,
and ability to operate at high Vapour flow rates.

A Plate Column is designed, with Sieve Plates, for above specs, between stages
1-29:
Flow Rates:

Feed Rate 𝐹 = 304.008 kmol/h

Distillate Rate 𝐷 = 23.68527 kmol/h

Bottoms Rate 𝐵 = 280.3228271 kmol/h

The feed enters as 303.87 kmol/h Liquid feed and 0.13378 kmol/h Vapor Feed.
∴ 𝑉𝑎𝑝𝑜𝑢𝑟 𝑅𝑎𝑡𝑒 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑 𝑉 = 𝐷(1 + 𝑅) = 23.68527(1 + 2.5) = 82.898 𝑘𝑚𝑜𝑙/ℎ
𝑉𝑎𝑝𝑜𝑢𝑟 𝑅𝑎𝑡𝑒 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑 𝑉 ′ = 𝐷(1 + 𝑅) − 𝐹𝑣 = 82.898 − 0.13378 = 82.7606 𝑘𝑚𝑜𝑙/ℎ
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑎𝑏𝑜𝑣𝑒 𝑓𝑒𝑒𝑑, 𝐿 = 𝑅𝐷 = 2.5 × 23.68527 = 59.21318 𝑘𝑚𝑜𝑙/ℎ
𝐿𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤 𝑏𝑒𝑙𝑜𝑤 𝑓𝑒𝑒𝑑, 𝐿′ = 𝑅𝐷 + 𝐹 = 52.21318 + 304.0081 = 363.2213 𝑘𝑚𝑜𝑙/ℎ

Physical Properties:

Assuming column efficiency of 60%, ignoring reboiler:

30
Number of real stages = = 50
0.6

Assuming pressure drop per plate is 100 mm water.

Column pressure drop = 100 × 10−3 × 1000 × 9.81 × 50 = 49050 𝑃𝑎

Top Tray Properties:

Temperature = 85°𝐶

𝑉𝑎𝑝𝑜𝑢𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 2.46217 𝑘𝑔/𝑚3

𝐿𝑖𝑞𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 863.867 𝑘𝑔/𝑚3

𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 24.7639 𝑚𝑁/𝑚
𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑊𝑒𝑖𝑔ℎ𝑡 = 72.87357 𝑔/𝑚𝑜𝑙

Bottom Tray Properties:

Temperature = 147.729 °𝐶

𝑉𝑎𝑝𝑜𝑢𝑟 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 3.27824 𝑘𝑔/𝑚3

𝐿𝑖𝑞𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 784.094 𝑘𝑔/𝑚3
𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑇𝑒𝑛𝑠𝑖𝑜𝑛 = 17.993 𝑚𝑁/𝑚
𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑊𝑒𝑖𝑔ℎ𝑡 = 104.1518 𝑔/𝑚𝑜𝑙

Column Diameter:

Neglecting changes in molar flow rate due to differences in molecular weight

between vapour and liquid:

𝐿′ 𝜌𝐺
𝐹𝐿𝑉 𝑏𝑜𝑡𝑡𝑜𝑚 = √ = 0.2838
𝐺′ 𝜌𝐿
 𝐿 𝜌𝐺
𝐹𝐿𝑉 𝑡𝑜𝑝 = √ = 0.03813
𝐺 𝜌𝐿

Taking plate spacing as 0.9 m.

Assuming a nonfoaming system, with hole size less than 6.5mm, weir height less
than 15% of the plate spacing, and assuming hole-active area as 10%.

Using the correlation between 𝐹𝐿𝑉 and 𝐾1 [Ref 64, Figure 17.34],

Bottom 𝐾1 = 0.08.

Top 𝐾1 = 0.1

After correcting for Surface Tension,

17.993 0.2
𝐵𝑜𝑡𝑡𝑜𝑚 𝐾1 = 0.11 × ( ) = 0.078
20
24.7639 0.2
𝑇𝑜𝑝 𝐾1 = 0.095 × ( ) = 0.104
20
(𝜌𝐿 −𝜌𝑉 )
Bottom 𝑢𝑓 = 𝐾1 × √ 𝜌𝑉
= 1.209 𝑚/𝑠

(𝜌𝐿 −𝜌𝑉 )
Top 𝑢𝑓 = 𝐾1 × √ = 1.952 𝑚/𝑠
𝜌𝑉

Designing for 85% flooding at maximum flow rate:

Bottom 𝑢𝑚𝑎𝑥 = 𝑢𝑓 × 0.85 = 1.027 𝑚/𝑠

Top 𝑢𝑚𝑎𝑥 = 𝑢𝑓 × 0.85 = 1.660 𝑚/𝑠

Maximum volumetric flow rate:

𝐺′×𝑚𝑤
Bottom 𝑄𝑚 = 𝜌 = 0.7304 𝑚3 /𝑠
𝐺 ×3600

𝐺×𝑚𝑤
Top 𝑄𝑚 = 𝜌 = 0.6816 𝑚3 /𝑠
𝐺 ×3600

Taking downcomer area as 12% of total:

Column cross-sectional area:

𝑄𝑚 1
Bottom = 𝑢𝑚𝑎𝑥
× 0.88 = 0.8078 𝑚2

𝑄𝑚 1
Top = 𝑢𝑚𝑎𝑥
× 0.88 = 0.4668 𝑚2

Column diameter:

𝐴×4 6.467×4
Bottom = √ 𝜋
=√ 𝜋
= 1.0141 𝑚

𝐴×4 37.92×4
Top = √ 𝜋
=√ 𝜋
= 0.7709 𝑚
Hence the column diameter is taken as the larger of the two, 1.0141 m, and the
perforated area of the plates above the feed are reduced accordingly.

Provisional Plate Design:

Column Diameter = 1.0141 m

Column Area 𝐴𝐶 = 0.8078 m2

Downcomer Area (at 12%) 𝐴𝐷 = 0.12 × 𝐴𝐶 = 0.0969 𝑚2

Net Area 𝐴𝑁 = 𝐴𝐶 − 𝐴𝐷 = 10.165 − 1.220 = 0.7108 𝑚2

Active Area 𝐴𝐴 = 𝐴𝐶 − 2𝐴𝐷 = 0.6139 𝑚2

Hole Area, taking 10% of 𝐴𝐴 as first trial 𝐴𝐻 = 0.10𝐴𝐴 = 0.06139 𝑚2

Weir Length, using the correlation between downcomer area and weir length
[Ref 64, Figure 17.39]:
𝑙𝑤 = 0.76 × 𝑑 = 0.7707 𝑚

Taking: 𝑊𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 = 50 𝑚𝑚, 𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑑ℎ = 5 𝑚𝑚, 𝑃𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 5 𝑚𝑚

Checking for Weeping:

𝐿′ × 𝑚𝑤
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑖𝑞𝑢𝑖𝑑 𝑅𝑎𝑡𝑒 𝑚𝑚𝑎𝑥 = = 10.5084 𝑘𝑔/𝑠
3600
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐿𝑖𝑞𝑢𝑖𝑑 𝑅𝑎𝑡𝑒 𝑎𝑡 70% 𝑡𝑢𝑟𝑛𝑑𝑜𝑤𝑛 𝑚0.7 = 0.7 × 𝑚𝑚𝑎𝑥 = 7.3559 𝑘𝑔/𝑠

Height of Weir Liquid Crest ℎ𝑜𝑤 :

𝑚𝑚𝑎𝑥 2/3
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = [ ] = 0.06712 𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 𝑙𝑤
𝑚0.7 2/3
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑜𝑤 = [ ] = 0.05291 𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿 𝑙𝑤

At minimum rate, ℎ𝑤 + ℎ𝑜𝑤 = 102.914 𝑚𝑚

From the Weep-point Correlation [Ref 64, Figure 17.37], 𝐾2 = 30.9

𝐾2 −0.90(25.4−𝑑ℎ )
Minimum velocity through hole 𝑢ℎ (𝑚𝑖𝑛) = 0.5
𝜌𝑉
= 20.76 𝑚/𝑠

𝑄𝑉 ×0.7
Actual minimum vapour velocity = = 8.328 𝑚/𝑠
𝐴𝐻

Since actual minimum velocity is lower than the weep point velocity, weeping
will occur at minimum operating conditions. Reducing hole area to 4% of active
area:

𝐴𝐻 = 0.02𝐴𝐴 = 0.024556 𝑚2
𝑄𝑉 ×0.7 𝑚
New Actual minimum vapour velocity = 𝐴𝐻
= 20.82 𝑠
> 20.76

With the new hole area, weeping will not occur even at minimum operating
conditions.
Plate Pressure Drop:

Dry plate drop:

𝑄𝑉
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑡ℎ𝑟𝑜𝑢𝑔ℎ ℎ𝑜𝑙𝑒𝑠: 𝑢ℎ = = 29.743 𝑚/𝑠
𝐴𝐻

From Correlation between Orifice Coefficient and perforated area [Ref 64, Figure
𝐴𝐻
17.42], with 𝐴𝑃
≈ 0.1, plate thickness / plate diameter = 1, we obtain 𝐶0 = 0.84

𝑢ℎ 2 𝜌𝐺
ℎ𝑑 = 51 [ ] = 267.336 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝐶0 𝜌𝐿
12.5×103
Residual Head ℎ𝑟 = = 15.94 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
𝜌𝐿

Total plate pressure drop ℎ𝑡 = ℎ𝑑 + ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑟 = 333.345 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

Downcomer Liquid Backup

ℎ𝑎𝑝 = ℎ𝑤 − 10 = 40𝑚𝑚

Area under apron, 𝐴𝑎𝑝 = 𝑙𝑤 × ℎ𝑎𝑝 × 10−3 = 0.0308 𝑚2

𝑚
Downcomer head loss ℎ𝑑𝑐 = 166 [𝜌 𝑚𝑎𝑥
𝐴
] = 31.3688 𝑚𝑚
𝐿 𝑎𝑝

1
Backup in downcomer ℎ𝑏𝑐 = ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑡 + ℎ𝑑𝑐 = 414.781 𝑚𝑚 < (0.9 + 𝑙𝑤 ) 𝑚
2

Hence plate spacing of 0.9m is acceptable.

Residence Time:
𝐴𝐷 ℎ𝑏𝑐 𝜌𝐿
𝑡𝑟 = = 3.000 𝑠
𝑚𝑚𝑎𝑥

Entrainment:
𝑄𝑉
𝑢𝑣 = = 1.0275 𝑚/𝑠
𝐴𝑁
𝑢
Percent flooding 𝑓% = 𝑢𝑣 = 85%
𝑓

From Entrainment Correlation with 𝐹𝐿𝑉 [Ref 64, Figure 17.36], Ψ = 1 × 10−2 , well
below 0.1

Thus, the percent flooding satisfies the design requirement.

