Production of Cyclohexane from Benzene
Session 2005-2009 Project Advisor Prof !r Shahid "aveed Authors# $aeema %ahir
2005&'C-CP(-)0
Sidra-tul-*untaha
2005&'C-CP(-)+
Ahmad ,aas /sman ameed
2005&'C-CP(-). 2005&'C-CP(-01
DEPARTMENT DEPARTMENT OF CHEMICAL ENGINEERING
/(% - A34( -PA6S%A -PA6S%A" "
Production of Cyclohexane from Benzene
Session 2005-2009 Project Advisor Prof !r Shahid "aveed Authors# $aeema %ahir
2005&'C-CP(-)0
Sidra-tul-*untaha
2005&'C-CP(-)+
Ahmad ,aas /sman ameed
2005&'C-CP(-). 2005&'C-CP(-01
DEPARTMENT DEPARTMENT OF CHEMICAL ENGINEERING
/(% - A34( -PA6S%A -PA6S%A" "
%his re7ort is su8mitted to de7artment of Chemical (nineerin: /niversity of (nineerin ; %echnoloy ahore- Pa
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6nternal (xaminer#
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!(PA4%*("% !(PA4%*("% 3' C(*6CA (">6"((46"> /"6@(46S6% 3' (">6"((46"> A"! %(C"33> A34(-PA6S%A"
DEDICATED TO
Our Beloved Parents, Respected Teachers And Sincere Friends
ACKNOWLEDGEMENT We expr es s gr at i t ude and pr ai se t o ALMI GHTY ALLAH,t hec r eat orofuni v er se,whoi sbenefic entandmer c i f ul , gui ded usi n di ffic ul tand c ongealc i r c umst anc e,whoendowed uswi t ht hewi l lt ounde r t aket hi sde si g n pr o j e c t .Gr e atr e spe c t ourHol yPr ophetHazr atMuhammad ( PBUH) ,whot aughtust o l ear nt i l ll apofgr av e. Att hi spoi nt ,t heendofapur posef ull ear ni ngper i od, o ure mo t i o nsar eve r ys t r o ng,f e el i ngsar ede ep,andwear es t i l l r emembe r i ng t he t i me when our dr eams c ame t r ue and we c ameatU. E. T ,a dynami ci ns t i t ut i o n wi t h pr o f e s si o nal sl o v i ng andpr of essi onalmaki ngset up. The t i me whi c h was spend ov erher e,t he pr ac t i c al and c once pt ualknowl edgewhi c h wegai ned madet hi sgol den t i me ,o fc o ur s e,a mi l e s t o nei no urpr o f e ss i o nalc ar e erwi t ht he nameo fde par t me nto fc he mi c ale ng i ne er i ngal o ngl i s to fpo l i t e c o o pe r at i v eand affe c t i o nat epr o f e s s i o nalt e ac he r sc a meac r o s s ourmi nd.Forwhom weconf essournegl i genc eofvoc abul ar yt o s ayt hanksf o rt he i ras si s t anc e .
Wepays pe c i alho mag et oourr e s pe c t i v et e ac he r s ;Dr . Sal ee mi ( Chai r man of Depar t ment ) and our l eni ent and c o o pe r at i v epr o j e c tadv i s orPr o f .Dr . Shahi d Nav e ed,whor e al l y pai dt hei rspec i alat t ent i oni nt hec ompl e t i onofourpr oj ec t .
TABLE OF CONTENTS PREFACE....................................................................................................................................... CHAPTER 1...................................................................................................................................... Introduction................................................................................................................................ CHAPTER 2...................................................................................................................................... Process selection and description of flow sheet..................................................................... CHAPTER 3...................................................................................................................................... aterial !alance " Ener#$ !alance....................................................................................... CHAPTER 4...................................................................................................................................... %esi#n of E&uip'ents.............................................................................................................. Reactor design .................................................................................................................. Vapor/liquid separator design............................................................................................ Stabilization column design.......................................................................... Heat Exchanger design.................................................................................
CHAPTER 5...................................................................................................................................... echanical %esi#n of (eat E)chan#er................................................................................ CHAPTER ...................................................................................................................................... Instru'entation and Process control................................................................................... Control sc!e"e o# $uter%recirculation Cooler................................................................. CHAPTER &...................................................................................................................................... (A*OP Stud$ ........................................................................................................................ HAZOP Study of Gas/i!uid Se"arator..............................................................