Number of Holes:
2
𝜋𝑑ℎ
Area of one hole = 𝑎𝐻 = 4
= 1.964 × 105 𝑚2
𝐴𝐻
Number of holes = 𝑎𝐻
= 1251

Height of Tower:
Given 49 plates, with 0.9 m spacing between them, a height of 44.1 m is
obtained. Adding a 0.5 m manhole at feed stage, a manhole every 10 trays in
the column, 1 m height at top of column, and a skirt of height 4 m, the total
height obtained is 52.1 m.

Final Column Specifications:

Column Diameter 1.0141 m

Tower Height 52.1 m
Cross-Sectional Area 0.8078 sqm
Number of Plates 49
Plate Type Sieve
Downcomer Area 0.0969 sqm (12%)
Total Hole Area 0.0.0614 sqm
Hole Diameter 5 mm
Total Number of Holes 1251
Weir Height 50 mm
Weir Length 0.7707 m
Plate Spacing 0.9 m
Plate Material Mild Steel
Downcomer Material Mild Steel
Plate thickness 5 mm
Turn-down 70%
Reflux Drum:

The Reflux Drum was sized such that fifteen minutes of accumulation would
result in the vessel becoming half-full. Given the volumetric Reflux Rate of 95.03
l/min, the resultant volume of the Reflux Drum is 2851.04 L.

Using an L/D aspect ratio of 3 for a horizontal vessel:

𝑉𝑜𝑙𝑢𝑚𝑒 = 2.85104 𝑚3 = 3𝜋𝐷 2 𝐿 = 3𝜋𝐷 3
𝐷 = 0.6713 𝑚, 𝐿 = 3.0139 𝑚

Apart from Distillation Columns, Separations also take place in 4 Flash vessels.
These were modelled as FLASH2 and FLASH3 blocks in AspenPlus.
FLASH1: Flash Drum

The Flash 1 Column takes input from stream FLH1FEED, consisting mainly of
Ethylbenzene and Diethylbenzene, which is the Bottoms output from COL1. The
Vapour stream outlet of the Flash is sent back to the Distillation column as
reflux, and the Liquid Flash output is sent to COL2 for further separation of EB
from DEB.

Designed as a Vertical Flash Drum.

Stream Data:

Permissible vapour velocity

𝜌𝐿 − 𝜌𝑉
𝑢𝑝𝑒𝑟𝑚 = 𝐾𝐷𝑅𝑈𝑀 √
𝜌𝑉

𝐾𝐷𝑅𝑈𝑀 is an empirical constant that depends on the type of rum. Assuming 85%
flooding with no demister, with a maximum of 5% entrainment, using the
Blackwell-Watkins’ correlation equation for 𝐾𝐷𝑅𝑈𝑀 ,

𝐾𝐷𝑅𝑈𝑀 = exp (𝐴 + 𝐵𝑙𝑛𝐹𝐿𝑉 + 𝐶(𝑙𝑛𝐹𝐿𝑉 )2 + 𝐷(𝑙𝑛𝐹𝐿𝑉 )3 + 𝐸(𝑙𝑛𝐹𝐿𝑉 )4

 𝑊𝐿 𝜌𝑉
𝐹𝐿𝑉 = √ = 0.0290
𝑊𝑉 𝜌𝐿

Where 𝑊𝐿 and 𝑊𝑉 are the mass flow rates of liquid and vapour streams.

Using the values of the empirical constants in the above formula [Ref 82 Eq 2-
60],

A = -1.8775, B = -0.8146, C =-0.1871, D =-0.0145, E=-0.0010

𝐾𝐷𝑅𝑈𝑀 = 0.4285 𝑓𝑡/𝑠
𝑢𝑝𝑒𝑟𝑚 = 11.7 𝑓𝑡/𝑠 = 3.566 𝑚/𝑠

Cross Sectional Area and Column Diameter

In accordance with maximum permissible vapour velocity,

𝑄𝑉
𝐴𝐶 = = 4.0211 𝑚2
𝑢𝑝𝑒𝑟𝑚

Column Diameter 𝑑 = 2.2627 𝑚

Assuming an L/D ratio of 3,

𝐿 = 6.788 𝑚.

Final Specifications

Flash Column Type Vertical Flash Drum

Diameter 2.2627 m
Height of Column 6.788 m
FLASH2: Flash Drum

The Flash 2 Column takes input from stream FLH2FEED, consisting mainly of
Ethylbenzene and Diethylbenzene, which is the Bottoms output from COL2. The
Vapour stream outlet of the Flash is sent back to the Distillation column as
reflux, and the Liquid Flash output is pumped back into the Transalkylator as
recycle.

Designed as a Vertical Flash Drum.

Stream Data:

Permissible vapour velocity

𝜌𝐿 − 𝜌𝑉
𝑢𝑝𝑒𝑟𝑚 = 𝐾𝐷𝑅𝑈𝑀 √
𝜌𝑉

𝐾𝐷𝑅𝑈𝑀 is an empirical constant that depends on the type of rum. Assuming 85%
flooding with no demister, with a maximum of 5% entrainment, using the
Blackwell-Watkins’ correlation equation for 𝐾𝐷𝑅𝑈𝑀 ,
 𝐾𝐷𝑅𝑈𝑀 = exp (𝐴 + 𝐵𝑙𝑛𝐹𝐿𝑉 + 𝐶(𝑙𝑛𝐹𝐿𝑉 )2 + 𝐷(𝑙𝑛𝐹𝐿𝑉 )3 + 𝐸(𝑙𝑛𝐹𝐿𝑉 )4

𝑊𝐿 𝜌𝑉
𝐹𝐿𝑉 = √ = 0.00661
𝑊𝑉 𝜌𝐿

Where 𝑊𝐿 and 𝑊𝑉 are the mass flow rates of liquid and vapour streams.

Using the values of the empirical constants in the above formula [Ref 82 Eq 2-
60],

A = -1.8775, B = -0.8146, C =-0.1871, D =-0.0145, E=-0.0010

𝐾𝐷𝑅𝑈𝑀 = 0.27 𝑓𝑡/𝑠
𝑢𝑝𝑒𝑟𝑚 = 11.9205 𝑓𝑡/𝑠 = 3.6332 𝑚/𝑠

Cross Sectional Area and Column Diameter

In accordance with maximum permissible vapour velocity,

𝑄𝑉
𝐴𝐶 = = 8.8623 𝑚2
𝑢𝑝𝑒𝑟𝑚

Column Diameter 𝑑 = 3.3591 𝑚

Assuming an L/D ratio of 3,

𝐿 = 10.07743 𝑚.

Final Specifications

Flash Column Type Vertical Flash Drum

Diameter 3.3591 m
Height of Column 10.0774 m
FLASH3: Flash Drum
FLASH3 is a 3-component Flash, with two output liquid streams and a single
output vapour stream. It is designed as a Horizontal Flash Drum. The properties
of the two-component liquid mixture is approximated to be that of a
homogenous solution for the purposes of the sizing.

Stream Data:

Permissible vapour velocity

𝜌𝐿 − 𝜌𝑉
𝑢𝑝𝑒𝑟𝑚 = 𝐾𝐷𝑅𝑈𝑀 √
𝜌𝑉

𝐾𝐷𝑅𝑈𝑀 is an empirical constant that depends on the type of rum. Assuming 85%
flooding with no demister, with a maximum of 5% entrainment, using the
Blackwell-Watkins’ correlation equation for 𝐾𝐷𝑅𝑈𝑀 ,
 𝐾𝐷𝑅𝑈𝑀 = exp (𝐴 + 𝐵𝑙𝑛𝐹𝐿𝑉 + 𝐶(𝑙𝑛𝐹𝐿𝑉 )2 + 𝐷(𝑙𝑛𝐹𝐿𝑉 )3 + 𝐸(𝑙𝑛𝐹𝐿𝑉 )4

For a Horizontal Drum,

𝐾𝐷𝑅𝑈𝑀 = 1.25𝐾𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙

𝑊𝐿 𝜌𝑉
𝐹𝐿𝑉 = √ = 0.0285
𝑊𝑉 𝜌𝐿

Where 𝑊𝐿 and 𝑊𝑉 are the mass flow rates of liquid and vapour streams. Here 𝑊𝐿
is the total mass flow rate of the two liquid streams, and 𝜌𝐿 is approximated to
be the mass-averaged density.

Using the values of the empirical constants in the above formula [Ref 82 Eq 2-
60],

A = -1.8775, B = -0.8146, C =-0.1871, D =-0.0145, E=-0.0010

𝐾𝐷𝑅𝑈𝑀 = 0.065 𝑓𝑡/𝑠
𝑢𝑝𝑒𝑟𝑚 = 3.893 𝑓𝑡/𝑠 = 1.18667 𝑚/𝑠

Cross Sectional Area and Column Diameter

In accordance with maximum permissible vapour velocity,

𝑄𝑉
𝐴𝐶 = = 12.0836 𝑚2
𝑢𝑝𝑒𝑟𝑚

Column Diameter 𝑑 = 3.92241 𝑚

Assuming an L/D ratio of 5, which is standard for a Horizontal Drum,

𝐿 = 19.612 𝑚.

Final Specifications

Flash Column Type Horizontal Flash Drum

Diameter 3.9224 m
Length of Column 19.612 m
FLASH4: Flash Drum
Designed as a Vertical Flash Drum.

Stream Data:

Permissible vapour velocity

𝜌𝐿 − 𝜌𝑉
𝑢𝑝𝑒𝑟𝑚 = 𝐾𝐷𝑅𝑈𝑀 √
𝜌𝑉
𝐾𝐷𝑅𝑈𝑀 is an empirical constant that depends on the type of rum. Assuming 85%
flooding with no demister, with a maximum of 5% entrainment, using the
Blackwell-Watkins’ correlation equation for 𝐾𝐷𝑅𝑈𝑀 ,

𝐾𝐷𝑅𝑈𝑀 = exp (𝐴 + 𝐵𝑙𝑛𝐹𝐿𝑉 + 𝐶(𝑙𝑛𝐹𝐿𝑉 )2 + 𝐷(𝑙𝑛𝐹𝐿𝑉 )3 + 𝐸(𝑙𝑛𝐹𝐿𝑉 )4

𝑊𝐿 𝜌𝑉
𝐹𝐿𝑉 = √ = 0.0211
𝑊𝑉 𝜌𝐿

Where 𝑊𝐿 and 𝑊𝑉 are the mass flow rates of liquid and vapour streams.