CHAPTER '...................................................................................................................................... En+iron'ental i'pacts of C$clohe)ane Plant..................................................................... CHAPTER (..................................................................................................................................... aterial of Construction....................................................................................................... CHAPTER 1).................................................................................................................................... Cost Esti'ation ..................................................................................................................... REFERENCES.......................................................................................................................... APPEN%I,.................................................................................................................................
Production o# C*clo!e+ane #ro" ,en-ene
PREACE T!is proect is su0"itted to t!e epart"ent o# C!e"ical Engineering niersit* $# Engineering And Tec!nolog* a!ore Pa6istan #or t!e #ul#ill"ent o# t!e ,ac!elors egree. T!is researc! report is concerned a0out t!e actiit* o# designing a plant #or "anu#acture o# C*clo!e+ane. T!e stud* o# said su0ect o##ers a 7a* to "a6e Pa6istan sel# supported in c*clo!e+ane as all consu"er societ* o# it i"ports t!is c!e"ical #ro" 8audi Ara0ia C!ina AE and 9ala*sia. T!e report descri0es t!e "ost econo"ical 7a* to produce c*clo!e+ane in Pa6istan 6eeping in ie7 all t!e resources o# countr*. C*clo!e+ane is t!e "aor pre%cursor #or t!e production o# :*lon. Auto"otie applications o# n*lon !ae 0een gro7ing strongl* 7!ere t!ere !as 0een a drie to replace "etals 7it! plastics to reduce t!e 7eig!t o# "otor. Hence it 7ill a cost e##ectie solution in t!is sector also. T!e sure* o# de"and o# c*clo!e+ane in Pa6istan !as 0een "ade 7it! t!e !elp o# a!ore C!a"0er $# Co""erce and Trade. Hence t!e production capacit* o# our plant is 0ased on t!e present needs o# it. T!e 0asic structure o# report is gien 0elo7. C!apter ; 1 is t!e introduction o# c*clo!e+ane t!at coers t!e areas o# de"and o# it in present da*s and as 7ell as in #uture. A 0rie# ie7 o# natural resources and p!*sical properties !as 0een gien. T!e properties o# 0en-ene and !*drogen !ae 0een gien 7!ere eer t!eir need is. <"portant
Production o# C*clo!e+ane #ro" ,en-ene de"and o# t!e 7or6. Contrar* to t!is process selection is 0ased on t!e econo"ic anal*sis o# di##erent "et!ods o# production.
$
Production o# C*clo!e+ane #ro" ,en-ene !as 0een collected #ro" arious 0oo6s and si"ulation so#t7are H*s*s at t!e process conditions. inall* as is custo"ar* t!e errors t!at re"ain are our. T!e Aut!ors =aee"a Ta!ir 8idra%tul%"unta!a s"an Ha"eed >aqas A!"ed
Chapter 0 1 %
Production o# C*clo!e+ane #ro" ,en-ene
INTRO%2CTION C*clo!e+ane is a c*cloal6ane. C*cloal6anes are t*pes o# al6anes 7!ic! !ae one or "ore rings o# car0on ato"s in t!e c!e"ical structure o# t!eir "olecules. Al6anes are t*pes o# organic !*drocar0on co"pounds 7!ic! !ae onl* single c!e"ical 0onds in t!eir c!e"ical structure. C*cloal6anes consist o# onl* car0on ?C@ and !*drogen ?H@ ato"s and are saturated. C*clo!e+ane
!as
#ollo7ing
s*non*"s.
,en-ene!e+a!*drideCiclo!e+ano
He+a!idro0enceno He+a!*dro0en-ene He+a"et!*lene He+a"etileno He+anap!t!ene :ap!t!ene. :*lon gro7t! 7!ic! is t!e "ain drier in t!e c*clo!e+ane "ar6et !as stagnated in "an* applications to 0elo7 P leels alt!oug! t!ere is still so"e gro7t! in n*lon plastics #or auto"otie and ot!er resin applications. $ne o# t!e 0etter per#or"ing "ar6ets #or n*lon is engineering t!er"oplastics. T!ese "aterials !ae toug! p!*sical properties suc! as !ig! tensile strengt! e+cellent a0rasion c!e"ical and !eat resistance 7!ic! allo7 t!e" to replace "etals. Auto"otie applications !ae 0een gro7ing strongl* 7!ere t!ere !as 0een a drie to replace "etals 7it! plastics to reduce t!e 7eig!t o# "otor e!icles.