Using the values of the empirical constants in the above formula [Ref 82 Eq 2-
60],

A = -1.8775, B = -0.8146, C =-0.1871, D =-0.0145, E=-0.0010

𝐾𝐷𝑅𝑈𝑀 = 0.402 𝑓𝑡/𝑠
𝑢𝑝𝑒𝑟𝑚 = 17.768 𝑓𝑡/𝑠 = 5.4153 𝑚/𝑠

Cross Sectional Area and Column Diameter

In accordance with maximum permissible vapour velocity,

𝑄𝑉
𝐴𝐶 = = 0.4907 𝑚2
𝑢𝑝𝑒𝑟𝑚

Column Diameter 𝑑 = 0.7905 𝑚

Assuming an L/D ratio of 3,

𝐿 = 2.3714 𝑚.

Final Specifications

Flash Column Type Vertical Flash Drum

Diameter 0.7905 m
Height of Column 2.3714 m
B2b: Distillation Columns Mechanical Design
COL1: Distillation Column - Tray Tower (Sieve Plates)
COLUMN DESIGN

Selection of Shell Material

The Shell material used is Carbon Steel R275 (as per IS:2041-2009). It is
relatively inexpensive and readily available for manufacturing. It can withstand
stress up to 15000 psia (103.4 MPa). Its tensile strength ranges from 390 to 510
MPa, with a density of approximately 7850 kg/m3 [IS 2041 2009]

Shell Thickness

As the design pressure is below atmospheric conditions, the shell thickness will
have to be designed according to the standard for cylindrical shells under
external pressure [77 Section 3.3.3.2].
2
𝐷𝑜 1.15𝑝 𝐾𝜎𝐿 3
𝑡= [ + 0.053 ( ) ]
100 𝜎 𝐷𝑜

For Carbon Steel, at design temperature 114°C and design pressure of 0.304
bar, using the material properties as described in [77], the thickness is obtained
as:
𝑡 = 12.5 𝑚𝑚

Using 𝑡𝑠 = 18.5 𝑚𝑚 thickness including corrosion allowance of 6 mm. This value is

in accordance to IS 2844-1964.
𝒎𝒂𝒋𝒐𝒓 𝒂𝒙𝒊𝒔
Standard ellipsoidal head with 𝒎𝒊𝒏𝒐𝒓 𝒂𝒙𝒊𝒔
= 𝟐:

The minimum thickness is same as calculated above: 18.5 mm.

Insulation Material

The insulation material is taken as Asbestos. The thickness of insulation

considered is 50 mm, and density is 270 kg/m3.

PLATE DESIGN

Selection of Plate Type

As mentioned in Deliverable 4, due to the capability of sieve plates to operate at

a large range of flow rates (typically 50% to 120% [64 page 858]), high
capacity, low susceptibility to fouling and lower cost of installation, the Plate
Type chosen was the Sieve Plate.

Selection of Plate Material

The Plate material used is Carbon Steel (IS:2041-2009). It is relatively

inexpensive and readily available for manufacturing. It can withstand pressures
of up to 15000 psia. Its tensile strength ranges from 380 to 515 MPa, with a
density of approximately 7850 kg/m3 [IS 2041 2009]

Plate Construction

As the column diameter is well above 1.2 m, Stacked Plates will not be used.
The plate will be welded onto the vessel wall using a support ring of 50 mm
width. Due to the larger diameter, the plates will have to be supported
underneath with beams of 50 mm width. With a 0.6 m spacing between each
beam, a total of 6 such beams will be required.

Downcomers

The segmental or chord downcomer is used for the plate design.

Feed inlets

Feed liquid is introduced vertically downward into the downcomer. An additional

0.5 m spacing is provided for the downcomer leading to the feed stream.

Tray manways

Rectangular manholes of dimensions 40cm x 50cm are to be provided every 10

trays in the column, resulting in 3 manholes. An additional manhole is provided
above the feed stage.

Plate Hydraulic Design

As part of the sizing process in Deliverable 4, the plate hydraulic design was
performed after taking into consideration the operating conditions (85%
flooding, 70% turndown). Using a weir height of 0.05 m, a weir length of 2.734
m was obtained for plate spacing of 0.6 m and thickness 5 mm.

Calming zones of width 100 mm is provided at the inlet and outlet sides of the
plate.

Hole Specifications

The hole diameter is set as 5 mm. Using an equilateral triangular pattern, the
pitch 𝑙𝑝 is calculated as [64 page 872]:
2
𝐴ℎ 𝑑ℎ
= 0.9 [ ]
𝐴𝑝 𝑙𝑝

From the calculations shown in Deliverable 4,

𝐴ℎ = 0.7725 𝑚2

Assuming minimal obstruction caused by the support rings, beams and calming
zones, the perforated area can be taken as the total active area. 𝐴𝑝 = 7.725.

Thus, we obtain 𝑙𝑝 = 3𝑑ℎ = 15 𝑚𝑚.

Hence hole pitch is 3 times hole diameter.

Total Plate Pressure Drop

 The total plate pressure drop was obtained in Deliverable as 194.482 mm liquid,
or a maximum of 1602.1 Pa in the top tray. The pressure drop across all plates
will not exceed this amount. Hence, approximately 0.5 bar pressure difference
exists between bottom and top plates.

Downcomer Liquid Backup

The height of the apron above the plate was taken as 40 mm. The maximum
downcomer backup under the specified operating range does not exceed the
outlet weir, as calculated in Deliverable 4.

Downcomer Residence Time

The residence time was obtained as 5.774 seconds, which is well above the
recommended 3 seconds [64 page 877].

Thus, the Plate Specifications are finalized to:

Plate number 1-32 Turn-down 70% of max rate

Plate inside 3.5975 m Plate material Carbon steel A
diameter
Hole size 5 mm Downcomer Carbon steel
material
Hole pitch 15 mm (equi. Plate spacing 0.6 m
tri.)
Total holes - Plate thickness 5 mm
Active holes 39344 Plate pressure 194.48 mm liq (1602
drop Pa)
Weir Length 2.734 m Weir Height 50 mm
Downcomer Area 1.220 sq m Apron Height 40 mm
Support Beam 50 mm Support Ring 50 mm
thickness thickness
Beam count 6 Beam spacing 0.6 m
STRESSES DEVELOPED IN COLUMN

Axial and Circumferential stresses

The axial stress resulting from external pressure is given as ([84 page 155])
𝑝𝐷𝑜
𝑓𝑎𝑠 = = 0.4128 𝑀𝑃𝑎
4𝑗𝑡𝑠

Circumferential stress =2𝑓𝑎𝑠 = 0.8257 𝑀𝑃𝑎

Compressive stress caused by dead loads

𝜋
Total mass of shell 𝑚𝑠ℎ𝑒𝑙𝑙 = (𝐷𝑜2 − 𝐷𝑖2 )𝐻𝜌𝑠 = 21725.8 𝑘𝑔
4

Taking 20% extra weight for head covers, flanges, bolting etc.
𝑚𝑠ℎ𝑒𝑙𝑙 ≈ 26071 𝑘𝑔

Shell weight stress [84 page 156]:

𝑚𝑠ℎ𝑒𝑙𝑙 𝑔
𝑓𝑑𝑒𝑎𝑑 𝑤𝑡.𝑠ℎ𝑒𝑙𝑙 = 𝜋 = 2.440 𝑀𝑃𝑎
2 2
4 (𝐷𝑜 − 𝐷 𝑖 )
Mass of column insulation 𝑚𝑖𝑛𝑠 = 𝜋𝐷𝑖𝑛𝑠 𝜌𝑖𝑛𝑠 𝐻𝑡𝑖𝑛𝑠 = 4076.70 𝑘𝑔

Insulation weight stress

𝑚𝑖𝑛𝑠 𝑔
𝑓𝑑𝑒𝑎𝑑 𝑤𝑡 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = = 0.07 𝑀𝑃𝑎
𝜋𝐷𝑖𝑛𝑠 𝑡𝑖𝑛𝑠

Mass of liquid in the column, assuming a maximum depth of ℎ𝑙𝑖𝑞 = ℎ𝑤 + ℎ𝑜𝑤 (Weir
height + Maximum height of liquid crest) in each tray, and 30% additional liquid
held in downcomers:
1.3 × 𝐴𝐴 ℎ𝑙𝑖𝑞 𝑁ℎ𝑙𝑖𝑞 𝜌𝐿 = 20094.06 𝑘𝑔

Stress due to weight of liquid (without considering the thickness for corrosion
allowance):
𝑚𝑙𝑖𝑞 𝑔
𝑓𝑑𝑒𝑎𝑑 𝑤𝑡.𝑙𝑖𝑞𝑢𝑖𝑑 = = 1.38 𝑀𝑃𝑎
𝜋𝐷𝑎𝑣𝑔 (𝑡𝑠 − 𝑐)

Here, 𝐷𝑎𝑣𝑔 is the mean shell diameter and 𝑐 is the corrosion allowance thickness.

Mass of column attachments is taken as 100% of the mass of the shell.

Stress due to column attachments:

𝑚𝑎𝑡𝑡𝑎𝑐ℎ 𝑔
𝑓𝑑𝑒𝑎𝑑 𝑤𝑡.𝑎𝑡𝑡𝑎𝑐ℎ𝑚𝑒𝑛𝑡𝑠 = = 1.49 𝑀𝑃𝑎
𝜋𝐷𝑎𝑣𝑔 (𝑡𝑠 − 𝑐)

Total dead weight stress:

𝑓𝑑𝑒𝑎𝑑 𝑤𝑡 𝑡𝑜𝑡𝑎𝑙 = 𝑓𝑑𝑒𝑎𝑑 𝑤𝑡 𝑠ℎ𝑒𝑙𝑙 + 𝑓𝑑𝑒𝑎𝑑 𝑤𝑡 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 + 𝑓𝑑𝑒𝑎𝑑 𝑤𝑡 𝑙𝑖𝑞𝑢𝑖𝑑 + 𝑓𝑑𝑒𝑎𝑑 𝑤𝑡 𝑎𝑡𝑡𝑎𝑐ℎ𝑚𝑒𝑛𝑡𝑠
= 5.378 𝑀𝑃𝑎

This is much lower than the allowable stress for the shell material chosen. Hence
this design is acceptable.

Axial Stresses due to wind loads

The wind loading depends on wind velocity, air density and shape of the column.
The maximum anticipated wind speed of the location of the plant
(Vishakapatnam) is 11.2 m/s, based on 2018-2019 meteorological data.

Wind loading acting on vertical vessel:

1 2
𝑃𝑤 = 𝐶𝐷 𝜌𝑎𝑖𝑟 𝑉𝑊 𝐴 = 8936.19 𝑃𝑎 (𝐴𝑡 𝑚𝑎𝑥 𝑤𝑖𝑛𝑑 𝑠𝑝𝑒𝑒𝑑)
2
𝐶𝐷 =drag coefficient, 𝜌𝑎𝑖𝑟 =density of air,𝑉𝑊 =wind velocity, 𝐴=projected area of
column normal to direction of wind.

Bending moment acting on the vessel, without guy wiring:

1
𝑀𝑤𝐻 = 𝑃𝑤 𝐻2 𝐷𝑎𝑣𝑔 [ 84 𝑝𝑎𝑔𝑒 159] = 11338.40 𝑘𝑁 𝑚
2
Bending stress due to wind load:
 4𝑀𝑤,𝐻
𝑓𝑤𝑖𝑛𝑑,𝐻 = 2 [84 𝑝𝑎𝑔𝑒 159] = 87.09 𝑀𝑃𝑎
𝜋𝐷𝑎𝑣𝑔 (𝑡𝑠 − 𝑐)

This stress value is close to the maximum permissible stress of the shell.
Therefore, for additional structural support, 4 guy cables equally placed
subtending an angle of 45° at a height H/4 from base are considered.

The maximum bending moment caused by wind load from guyed wire to column
located H/4 above base is given by (ref 5 page 162)
𝑃𝑊 𝐻 2 𝐷𝑒𝑓𝑓 𝑀𝑤𝐻
𝑀𝑤,𝑔𝑢𝑦 = = = 708.65 𝑘𝑁 𝑚
32 16
Corresponding bending stress:
𝑓𝑤𝑖𝑛𝑑,𝐻
𝑓𝑤𝑖𝑛𝑑,𝑔𝑢𝑦 = = 5.443 𝑀𝑃𝑎
16
The compressive stress in column induced by guy wire tension, where angle 45°
is subtended by guy wires onto vertical wall [ref 84 page 162]:
0.04𝑃𝑤 𝐻𝐷𝑎𝑣𝑔
𝑓𝑐𝑜𝑚,𝑔𝑢𝑦 = = 0.760 𝑀𝑃𝑎
𝑡𝑎𝑛𝜃(𝑡𝑠 − 𝑐)𝐷𝑜

The total bending stress of unguyed tower is 85.26 MPa, whereas on addition of
guy wires it reduced to:
𝑓𝑡𝑜𝑡𝑎𝑙,𝑔𝑢𝑦 = 𝑓𝑤𝑖𝑛𝑑,𝑔𝑢𝑦 + 𝑓𝑐𝑜𝑚,𝑔𝑢𝑦 = 6.203 𝑀𝑃𝑎

This is significantly lower than the maximum allowable stress. Therefore, the 45°
guy wire setup is preferred over the self-supporting unguyed tower setup.

Structural Support

A skirt of height 3m is to be installed to provide structural support. This height

has been included in the above stress calculations. Skirt is made of cylindrical
shape (at angle 0 with vertical) to minimise the area required. The minimum
thickness required to withstand the maximum compressive stress produced due
to wind load is found in a similar manner as (ref 5 page 159):
4𝑀𝑤
𝑓𝑤𝑖𝑛𝑑,𝑡𝑜𝑡𝑎𝑙 =
𝜋(𝐷𝑖𝑛𝑠 + 𝑡𝑤𝑖𝑛𝑑 )2 𝑡𝑤𝑖𝑛𝑑

Where 𝑡𝑤𝑖𝑛𝑑 is the skirt thickness. As per IS 2825-1969, this value should be
greater than or equal to 7 mm. Upon solving for 𝑡𝑤𝑖𝑛𝑑 , it is obtained as:
𝑡𝑤𝑖𝑛𝑑 = 0.0109 𝑚

Which is greater than the minimum required value, 7 mm.

The minimum thickness required to withstand the maximum compressive stress

produced due to weight load (both dead weight and maximum active weight) is
obtained as [84 page 156]:
4𝑊𝑚𝑎𝑥
𝑓𝑤𝑒𝑖𝑔ℎ𝑡,𝑡𝑜𝑡𝑎𝑙 =
𝜋(𝐷𝑖 + 𝑡𝑤𝑒𝑖𝑔ℎ𝑡 )𝑡𝑤𝑒𝑖𝑔ℎ𝑡
The value of t obtained is:
𝑡𝑤𝑒𝑖𝑔ℎ𝑡 = 0.0431 𝑚

The greater of the two thickness, 0.0431 𝑚 is taken as the thickness value.

Size of guy wire required for four cables [84 page 162]

Total tensile force in each guy wire on the upwind side, using 𝑛 = 4 for four
cables per wire:
5
𝑃𝑤 𝐻𝑑𝑒𝑓𝑓
𝐹𝑔𝑤 =4 = 23367.52 𝑁
16𝑛𝑠𝑖𝑛𝜃
Using safety factor of 4, and a cast-steel cable, we obtain:

Breaking strength (in tons) 𝑇 = 30𝑑2

𝑇 30𝑑2
𝑇𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = =
𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 4

4𝑇
𝑑 = √ = 0.0144 𝑚
30

Hence, the guy wires are designed with four 0.0144 diameter cables and made
from cast-steel. They are placed at a 45° angle from vertical wall, at one-fourth
of the height of the column. Four such guy wires are placed equidistant from
each other.

Seismic load

As Visakhapatnam falls under the stable zone II of seismic zoning classification

as notified by the seismic zoning committee, Government of India (August
2017), which is considered the most stable zoning classification, and has not
experienced any major seismic activity in the past 40 years, the influence of
seismic load and related stress is not considered. Thus, dynamic seismic analysis
is not performed for the equipment designs, with the assumption that stresses
due to seismic vibrations are negligible compared to stresses due to wind
pressure.

Results Summary of Mechanical Design of COL1: Distillation Column

COLUMN DESIGN
Shell Material Carbon Steel R275 (IS 2041 – 2009)
Shell Thickness 18.5 mm
Insulation Material Asbestos
Insulation Thickness 50 mm
Manhole size 0.4m x 0.5m
PLATE DESIGN
Plate Type Sieve Plate
Plate Material Carbon Steel R275 (IS 2041 – 2009)
Downcomer Type Segmental Downcomer
Weir Length 2.734 m
Weir Height 50 mm
Hole Diameter 5 mm
Hole Pitch 15 mm
Downcomer Area 1.220 sqm (12%)
Apron Height 40 mm
Support Beam thickness 50 mm
Support Ring thickness 50 mm
Beam count 6
Beam spacing 0.6 m
STRESS ANALYSIS
Maximum Weight Stress 5.378 MPa
Total Bending Stress due to Wind 6.203 MPa
Structural Support Four 4-cable Guy Wires at H / 4 at
45° with vertical, equally spaced
Guy wire cable diameter 14.43 mm
Skirt Height 3 m (Cylindrical)
Skirt Thickness 43.1 mm
SEISMIC ANALYSIS
Seismic stresses are assumed to be negligible in comparison to wind stresses
COL2: Distillation Column - Tray Tower (Sieve Plates)
The same procedure of mechanical design as followed for COL1: Distillation
Column, was followed for COL2.

Results Summary of Mechanical Design of COL2: Distillation Column

(Same procedure followed as COL1: Distillation Column)

COLUMN DESIGN
Shell Material Carbon Steel R275 (IS 2041 – 2009)
Shell Thickness 13.2 mm
Insulation Material Asbestos
Insulation Thickness 50 mm
Manhole size 0.4m x 0.5m
PLATE DESIGN
Plate Type Sieve Plate
Plate Material Carbon Steel R275 (IS 2041 – 2009)
Downcomer Type Segmental Downcomer
Weir Length 2.8503 m
Weir Height 50 mm
Hole Diameter 5 mm
Hole Pitch 15 mm
Downcomer Area 1.3256 sqm (12%)
Apron Height 40 mm
Support Beam thickness 50 mm
Support Ring thickness 50 mm
Beam count 6
Beam spacing 0.6 m
STRESS ANALYSIS
Maximum Weight Stress 8.26 MPa
Total Bending Stress due to Wind 15.35 MPa
Structural Support Four 4-cable Guy Wires at H / 4 at
45° with vertical, equally spaced
Guy wire cable diameter 16.94 mm
Skirt Height 4 m (Cylindrical)
Skirt Thickness 28.1 mm
SEISMIC ANALYSIS
Seismic stresses are assumed to be negligible in comparison to wind stresses
STYCOL: Distillation Column - Tray Tower (Sieve
Plates)
The same procedure of mechanical design as followed for COL1: Distillation
Column, was followed for STYCOL. Results Summary of Mechanical Design
of STYCOL: Distillation Column

(Same procedure followed as COL1: Distillation Column)

COLUMN DESIGN
Shell Material Carbon Steel R275 (IS 2041 – 2009)
Shell Thickness 16.72 mm
(Note: Additional 10 mm thickness
provided on top of calculated value to
reduce bending stress due to wind)
Insulation Material Asbestos
Insulation Thickness 50 mm
Manhole size 0.4m x 0.5m
PLATE DESIGN
Plate Type Sieve Plate
Plate Material Carbon Steel R275 (IS 2041 – 2009)
Downcomer Type Segmental Downcomer
Weir Length 0.771 m
Weir Height 50 mm
Hole Diameter 5 mm
Hole Pitch 23.72 mm
Downcomer Area 0.0969 sqm (12%)
Apron Height 40 mm
Support Beam thickness 50 mm
Support Ring thickness 50 mm
Beam count 2
Beam spacing 0.6 m
STRESS ANALYSIS
Maximum Weight Stress 9.05 MPa
Total Bending Stress due to Wind 51.84 MPa
Structural Support Four 4-cable Guy Wires at H / 4 at
45° with vertical, equally spaced
Guy wire cable diameter 8.34 mm
Skirt Height 4 m (Cylindrical)
Skirt Thickness 36.91 mm
SEISMIC ANALYSIS
Seismic stresses are assumed to be negligible in comparison to wind stresses
B3: Calculations for Heat Exchangers
There are totally 14 Heat Transfer Equipment (3 Distillation Column Reboilers, 3
Column condensers, 1 cooler (with utility), and 7 Process Stream Heat
Exchangers) used in the production of 700 TPD of Styrene.

Column Reboilers: HEATEX3, HEATEX4, HEATEX10

Column Condensers: CONDENSER1, CONDENSER2, CONDENSER3

Cooler: COOLER1

Process Stream Heat Exchangers: HEATEX1, HEATEX2, HEATEX5,

HEATEX6, HEATEX7, HEATEX8, HEATEX9

• All the three Distillation Column Reboilers use process streams for
heating, whereas all the three Condensers use cooling water as the utility.
• All heat exchangers are chosen to be of the Shell-and-Tube type, mainly
because of flexibility in design and easy maintenance and repair of such
exchangers. They are ubiquitous in the Process Industry.