F2T2RE %EAN% uture glo0al de"and gro7t! #or c*clo!e+ane is put at around 2%3B/*ear. 8R< Consulting esti"ates glo0al de"and #or c*clo!e+ane 7as ust oer 5" tonnes in igure1.1 2))5. >it! an aerage gro7t! rate o# 3B/*ear de"and s!ould reac! " tonnes 0* 2)1).
Production o# C*clo!e+ane #ro" ,en-ene plant in 9a* 2)) alt!oug! production could 0e increased to1')))) tonnes/*ear depending on #eedstoc6 aaila0ilit*.
NAT2RAL RESO2RCES C*clo!e+ane occurs naturall* in crude oil and can 0e released #ro" petroleu" #ractions 7!eneer t!e* are re#ined stored or used. Anot!er "aor release is #ro" "otor gases. :aturall* is also released #ro" olcanos.
!ile 0io%concentration in aquatic organis" and adsor0tion to sedi"ents is esti"ated to occur to a "oderate e+tent.
PROPERTIES C*clo!e+ane CH12 #or"ula 7eig!t '4 is a colorless 7ater%insolu0le non% corrosie liquid.
Ta0le 1.1 C$clohe)ane Sol+ent Properties 'AS ##()*$)+
,
Production o# C*clo!e+ane #ro" ,en-ene
Ph$sical Properties 9olecular 7eig!t ,oiling point Vapor pressure ree-ing point Re#ractie inde+ ensit* ielectric constant ipole "o"ent Polarit* inde+ ?PD@ Viscosit* 8ur#ace tension 8olu0ilit* in 7ater 8olu0ilit* o# 7ater in c*clo!e+ane 8torage
'4.1 ').&2C &&.5 Torr at 2)C .54C 1.422 at 2)C ).&&'5 g/" ?.4(& l0/gal@ at 2)C ).&&3( g/" ?.45& l0/gal@ at 25C 2.)2 at 2)C ) at 2)C ).2 1.) cP at 2)C 24.(' d*n/c" at 2)C ).))B at 25C ).)1B at 2)C 8tore in an area designed #or #la""a0le storage or in an approed "etal ca0inet a7a* #ro" direct sunlig!t !eat and sources o# ignition.
las! point o7er e+plosie li"it pper e+plosie li"it
%4 ?%2)C@ 0* closed cup 1.3B '.)B
-
Production o# C*clo!e+ane #ro" ,en-ene
(ISTOR3
and in t!e sa"e *ear E. Ha7ort! and >.H. Per6in Gr. ?1') % 1(2(@ did t!e sa"e in a >urt- reaction o# 1%di0ro"o!e+ane.
8urprisingl* t!eir c*clo!e+anes 0oiled !ig!er 0* 1)C t!an eit!er !e+a!*dro0en-ene or !e+anap!tene 0ut t!is riddle 7as soled in 1'(5 0* 9ar6oni6o :.9. is!ner and :i6ola* =elins6* 7!en t!e* re%diagnosed !e+a!*dro0en-ene and !e+anap!tene as "et!*lc*clopentane t!e result o# an une+pected rearrange"ent reaction.
IN%2STRIAL APPLICATIONS +
Production o# C*clo!e+ane #ro" ,en-ene 1%Co""erciall* "ost o# c*clo!e+ane produced is conerted into c*clo!e+anone. C*clo!e+anone is t!e organic co"pound 7it! t!e #or"ula 5C$. T!e "olecule consists o# si+%car0on c*clic "olecule 7it! a 6etone #unctional group. T!is colorless oil !as an odour re"iniscent o# pear drop s7eets as 7ell as acetone. 2%C*clo!e+anol ?or A oil@ is t!e organic co"pound and is #or"ed 0* catal*tic o+idation. A oil is t!en used as a ra7 "aterial #or adipic acid. Adipic acid is t!e organic co"pound 7it! t!e #or"ula 4?C$2H@2. ro" t!e industrial perspectie it is t!e "ost i"portant dicar0o+*lic acidF A0out 2.5 0illion 6ilogra"s o# t!is 7!ite cr*stalline po7der are produced annuall* "ainl* as a precursor #or t!e production o# n*lon. 3%C*clo!e+ane is also an i"portant organic solent. Also it is used in Electroplating Electroplating % Vapor egreasing 8olents a0orator* C!e"icals 8olents I E+traction 9ac!iner* 9#g and Repair Ru00er 9anu#acture 8olents % Ru00er 9anu#acture >ood 8tains and Varnis!es
STR2CT2RE