Convention: T – Hot stream Temperature | t – Cold Stream Temperature

B3a: Heat Exchanger Equipment Sizing

HEATEX1: Heat Exchanger

Assumption: Number of passes = np = 2
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 420.97 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 33 BTU/(hr-ft2-oF)

= 33*1.8*(1000*0.000293/0.092903) W/(m2-K) = 187.373 W/(m2-K)
(𝑇1−𝑇2)
R= (𝑡2−𝑡1)
= 0.4069

(𝑡2−𝑡1)
S= (𝑇1−𝑡1)
= 0.25447

The above two variables, S and R, are interpreted as the capacity ratio and a
measure of heat exchanger effectiveness.
1−𝑆
√𝑅2 +1 ln ( )
F = LMTD correction Factor = 2
1−𝑅𝑆
= 0.993
(𝑅−1) −1−𝑅+√𝑅2 +1
ln (𝑆2 )
−1−𝑅−√𝑅2 +1
𝑆

Q = Exchanger Duty = 3735.69 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 47.68 m2

Tube Side:
Length of each tube L = 80 in (assumed; will be changed if the requisite
pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 0.75 in | Pitch = PT = 1 in (again

assumed)
𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 392 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 1.59 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 1.15E+04 (Turbulent flow) ➔ utube = = 1.9 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 40

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 0.687 and β = ( ) = 0.627 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 92.842 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 55 in (suitable to have a 392-tube bundle)

Baffle Spacing, B = Ds = 55 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = = 0.947 in, for a square pitch
𝜋𝑑𝑜

Tube Clearance = Ct = PT - do = 0.25 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = = 756.25 sq.in.
𝑃𝑇

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 62.5689 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 53787.74

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 150

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 1.716 and β = ( 𝑠ℎ𝑒𝑙𝑙 ) = 1.072 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 81.442 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.001 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = (ℎ + 𝑅𝑑𝑜 + ( 𝐴𝑜 ) (2𝑘𝑜 ) + ( 𝐴𝑜 ) (ℎ ) + ( 𝐴𝑜 ) 𝑅𝑑𝑖 )
𝑜 𝑖 𝑤𝑎𝑙𝑙 𝑖 𝑖 𝑖

From the values in the above table, we get Uo,cal = 33.55 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 1.67% (< 30%). Hence, we go ahead and calculate shell
and tube-side pressure drops.

Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.00026*144 sq.ft/sq.ft. = 0.03744 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 392*(πdi2/(4*2))

= 0.418 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = = 224.47 kg/(m2-s)
𝐴𝑡

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿𝑇 𝑛𝑝
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡
∗𝑆
psi = 0.296 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.077 psi

Sk = Relative Density of tube-side fluid = 0.8

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 0.373 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 1

Friction factor, f = 0.0015*144 sq.ft/sq.ft. = 0.216 sq.ft./sq.ft. ([85], Fig.29)

𝑚𝑠ℎ𝑒𝑙𝑙
Gshell = = 62.5689 kg/(m2-s)
𝐴𝑆

Sk = Relative Density of shell-side fluid = 3.3E-04

𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 4.701 psi
𝒆 ∗𝑺𝒌

HEATEX2: Heat Exchanger

Assumption: Number of passes = np = 6
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 363.36 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 34 BTU/(hr-ft2-oF)

= 33*1.8*(1000*0.000293/0.092903) W/(m2-K) = 193.01 W/(m2-K)

Assuming F = LMTD Correction Factor = 1

Q = Exchanger Duty = 2768.85 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 39.7 m2

Tube Side:
Length of each tube L = 60 in (assumed; will be changed if the requisite
pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 1.25 in | Pitch = PT = 1.5625 in (again

assumed)
𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 261 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 2.65 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 3.26E+04 (Turbulent flow) ➔ utube = = 0.676 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 100

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 1.448 and β = ( ) = 0.5 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 138.0315 BTU/(hr-ft2-

F)

Shell Side:

Assume Shell ID = Ds = 55 in (suitable to have a 261-tube bundle)

Baffle Spacing, B = Ds = 55 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = 𝜋𝑑𝑜
= 1.237 in, for a square pitch

Tube Clearance = Ct = PT - do = 0.3125 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = = 605 sq.in.
𝑃𝑇

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = = 78.21 kg/(m2-s) ➔ Reshell = = 94498.92
𝐴𝑆 𝜇𝑠ℎ𝑒𝑙𝑙

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 180

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 2.577 and β = (𝑘 𝑠ℎ𝑒𝑙𝑙 ) = 1.05 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 66.273 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = (ℎ + 𝑅𝑑𝑜 + ( 𝐴𝑜 ) (2𝑘𝑜 ) + ( 𝐴𝑜 ) (ℎ ) + ( 𝐴𝑜 ) 𝑅𝑑𝑖 )
𝑜 𝑖 𝑤𝑎𝑙𝑙 𝑖 𝑖 𝑖

From the values in the above table, we get Uo,cal = 37.17 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, = 9.33% (< 30%). Hence, we go ahead and calculate shell
𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
and tube-side pressure drops.
Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.0002*144 sq.ft/sq.ft. = 0.0288 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 392*(πdi2/(4*2))

= 0.773 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 180.36 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿𝑇 𝑛𝑝
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡
∗𝑆
psi = 0.029 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.031 psi

Sk = Relative Density of tube-side fluid = 0.8

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 0.06 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 1

Friction factor, f = 0.0015*144 sq.ft/sq.ft. = 0.216 sq.ft./sq.ft. ([85], Fig.29)

𝑚𝑠ℎ𝑒𝑙𝑙
Gshell = 𝐴𝑆
= 78.21 kg/(m2-s)

Sk = Relative Density of shell-side fluid = 3.3E-04

𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 5.628 psi
𝒆 ∗𝑺𝒌

HEATEX3: Reboiler
Assumption: Number of passes = np = 1
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 225.55 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 7 BTU/(hr-ft2-oF)

= 33*1.8*(1000*0.000293/0.092903) W/(m2-K) = 39.74 W/(m2-K)

F (LMTD Correction Factor) is assumed = 1

Q = Exchanger Duty = 5491.99 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 612.75 m2
Tube Side: (Vapour phase)

Length of each tube L = 170 in (assumed; will be changed if the requisite

pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 2 in | Pitch = PT = 2.5 in (again assumed)

𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 889 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 4.24 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 4.55E+04 (Turbulent flow) ➔ utube = = 67.7 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Under vacuum conditions, 50-70 m/s for vapour phase tube fluid -
Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 110

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 4.088 and β = ( ) = 1.06 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 25.312 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 100 in (suitable to have a 889-tube bundle)

Baffle Spacing, B = Ds = 100 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = = 1.98 in, for a square pitch
𝜋𝑑𝑜

Tube Clearance = Ct = PT - do = 0.5 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = 𝑃𝑇
= 200 sq.in.

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 21.345 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 132949

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 250

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 17 and β = (𝑘 𝑠ℎ𝑒𝑙𝑙 ) = 1.107 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 13.28 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑𝑜 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = ( + 𝑅𝑑𝑜 + ( 𝑜 ) ( ) + ( 𝑜 ) ( ) + ( 𝑜 ) 𝑅𝑑𝑖 )
ℎ𝑜 𝐴𝑖 2𝑘𝑤𝑎𝑙𝑙 𝐴𝑖 ℎ𝑖 𝐴𝑖

From the values in the above table, we get Uo,cal = 7.48 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 6.93% (< 30%). Hence, we go ahead and calculate shell
and tube-side pressure drops.
Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.00026*144 sq.ft/sq.ft. = 0.03744 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 392*(πdi2/(4*2))

= 6.745 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 48.715 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿𝑇 𝑛𝑝
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡
∗𝑆
psi = 1.822 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.239 psi

Sk = Relative Density of tube-side fluid = 3.6E-04

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 2.06 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 2

Friction factor, f = 0.0015*144 sq.ft/sq.ft. = 0.216 sq.ft./sq.ft. ([85], Fig.29)

𝑚𝑠ℎ𝑒𝑙𝑙
Gshell = 𝐴𝑆
= 21.345 kg/(m2-s)

Sk = Relative Density of shell-side fluid = 1.06E-03

𝟎.𝟓𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 0.061 psi
𝒆 ∗𝑺𝒌

(0.5 factor due to boiling)

HEATEX4: Reboiler
Assumption: Number of passes = np = 1
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 157.44 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 1]3 BTU/(hr-ft2-

o
F) = 33*1.8*(1000*0.000293/0.092903) W/(m2-K) = 73.8 W/(m2-K)

Assuming F = LMTD Correction Factor = 1

Q = Exchanger Duty = 4816.81 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 417.029 m2
Tube Side:

Length of each tube L = 120 in (assumed; will be changed if the requisite

pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 2 in | Pitch = PT = 2.5 in (again assumed)

𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 857 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 4.24 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 5.46E+04 (Turbulent flow) ➔ utube = = 61.6 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Under vacuum conditions, 50-70 m/s for vapour phase tube fluid -
Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 160

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 4.96 and β = ( ) = 1.06 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 30.368 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 80 in (suitable to have a 392-tube bundle)

Baffle Spacing, B = Ds = 80 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = = 1.978 in, for a square pitch
𝜋𝑑𝑜

Tube Clearance = Ct = PT - do = 0.5 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = 𝑃𝑇
= 1280 sq.in.

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 20.076 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 132775.4

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 220

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 2.55 and β = (𝑘 𝑠ℎ𝑒𝑙𝑙 ) = 1.945 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 44.44 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑𝑜 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = ( + 𝑅𝑑𝑜 + ( 𝑜 ) ( ) + ( 𝑜 ) ( ) + ( 𝑜 ) 𝑅𝑑𝑖 )
ℎ𝑜 𝐴𝑖 2𝑘𝑤𝑎𝑙𝑙 𝐴𝑖 ℎ𝑖 𝐴𝑖

From the values in the above table, we get Uo,cal = 14.01 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 7.81% (< 30%). Hence, we go ahead and calculate shell
and tube-side pressure drops.
Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.00018*144 sq.ft/sq.ft. = 0.02592 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 392*(πdi2/(4*2))

= 6.502 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 50.53 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿𝑇 𝑛𝑝
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡
∗𝑆
psi = 0.841 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.2257 psi

Sk = Relative Density of tube-side fluid = 4.1E-04

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 1.06 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 2

Friction factor, f = 0.0013*144 sq.ft/sq.ft. = 0.1872 sq.ft./sq.ft. ([85], Fig.29)

𝑚𝑠ℎ𝑒𝑙𝑙
Gshell = 𝐴𝑆
= 20.076 kg/(m2-s)

Sk = Relative Density of shell-side fluid = 5.2E-04

𝟎.𝟓𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 0.095 psi
𝒆 ∗𝑺𝒌

(0.5 factor due to boiling)

HEATEX5: Heat Exchanger

Assumption: Number of passes = np = 8
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 301.81 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 40 BTU/(hr-ft2-oF)

= 33*1.8*(1000*0.000293/0.092903) W/(m2-K) = 227.056 W/(m2-K)

F = LMTD correction Factor = 1 (Assumed)

Q = Exchanger Duty = 520.191 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 7.597 m2
Tube Side:

Length of each tube L = 10 in (assumed; will be changed if the requisite

pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 0.75 in | Pitch = PT = 1 in (again

assumed)
𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 500 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 1.59 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 1.21E+04 (Turbulent flow) ➔ utube = = 3.78E-01
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
m/s (Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 50

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 0.81 and β = ( ) = 0.507 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 120.98 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 43 in (suitable to have a 500-tube bundle)

Baffle Spacing, B = Ds = 43 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = = 0.947 in, for a square pitch
𝜋𝑑𝑜

Tube Clearance = Ct = PT - do = 0.25 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = 𝑃𝑇
= 462.25 sq.in.