C*cloal6anes ?also called nap!t!enes especiall* i# #ro" petroleu" sources@ are t*pes o# al6anes 7!ic! !ae one or "ore rings o# car0on ato"s in t!e c!e"ical structure o# t!eir "olecules. Al6anes are t*pes o# organic !*drocar0on co"pounds 7!ic! !ae onl* single c!e"ical 0onds in t!eir c!e"ical structure. C*cloal6anes consist o# onl* car0on ?C@ and !*drogen ?H@ ato"s and are saturated 0ecause t!ere are no "ultiple C%C 0onds to !*drogenate ?add "ore !*drogen to@. A general c!e"ical #or"ula #or c*cloal6anes 7ould 0e CnH2?nJ1%g@ 7!ere n K nu"0er o# C ato"s and g K nu"0er o# rings in t!e "olecule. C*cloal6anes 7it! a single ring are na"ed analogousl* to t!eir nor"al al6ane counterpart o# t!e sa"e car0on countF c*clopropane c*clo0utane c*clopentane *
Production o# C*clo!e+ane #ro" ,en-ene c*clo!e+ane etc. T!e larger c*cloal6anes 7it! greater t!an 2) car0on ato"s are t*picall* called c*clopara##ins. C*cloal6anes are classi#ied into s"all co""on "ediu" and large c*cloal6anes 7!ere c*clopropane and c*clo0utane are t!e s"all ones c*clopentane c*clo!e+ane c*clo!eptane are t!e co""on ones c*clooctane t!roug! c*clotridecane are t!e "ediu" ones and t!e rest are t!e larger ones.
Chapter 0 4
PROCESS SELECTION " %ESCRIPTION OF FLO5 S(EET Co""erciall* c*clo!e+ane is s*nt!esi-ed 0* arious processes. Eac! process !as its o7n "erits and de"erits. Categori-ing arious processes 7e can di##erentiate a"ong t!e" on #ollo7ing c!aracteristicsL
Production o# C*clo!e+ane #ro" ,en-ene 1@ OPERATIN6 CON%ITIONS T!ere e+ist t7o t*pes o# processes one is called liquid p!ase process and ot!er is called apor p!ase process o# c*clo!e+ane "anu#acture. T!e p!ase to 0e !andled dictates t!e operating conditions o# process.
,* installing seeral adia0atic reactors in series and lo7ering t!e te"perature 0et7een eac! reactor 0* direct quenc! or 0* cooling in !eat
<<.
e+c!angersL !o7eer t!is solution requires considera0le equip"ent. ,* using a atitude reactor 7it!1 circulation o# a !eat trans#er #luid on t!e s!ell sideL !o7eer t!e need to #ill eac! catal*st tu0e uni#or"l* to guarantee uni#or" pressure drops #lo7 rates and unit conersions as 7ell as t!e necessaril* large no. o# t!ese tu0es "a6es t!is solution costl* in ter"s o# capital e+penditure and pro0le"atic in operation.
<# t!e catal*st is in suspension t!e !eat can 0e re"oed 0* t!e circulation o# t!e "ediu" outside t!e reactor t!roug! a !eat e+c!anger. Various liquid and apor p!ase processes are ta0ulated 0elo7 7it! t!eir pro"inent c!aracteristics.
LI72I% P(ASE PROCESSES #(
Production o# C*clo!e+ane #ro" ,en-ene
TABLE 4.1 Process Na'e
Operatin# cond.
Catal$st
(eat Re'o+al
P$ ?niersal oil products@ H*drar
Te"pF 2)) % 3))C PressF 3+l)Pa a0s
i+ed 0ed o# o# pt 0ased catal*st
Muenc!ing s!ots #ro" cooled reactor e##luent
Te"pF 1) % 235C
Pt%0ased catal*st
T!ree reactors in
PressF seeral at"s
in #i+ed 0eds.
seriesL 1st treats 0ul6 o#
process Houdr* Process
#eed and rec*cle 2nd treats e##luent #ro" 1st re"ainder #eed and rec*cles. Adia0atic operation. 8inclair/engel!ard
Te"pL 25)C
process
:o0le "etal
Heat is re"oed in
#i+ed 0ed.
8itu 0* "eans o# a tu0e 0undle 7it! t!e production o# stea"
<P ?
Te"pF 2)) % 24)C
Rane* D:ic6el in
$uter% recirculation
rancais du Petrole@
PressF 35 at"
8uspension
Heat re"oal.