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 102.3639 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 98557.53

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 220

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 2.078 and β = (𝑘 𝑠ℎ𝑒𝑙𝑙 ) = 1.058 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 100.442 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑𝑜 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = ( + 𝑅𝑑𝑜 + ( 𝑜 ) ( ) + ( 𝑜 ) ( ) + ( 𝑜 ) 𝑅𝑑𝑖 )
ℎ𝑜 𝐴𝑖 2𝑘𝑤𝑎𝑙𝑙 𝐴𝑖 ℎ𝑖 𝐴𝑖

From the values in the above table, we get Uo,cal = 43.09 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 7.7% (< 30%). Hence, we go ahead and calculate shell
and tube-side pressure drops.
Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.0002*144 sq.ft/sq.ft. = 0.0288 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 392*(πdi2/(4*2))

= 0.533 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 76.97 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿𝑇 𝑛𝑝
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡
∗𝑆
psi = 0.00194 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.0076 psi

Sk = Relative Density of tube-side fluid = 0.815

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 0.0096 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 1

Friction factor, f = 0.0015*144 sq.ft/sq.ft. = 0.216 sq.ft./sq.ft. ([85], Fig.29)

𝑚𝑠ℎ𝑒𝑙𝑙
Gshell = 𝐴𝑆
= 102.3639 kg/(m2-s)

Sk = Relative Density of tube-side fluid = 3.3E-04

𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 6.292 psi
𝒆 ∗𝑺𝒌

HEATEX6: Heat Exchanger

Assumption: Number of passes = np = 6
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 339.31 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 60 BTU/(hr-ft2-oF)

Assuming F = LMTD Correction Factor = 1

Q = Exchanger Duty = 1177.91 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 10.209 m2

Tube Side:
Length of each tube L = 30 in (assumed; will be changed if the requisite
pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 0.75 in | Pitch = PT = 1 in (again

assumed)
𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 224 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 1.59 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 6.24E+04 (Turbulent flow) ➔ utube = = 1.47 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 175

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 0.8687 and β = ( ) = 0.5684 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 354.34 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 49 in (suitable to have a 224-tube bundle)

Baffle Spacing, B = Ds = 49 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = = 0.947 in, for a square pitch
𝜋𝑑𝑜

Tube Clearance = Ct = PT - do = 0.25 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = = 600.25 sq.in.
𝑃𝑇

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 78.83 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 75898.74

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 180

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 1.974 and β = ( 𝑠ℎ𝑒𝑙𝑙 ) = 1.068 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 85.37 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = (ℎ + 𝑅𝑑𝑜 + ( 𝐴𝑜 ) (2𝑘𝑜 ) + ( 𝐴𝑜 ) (ℎ ) + ( 𝐴𝑜 ) 𝑅𝑑𝑖 )
𝑜 𝑖 𝑤𝑎𝑙𝑙 𝑖 𝑖 𝑖

From the values in the above table, we get Uo,cal = 58.49 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 2.5% (< 30%). Hence, we go ahead and calculate shell
and tube-side pressure drops.

Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.0002*144 sq.ft/sq.ft. = 0.0288 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 392*(πdi2/(4*2))

= 0.239 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = = 392.82 kg/(m2-s)
𝐴𝑡

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿𝑇 𝑛𝑝
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡
∗𝑆
psi = 0.116 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.147 psi

Sk = Relative Density of tube-side fluid = 0.8

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 0.2626 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 1

Friction factor, f = 0.0015*144 sq.ft/sq.ft. = 0.216 sq.ft./sq.ft. ([85], Fig.29)

Sk = Relative Density of tube-side fluid = 3.3E-04

𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 7.46 psi
𝒆 ∗𝑺𝒌

HEATEX7: Heat Exchanger

Assumption: Number of passes = np = 2
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 383.6 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 45 BTU/(hr-ft2-oF)

F = LMTD correction Factor = 1 (Assumed)

Q = Exchanger Duty = 4726.59 kW

𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 48.65 m2

Tube Side:

Length of each tube L = 50 in (assumed; will be changed if the requisite

pressure drop/velocity constraints are violated)
do (Outer Diameter of Tube) = 0.75 in | Pitch = PT = 1 in (again
assumed)
𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 640 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 1.59 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 4.37E+04 (Turbulent flow) ➔ utube = = 0.724 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 90

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 0.868 and β = (𝑘 ) = 0.651 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 159.194 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 49 in (suitable to have a 640-tube bundle)

Baffle Spacing, B = Ds = 49 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = = 0.947 in, for a square pitch
𝜋𝑑𝑜

Tube Clearance = Ct = PT - do = 0.25 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = 𝑃𝑇
= 600.25 sq.in.

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 78.83 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 75898.74

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 175

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 1.974 and β = (𝑘 𝑠ℎ𝑒𝑙𝑙 ) = 1.068 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 83 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = (ℎ + 𝑅𝑑𝑜 + ( 𝐴𝑜 ) (2𝑘𝑜 ) + ( 𝐴𝑜 ) (ℎ ) + ( 𝐴𝑜 ) 𝑅𝑑𝑖 )
𝑜 𝑖 𝑤𝑎𝑙𝑙 𝑖 𝑖 𝑖

From the values in the above table, we get Uo,cal = 44.56 BTU/(hr-ft2-oF)
(𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, = 0.76% (< 30%). Hence, we go ahead and calculate shell
𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
and tube-side pressure drops.

Pressure Drop Calculations:

Tube-side:
Friction factor, f = 0.00026*144 sq.ft/sq.ft. = 0.03744 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 640*(πdi2/(4*2))

= 0.683 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 137.49 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿 𝑛
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡 𝑇 𝑝
∗𝑆
psi = 0.043 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = 𝑆𝑘
psi = 0.026 psi

Sk = Relative Density of tube-side fluid = 0.76

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 0.069 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 1

Friction factor, f = 0.0015*144 sq.ft/sq.ft. = 0.216 sq.ft./sq.ft. ([85], Fig.29)

Sk = Relative Density of tube-side fluid = 3.3E-04

𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 1.293 psi
𝒆 ∗𝑺𝒌

For Heat Exchangers HEATEX8, HEATEX9 and HEATEX10, since the procedure for
calculations is the same as that outlined above, results alone are presented

COOLER1: Cooler
Assumption: Number of passes = np = 1

6 Heat Exchangers with Cooling Water Utility in Parallel

For a single Heat Exchanger:

(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 60.67 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 17 BTU/(hr-ft2-oF)

F = LMTD correction Factor = 1 (Assumed)

Q = Exchanger Duty = 11534.92 kW

 𝑄
Therefore, Area of Heat Exchange = 𝐴 = 𝑈∗𝐹∗(𝐿𝑀𝑇𝐷) = 2033.953 m2

Tube Side:

Length of each tube L = 550 in (assumed; will be changed if the requisite

pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 0.75 in | Pitch = PT = 1 in (again

assumed)
𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 2433 (Number will be verified later according
to the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 1.59 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 5.08E+04 (Turbulent flow) ➔ utube = = 2.84 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 150

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 0.143 and β = (𝑘 ) = 0.552 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 1891.57 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 59 in (suitable to have a 2433-tube bundle)

Baffle Spacing, B = Ds = 59 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = 𝜋𝑑𝑜
= 0.947 in, for a square pitch

Tube Clearance = Ct = PT - do = 0.25 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = 𝑃𝑇
= 870.25 sq.in.

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 9.06 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 21812.8

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 90

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 3.95 and β = ( 𝑠ℎ𝑒𝑙𝑙 ) = 1.274 (from the table above)
𝑘𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 17.896 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑𝑜 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = ( + 𝑅𝑑𝑜 + ( 𝑜 ) ( ) + ( 𝑜 ) ( ) + ( 𝑜 ) 𝑅𝑑𝑖 )
ℎ𝑜 𝐴𝑖 2𝑘𝑤𝑎𝑙𝑙 𝐴𝑖 ℎ𝑖 𝐴𝑖

From the values in the above table, we get Uo,cal = 17.24 BTU/(hr-ft2-oF)
 (𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 1.41% (< 30%). Hence, we go ahead and calculate shell
and tube-side pressure drops.

Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.00018*144 sq.ft/sq.ft. = 0.02592 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) =

2433*(πdi2/(4*2)) = 2.5959 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 5689.26 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿 𝑛
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡 𝑇 𝑝
∗𝑆
psi = 53.445 psi (Acceptable
𝑖 𝑘
since it’s a utility stream)
(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = psi = 1.173 psi
𝑆𝑘

Sk = Relative Density of tube-side fluid = 1

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻

= 54.62 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 9

Friction factor, f = 0.0011*144 sq.ft/sq.ft. = 0.1584 sq.ft./sq.ft. ([85], Fig.29)

Sk = Relative Density of tube-side fluid = 7E-04

𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 0.1705 psi
𝒆 ∗𝑺𝒌

Total Cooler Duty = 69.2095 MW

Cooling water utility total flow rate = 29636950.8 kg/hr

CONDENSER1: Condenser
Note: Uses Cooling Water as utility
(𝑇2−𝑡1)−(𝑇1−𝑡2)
LMTD: (𝑇2−𝑡1) = 47.75 oC
ln ((𝑇1−𝑡2))

Assumed value of Overall Heat Transfer coefficient = Uass,ovl = 40 BTU/(hr-ft2-oF)

F = LMTD correction Factor = 1 (Assumed)

Q = Exchanger Duty = 9790.23 kW
𝑄
Therefore, Area of Heat Exchange = 𝐴 = = 902.904 m2
𝑈∗𝐹∗(𝐿𝑀𝑇𝐷)

Tube Side:

Length of each tube L = 500 in (assumed; will be changed if the requisite

pressure drop/velocity constraints are violated)

do (Outer Diameter of Tube) = 2 in | Pitch = PT = 2.5 in (again assumed)