8APOR P(ASE PROCESSES Ta!le 4.4 Process Na'e
Operatin# cond. Catal$st
,e+ane 89F
Te"p. 3&)C
(eat Re'o+al
Pt%0ased catal*st ,* a coolant ##
Production o# C*clo!e+ane #ro" ,en-ene :ederlandse
Pressure 3+l) pa a0s
H*tora* Process
Te"p. 3&)C Pressure 3+l) pa a0s
Pt%0ased
,* a coolant
catal*st
SELECTE% PROCESS FOR C3CLO(E,ANE AN2FACT2RE or t!is design report <P liquid p!ase process is selected. <P process is a "i+ed p!ase processL i.eL it is a !*0rid o# liquid p!ase and apor p!ase process. T!is process eno*s t!e 0ene#its o# 0ot! process and "a6es it econo"ical. 9aorl* it conerts 0en-ene in liquid p!ase at lo7 te"perature a#ter t!at it eli"inates t!e in!erited dra70ac6 o# liquid p!ase process o# lo7 purit* 0* conerting rest o# t!e 0en-ene in apor p!ase !ence also rela+es t!e need o# costl* reactor. T!e "ain #eatures o# t!is process are gien 0elo7L 1.
PROCESS %ETAILS 9I: BASIC C(EISTR3 T!e !*drogenation o# 0en-ene proceeds according toF #$
Production o# C*clo!e+ane #ro" ,en-ene CH J3H2
CH12
$ne "ole o# 0en-ene reacts 7it! t!ree "oles o# !*drogen to
produce one "ole o#
c*clo!e+ane. T!e reaction is !ig!l* e+ot!er"ic li0erating (15)) 0tu/l0%"ol o# 0en-ene conerted at 3)) o.
?II:
REACTION ;INETICS
T!e 6inetics are #irst order in !*drogen partial pressure -ero order o# 0en-ene and independent o# t!e pressure o# c*clo!e+ane.
PROCESS %ESCRIPTION " PROCESS FLO5 %IA6RA res! 0en-ene #ro" storage tan6 at 25oC and 1 at" "a6e%up !*drogen and rec*cle !*drogen are !eated to reaction te"perature ?0en-ene in !eat e+c!anger and !*drogen is !eated 0* co"pressing adia0aticall*@ and #ed to t!e slurr* reactor. 8lurr* p!ase reactor is an isot!er"al reactor in 7!ic! 0en-ene in liquid #or" and !*drogen in gas p!ase is introduced and reaction ta6es place on Rane* nic6el catal*st. T!e conersion in t!is reactor is (5B. 8lurr* p!ase reactor is proided 7it! an outer%recirculation !eat e+c!ange/cooler 7!ic! re"oes t!e !eat o# reaction and lo7 pressure ?&) psi@ stea" in generated.
Te"peratures in t!e reactor are !eld 0elo7 2)4oC to preent t!er"al
crac6ing side reactions and an un#aora0le equili0riu" constant t!at 7ould li"it 0en-ene conersion. :e+t to t!e slurr* p!ase reactor a catal*tic #i+ed 0ed pot reactor is proided 7!ic! "a6es%up t!e conersion al"ost to 1))B.
#%
Production o# C*clo!e+ane #ro" ,en-ene oer!eads o# lo7 pressure #las! are (5B !*drogen 7!ic! is used as #uel gas or "i+ed 7it! sales gas.
#&
Production o# C*clo!e+ane #ro" ,en-ene
(3%RO6ENATION CATAL3STS 1.
FOR LI72I% P(ASE #,
Production o# C*clo!e+ane #ro" ,en-ene :ic6el and no0le "etals ?r!odiu" rut!eniu" and Platinu"@ are catal*sts #or 0en-ene !*drogenation co""onl* and #or t!is proect Rane* :ic6el in suspension is used as a catal*st #or liquid p!ase !*drogenation. :ic6el catal*sts require generall* !ig! te"peratures and pressures. Rane* :ic6el is po7dered allo* o# :ic6el 7it! alu"inu" actiated 7it! caustic soda solution. :or"al percentage o# alu"inu" in t!e allo* is 1)%%15B.
Rane* :ic6el is classi#ied as >1 >2 >3 >5 > >& and >' due to t!e actiit* di##erence "ainl* i"parted #ro" t!e "et!od o# preparation. 9ost actie grade is > 0ut "ini"u" allo7ed te"perature is N 1))C. >e select >2 grade 0ecause it can 0e easil* stored under solent contained sealed container. :ic6el catal*sts are especiall* suscepti0le to sul#ur poisoning. 8ul#ur co"pounds in #eed are 6ept 0elo7
SL2RR3 CATAL3ST S3STE Particle si-e
K
ensit* o# cat.