𝑨
Number of tubes nt = 𝝅∗𝒅𝒐 ∗𝑳
= 445 (Number will be verified later according to
the value of Shell ID)

di = Inner Diameter of Tube = 0.834*do = 4.24 cm

𝑛𝑝
4𝑚𝑡𝑢𝑏𝑒 ( ) 𝑅𝑒_𝑡𝑢𝑏𝑒∗𝜇
Re_tube = = 8.84E+04 (Turbulent flow) ➔ utube = = 1.86 m/s
𝑛𝑡
𝜋𝑑𝑖 𝜇𝑡𝑢𝑏𝑒 𝜌𝑡𝑢𝑏𝑒 ∗𝑑𝑖
(Acceptable)

From the plot of jH vs Re_tube, ([85], Fig.24) we have jH,tube = 220

1
(− )
𝜇𝐶 3
α = di/ktube fluid = 0.383 and β = (𝑘 ) = 0.552 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

hi = Heat transfer coefficient, tube-side = (jH,tube)/(αβ) = 1040.37 BTU/(hr-ft2-F)

Shell Side:

Assume Shell ID = Ds = 49 in (suitable to have a 445-tube bundle)

Baffle Spacing, B = Ds = 49 in (to lower shell-side pressure drop)

(4𝑃𝑇2 −𝜋𝑑𝑜 2 )
Equivalent Diameter, De = 𝜋𝑑𝑜
= 1.67 in, for a square pitch

Tube Clearance = Ct = PT - do = 0.5 in

𝐶𝐵𝐷𝑆
Shell-side Cross flow area, as = = 400.17 sq.in.
𝑃𝑇

𝑚𝑠ℎ𝑒𝑙𝑙 𝐷𝑒 𝐺𝑆
Gshell = 𝐴𝑆
= 88.97 kg/(m2-s) ➔ Reshell = 𝜇𝑠ℎ𝑒𝑙𝑙
= 8465.019

From the plot of jH vs Re_shell, ([85], Fig.28) we have jH,shell = 50

1
(− )
𝜇 ∗𝐶 3
α = De/kshell fluid = 1.84 and β = (𝑘 𝑠ℎ𝑒𝑙𝑙 ) = 0.556 (from the table above)
𝑡𝑢𝑏𝑒 𝑓𝑙𝑢𝑖𝑑

ho = Heat transfer coefficient, shell-side = (jH,shell)/(αβ) = 48.875 BTU/(hr-ft2-F)

Fouling factor, assumed to be: Rdi=0.0005 hr-ft2-°F/BTU for tube-side fluid and
Rdo= 0.0005 hr-ft2-°F/BTU for shell-side fluid is taken.
1 𝐴 𝑑 −𝑑𝑖 𝐴 1 𝐴 −1
Uo,cal = (ℎ + 𝑅𝑑𝑜 + ( 𝐴𝑜 ) (2𝑘𝑜 ) + ( 𝐴𝑜 ) (ℎ ) + ( 𝐴𝑜 ) 𝑅𝑑𝑖 )
𝑜 𝑖 𝑤𝑎𝑙𝑙 𝑖 𝑖 𝑖

From the values in the above table, we get Uo,cal = 42.83 BTU/(hr-ft2-oF)
 (𝑼𝒐,𝒄𝒂𝒍𝒄 − 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅 )
Now, 𝑼𝒐,𝒂𝒔𝒔𝒖𝒎𝒆𝒅
= 7.707% (< 30%). Hence, we go ahead and calculate
shell and tube-side pressure drops.

Pressure Drop Calculations:

Tube-side:

Friction factor, f = 0.00015*144 sq.ft/sq.ft. = 0.0216 sq.ft./sq.ft. ([85], Fig.26)

at = (No. of tubes) (Flow area per tube)/(Number of Passes) = 445*(πdi2/(4*2))

= 3.376 sq.ft.
𝑚𝑡𝑢𝑏𝑒
Mass Velocity = Gtube = 𝐴𝑡
= 3712.6 kg/(m2-s)

(Use Imperial Unit System for each parameter’s value in the Pressure Drop
Equations written below)
𝑓𝐺 2 𝐿 𝑛
Frictional Pressure Drop: ∆𝑃𝑇 = (7.5𝐸+012)∗𝑑
𝑡 𝑇 𝑝
∗𝑆
psi = 6.46 psi
𝑖 𝑘

(1.334𝐸−013)(2𝑛𝑝 −1.5)𝐺𝑡2
Return Loss ∆𝑃𝑅𝑇 = psi = 0.5 psi
𝑆𝑘

Sk = Relative Density of tube-side fluid = 1

Total Pressure Drop in tube = ∆𝑷𝑻 + ∆𝑷𝑹𝑻 (Cooling water- Utility)

= 6.96 psi

Shell-side:

Number of Baffles = nb = (Tube Length)/(Baffle Spacing) = 10

Friction factor, f = 0.0011*144 sq.ft/sq.ft. = 0.1584 sq.ft./sq.ft. ([85], Fig.29)

Sk = Relative Density of tube-side fluid = 0.8417

𝟎.𝟓𝒇𝑮𝟐 𝑫 (𝒏 +𝟏)
Shell Pressure Drop: ∆𝑷𝑺 = (𝟕.𝟓𝑬+𝟎𝟏𝟐)∗𝑫
𝑺 𝑺 𝒃
psi = 0.004 psi
𝒆 ∗𝑺𝒌

(0.5 factor due to condensation)

For condensers CONDENSER2 and CONDENSER3, the procedure for calculations

is the same as that outlined above for CONDENSER1.
Plots of friction factors and Sieder & Tate Coefficient
Values for Shell and Tube sides [85]
B3b: Heat Exchangers Mechanical Design
The class of equipment used for heat transfer in the production of Styrene:
Unfired Shell and Tube heat exchangers (fixed tube sheet), and there are 14 of
them, whose preliminary design has been done as part of Deliverable-4. Their
mechanical design will be done subsequently, in this deliverable.

From Table-1 of IS:4503-1967, Cr-Mo steel has been chosen as the Material
of Construction since it can withstand Temperatures of up to 650oC

HEATEX1: Heat Exchanger – Shell and Tube

Design pressure = 1.1(Maximum operating pressure) [87]

P = 22.275 bara

Shell Diameter and Thickness:

The shell thickness, and hence the nominal diameter of the Heat exchanger can
be calculated from the equation below based on the maximum allowable stress,
accounting for joint efficiency.
𝑃𝐷𝑠
𝑡𝑠 = +𝑐
𝑓𝐽 − 0.6𝑃

Here,

ts = Shell thickness | P = Design Pressure | Ds = Shell ID | f = Maximum

allowable stress of MoC

J = Joint efficiency (assumed to be 0.8) | c = Corrosion allowance (= 6 mm) (In

accordance with IS 2844:1964)

For Cr-Mo steel, f is assumed to be 15% of its Yield Stress | f = 62.25 MPa
[89]

Ds = 1.372 m (From Deliverable-4)

ts = 63.04 mm

Hence, Nominal Diameter = Ds + 2ts = 1371.6 + 126.08 = 1497.68 mm

(Rounded off to 1500 mm)

Shell Cover:

Torispherical head is most widely used in chemical industries for operating

pressures up to 200 psi. Assuming torispherical shell-head, the required
thickness of the Shell cover is calculated using the below expression:

𝑃𝑅 𝑊 𝑅
𝑖
𝑡ℎ = (2𝑓𝐽−0.2𝑃) + 𝑐 | 𝑊 = 0.25 (3 + √ 𝑟 𝑖 ), where: Ri = Crown Radius (Assumed to be
𝑖

equal to Shell ID); ri = Knuckle Radius (Assumed to be 6% of Crown Radius).

Then,
 th = 60.56 mm
However, according to IS: 4503-1967, minimum thickness of shell cover =
Thickness of the shell
th = 63.04 mm

Channel Cover Diameter and Thickness:

The outside diameter of the channel shall be the same as that of the shell. The
effective channel cover thickness (𝑡𝑐𝑐 in mm) is calculated from the formula
(IS:4503-1967 section 15.6.1)

𝐷𝑐 √𝐶1 𝑃
t cc =
10𝑓

Where, Dc = Channel Cover Diameter = Nominal Diameter (in mm)

C1 = 0.3 (Assuming bolting with Ring-Type gaskets)

P = Design Pressure (in kgf/cm2)

f = Allowable Stress (in kgf/mm2)

tcc = 62.19 mm Therefore,

Tube sheet thickness:

Tube sheet is a circular flat plate with regular pattern drilled holes according to
the tube sheet layouts. The open end of the tubes is connected to the tube
sheet. The tube sheet is fixed with the shell and channel to form the main
barrier for shell and tube side fluids. The tube sheet’s material is also chosen to
be the same as that of the shell.

The minimum tube-sheet thickness (TEMA standard, [88]) to ‘resist bending’

can be calculated by:
FGp 𝑃
𝑡𝑡𝑠 = 3
√𝑘𝑓 , where: F = 1 (Assuming Fixed-tube sheet exchanger) | Gp =
Diameter over which pressure is exerted (Gp = Ds for Fixed-tube sheet
exchanger) | f = Allowable stress for the tube sheet material | k = Mean
0.785
Ligament Efficiency (𝑘 = [1 − ( 𝑃 2 )] for square pitch) | P = Maximum of
( 𝑡)
𝐷𝑜

shell/tube side pressure

tts = 11.03 cm Then,

Evaluating the need for Impingement plates:

According to IS:4503-1967, protection against impingement may not be
required for the services involving non-corrosive, non-abrasive fluids having
entrance line values of 𝜌𝑢2 < 125, where 𝜌- Density of fluid (in g/cc), u – velocity
of fluid (in m/s)

Here, u = 1.9, ρ = 0.118. Hence, 𝜌𝑢2 < 125 and Impingement plates are not
required

Shell ID = 54 in ➔ Nozzle ID = 10 in [[90], Table 2.3]

Gaskets:

Gaskets are used to make the metal-to-metal surfaces leak-proof. Gaskets are
elastoplastic materials and relatively softer than flange materials. Deformation of
gaskets under load seals the surface irregularities between metal-to-metal
surfaces and prevents leakage of the fluid.