K
Conc.in solution
K
15) A 'F( g/cc. ).)&B.
4. 8APOR P(ASE CATAL3ST
Production o# C*clo!e+ane #ro" ,en-ene 8peci#ic sur#ace 8g
K2&'"2/g
8peci#ic Volu"e Vg K).44c"3/g ensit* o# catal*st pg K2.3g/c"3 ensit* o# pellet p p O
K2.24g/c"3 K2(oA
REACTION CON%ITIONS SELECTION TEPERAT2RE SELECTION ,ecause it is an e+ot!er"ic reaction t!e equili0riu" constant decreases as t!e te"perature is increased. Conersel* at er* lo7 te"peratures t!e reaction rate is i"practical. T!ere are t7o li"its #or !ig! te"perature selection. Q Q
At 2)oC t!er"al crac6ing o# 0en-ene 0egins. At 24'oC iso"eri-ation o# c*clo!e+ane to "et!*l c*clopentane 0egins.
8o upper te"perature range is 24'.''oC
Ta!le 4.< TE9PERATRE EM<<,R<9 C$:8TA:T. ? C@ $
(3
2.2( l$1)
14(
2.+1)
2)4
2.1'1)3 #+
Production o# C*clo!e+ane #ro" ,en-ene
2)
&.1)
315
&.)3 + 1)%2.
>e selected 2)4oC at 7!ic! alue o# is apprecia0le. or pure #eed t!e *ield at t!is te"perature and s*ste" pressure is al"ost 1))B.
PRESS2RE SELECTION Hig! pressure i.e. 35 at"osp!ere is c!osen due to #ollo7ing reasons. ?i@
At 2)4C t!e apor pressure o# 0en-ene is er* !ig! so to get a liquid p!ase reaction !ig! pressure "ust 0e speci#ied.
?ii@
T!e e+pression #or equili0riu" constant #or t!is reaction is K
SCH12 SE/U3 SCHSH23
>!ere π = pressure in at"osp!eres a0solute. T!e e+pression s!o7s clearl* t!at !ig!er Pressure #aours !ig!er C H12 *ield. ?iii@
T!e stoic!io"etric equation #or reaction is
CH J 3H2
CH12
According to eD c!attier principle !ig! pressure 7ill #aour "ore 0en-ene inersion.
SELECTION OF (3%RO6EN TO BEN*ENE RATIO
#*
Production o# C*clo!e+ane #ro" ,en-ene A ta0le is gien 0elo7 7!ic! s!o7s t!e i"pact o# H 2/,- ratio on reaction conersion at 2)4 C. Ta!le 4.= Te'perature
(4>B
? E)cess
Benene Concentration
9OC:
9ol>ol:
($dro#en
2)4
3
)
11&)) pp".
2)4
3.)3
1.)
535) pp".
2)4
3.15
5.)
2)5 pp".
2)4
3.&5
25.)
pp".
2)4
.))
1)).)
1pp".
2)4
).5 pp".
$ur c!oosen conersion is ((.(('B equialent to 5% 1) pp" equili0riu" 0en-ene so 25B e+cess 0en-ene is used.
ASS2PTIONS AN% T(EIR @2STIFICATION 1.
All t!e sul#ur in 0en-ene #eed is conerted to H28. S (4 (4S T!e H28 in pp" is discarded in purge strea" #ro" liquid/gas separator. Alt!oug! #or purge concentration o# C$ is cared a0out lo7 pp" H28 is assu"ed to 0e 0lo7n % o##.
2.
Pressure
e##ects
on
solu0ilit*
is
neglected
0ecause
total
condensed c*clo!e+ane #las!ed #ro" separator is rec*cled 0ac6 ia oer%!ead condenser. #
Production o# C*clo!e+ane #ro" ,en-ene 3.
8tead* state equi"olar #lo7 o# c*clo!e+ane ?apor and liquid@ is assu"ed in sta0ili-er 0ecause 0ot! strea"s are #ed 7!en t!e* are saturated.
4.
or so"e !eat e+c!angers aerage trans#er coe##icients are used 7!ic! are usti#ied #or preli"inar* design.
RECOEN%E% %ESI6N CAPACIT3 ata ta6en #ro" a!ore C!a"0er $# Co""erce #