𝐷𝑂𝐺 𝑌 − 𝑃𝑚
= √
𝐷𝐼𝐺 𝑌 − 𝑃(𝑚 + 1)

where, DOG = Outside Gasket Diameter | DIG = Inside Gasket Diameter | Y =

Minimum Design Seating Stress | m = Gasket Factor [84]

[IS:4503-1967 specifies that the minimum width of peripheral ring

gaskets for external joints shall be 10 mm for shell sizes up to 600 mm nominal
diameter and 13 mm for all larger shell sizes]

Gasket material chosen: Flat Iron jacketed, Asbestos fill | m = 3.75 | Y

𝒌𝒈𝒇
= 5.35
𝒎𝒎𝟐

DIG = DS + 0.25 (in mm) = 1371.85 mm

Therefore, DOG = 1407.6 mm ➔ Gasket Width = 18 mm (>13 mm, so satisfies

IS)

Baffle Thickness: According to TEMA standards ([88], Table R-4.41), since

Nominal Shell ID> 39 in and Baffle spacing > 48 in, Baffle plate thickness =
15.9 mm

For all other heat exchanger equipment, the same procedure is followed
for mechanical design and the results are displayed in their respective
Equipment Datasheets and Mechanical Drawings.
B4: Calculations for Pumps
The pumps involved in the Process Flow Diagram (Appendix) are:

1. PUMP1
2. PUMP2
3. EBPUMP

We chose Centrifugal pumps for all of the pumps given, as it is the type most
widely used, and is supported by Aspen’s Economic Analysis.

B4a: Pump Equipment Sizing

Flow Rate for the Pumps
Flow rate and the Pressure change is obtained directly for the pumps from Aspen
Results as:
Head Generation
Head generated = Change in Pressure/(⍴g) = ΔP/(⍴g)

Where ⍴ = Density of Fluid in kg/m3 and g = Acceleration due to Gravity, in m/s2

The densities are given below, as obtained from Aspen.

We use the above formula to calculate the Head generated

Pump Name Pressure Density(kg/m3) Head

Change(bars) generated(m)

PUMP1 19.961 841.65 242.005

PUMP2 19.15 815.321 239.67

EBPUMP 5.398 825.816 66.69

Table 1

We verify the Head generated with the Aspen values and find that they match.

Selection of Centrifugal Pump Type

We choose a suitable RPM for the Centrifugal Pump based on the graph given
below.

The type of Centrifugal pump is chosen from the above diagram

Pump Name Flow Head Type chosen from
Rate(m^3/hr) generated(m) the Figure

PUMP1 55.38 242.005 High-speed Single

Stage Centrifugal
Pump, 6000 rpm

PUMP2 16.84 239.67 Multi-Stage

Centrifugal Pump,
7000 rpm

EBPUMP 38.02 66.69 Single-Stage

Centrifugal Pump,
3500 rpm
Table 2

Impeller Specific Speed Calculation

Centrifugal pumps are characterised by their Impeller speeds. Equation 5.1

below gives the dimensionless version of the Impeller Speed.

Using the above formula(5.2), we calculate the Impeller speeds for the pumps,
after converting the values to the required units in Aspen.

For impeller specific speeds between 400-4000, Centrifugal impellers are used.
Mixed flow impellers are used for Specific speeds between 4000 and 9000, and
Axial impellers for Specific speed above 9000.
Pump Name Impeller Speed(Ns’) Type of Impeller chosen

PUMP1 626.184 Centrifugal

PUMP2 405.876 Centrifugal

EBPUMP 795.909 Centrifugal

Table 3

Determining Pump efficiency

We obtain the efficiencies of the pumps from Figure 5.13

Pump Name Efficiency Obtained approximately(%)

PUMP1 54

PUMP2 47

EBPUMP 50.5
Table 4
Power required for the pumps
Power = (W*m)*100/η - (Equation 1)

where m = mass flow rate in kg/s, η = pump efficiency in % and W is calculated

from:

gΔz + ΔP/ρ - ΔPf /ρ - W = 0

where W = work done by the fluid, Δz = difference in elevation in metres, ΔP =

difference in system pressures in N/m2, ΔPf = pressure drop due to friction in
N/m2 and ρ = liquid density in kg/m3.

We have Δz = 0, and ΔPf = 0, which gives

W = ΔP/ρ

Densities and the Pressure changes are taken from Table 1 and the Power is
calculated below using Equation 1.

Sample Calculation for Pump 2

W = (19.15*10^6/815.321) = 2348.768 m2/s2

Power = W*3.814*100/47 = 19060.00 W = 19.06 kW

Pump Name Pressure Density(kg/ Mass flow Efficiency( Power

Change(bar m 3) Rate(kg/s) %) Required(k
s) W)

PUMP1 19.961 841.65 12.947 54 56.862

PUMP2 19.15 815.321 3.814 47 19.06

EBPUMP 5.398 825.816 8.722 50.5 11.289

Table 5
Choosing Impeller Size
We choose the impeller size for the pumps using the given diagram below.

Pump Name Impeller Size approx(mm)

PUMP1 250

PUMP2 250

EBPUMP 200

Seal Selection for Pump

The seal must serve several functions:

1. To keep the liquid contained

2. To prevent ingress of incompatible fluids, such as air

3. To prevent escape of flammable or toxic materials

The most common types of seals used are

1. Packed Glands
2. Mechanical seals
Mechanical Seals are chosen here because of the following reasons:

1. Leakage of Styrene led to a disaster most recently in Vishakapatnam in

2020, leading to loss of life. The non-leaking ability of a Mechanical seal is
hugely favourable in these circumstances
2. Packed glands are incompatible with flammable fluids.
B4b: Pump Mechanical Design
Stream Results for PUMP1
Stream Results for PUMP2
Stream Results for EBPUMP
Material Selection [91],[92]

The main points to keep in mind for Material selection of styrene pumps is to
avoid the possibility of allowing the pump to run against closed valves. The
pump design should allow for complete recirculation and drainage. The
Mechanical seals should be styrene compatible.

As Steel is fairly compatible with Benzene/Ethyl Benzene, and taking into

account the easy availability and smaller cost, We select Stainless Steel 316
type of material to design the pumps.

Selecting Casing[93]

Single Volutes
These are the most common type of Casing used in Centrifugal pumps. They are
easily manufacturable, and show high performance for specific speed above 600.

They are a good service choice by virtue of having a large useable range
compared to other diffusion device designs.

The only drawbacks are that they lead to larger diameter casings, and can
impose higher radial loads as the pump moves further away from the best
efficiency point.(Figure 2)
 Figure 2

As the specific speeds for the 3 pumps are either above or around the value of
600, we choose Single Volute casing for the pumps.

Selection of Number of Blades for Pump [94]

We choose the Number of Blades based on the below graph.

With the increase in Number of Blades, the head increases. However the variable
regulation of Efficiency with Number of Blades is quite complicated.

If we take the number of blades to be too many, the crowding out effect at the
impeller becomes serious, increasing the velocity of flow. Also the increase in
interface between Fluid stream and blade causes increased Hydraulic losses.
Keeping the number of blades to be too low will cause the diffuser loss to
increase.

We take the number of blades to be 10 for our pumps, as a PEAK in efficiency is

reached there.
Selection of Suction Pipe Diameter and Volute Wall
thickness[95]
We use the below graph to determine the Suction pipe diameter Ds based on the
Discharge and the Pump efficiencies.
 Pump Discharge(m3/min) Suction Pipe Diameter

PUMP1 0.923 95 mm

PUMP2 0.2807 55 mm

EBPUMP 0.6337 80 mm

Volute Wall Thickness

From the above table, we select thickness for the Volute Wall.

Pump Suction Pipe Diameter Volute Wall Thickness

PUMP1 95 mm 6 mm
PUMP2 55 mm 5 mm
EBPUMP 80 mm 5 mm

Net Positive Suction Head Calculation[64]

NPSHREQD is taken as 3 metres for capacity upto 100 m3/hr and 6 metres for
capacities higher than 100 m3/hr.

As all the 3 pumps have capacities well south of 100 m3/hr, we take the
NPSHREQD to be 3 metres.
Here, we take Pf = 0 as assumed in Deliverable 4. We also take H to be 5
metres.

Vapor pressure values taken from [96] and [97].

Pump Pressure(Pa) Vapor Density(kg/m3) NPSHA

Pressure(Pa)
PUMP1 30397.5 35730.4 841.65 4.353 mts
PUMP2 10132.5 7732.7 815.321 5.300 mts
EBPUMP 10132.5 10665.8 825.816 4.934 mts

Safety Considerations
As the material pumped is hazardous, there should not be any leakage in the
pump.

Leakage of Styrene led to the Vishakhapatnam Styrene accident in 2020.

Pump should not be run at higher than approved temperatures and pressure, or
at higher than approved speeds.
C1: Mechanical Drawings - Reactors
Mechanical drawing of ALK:

Mechanical drawing of TRANSALK:

Mechanical drawing of EB2STY:

C2: Mechanical Drawings: Distillation Columns
COL1
COL2
STYCOL
C3: Mechanical Drawings: Heat Exchangers
MECHANICAL DRAWING:
HEATEX1:

TUBESHEET LAYOUT:

Number of Tubes = 392

Tube OD = 0.75 in
Square Pitch

SUPPORTS:
HEATEX2:

TUBESHEET LAYOUT:

Number of tubes = 261

Tube OD = 1.25 in
Square Pitch

SUPPORTS:
HEATEX3:

TUBESHEET LAYOUT:

Number of Tubes = 889

Tube OD = 2 in
Square Pitch

SUPPORTS:
HEATEX4:

TUBESHEET LAYOUT:

Number of Tubes = 857

Tube OD = 2 in
Square Pitch

SUPPORTS:
HEATEX5:

TUBESHEET LAYOUT:

Number of Tubes = 500

Tube OD = 0.75 in
Square Pitch

SUPPORTS:
HEATEX6:

TUBESHEET LAYOUT:

Number of Tubes = 224

Tube OD = 0.75 in
Square Pitch

SUPPORTS:
HEATEX7:

TUBESHEET LAYOUT:

Number of Tubes = 640

Tube OD = 0.75 in
Square Pitch

SUPPORTS:
HEATEX8:

TUBESHEET LAYOUT:

Number of Tubes = 947

Tube OD = 2 in
Square Pitch

SUPPORTS:
HEATEX9:
TUBESHEET LAYOUT:

Number of Tubes = 926

Tube OD = 2 in
Square Pitch

SUPPORTS:
HEATEX10:
TUBESHEET LAYOUT:

Number of Tubes = 855

Tube OD = 2 in
Square Pitch

SUPPORTS:
COOLER1:

TUBESHEET LAYOUT:

Number of Tubes = 2433

Tube OD = 0.75 in
Square Pitch

SUPPORTS:
COL1COND:

TUBESHEET LAYOUT:

Number of Tubes = 445

Tube OD = 2 in
Square Pitch

SUPPORTS:
COL2COND:

TUBESHEET LAYOUT:

Number of Tubes = 193

Tube OD = 2 in
Square Pitch

SUPPORTS:
STYCOLCOND:

TUBESHEET LAYOUT:

Number of Tubes = 255

Tube OD = 2 in
Square Pitch

SUPPORTS:
C4 - Mechanical Drawings - Pumps

PUMP1:
PUMP2:
EBPUMP: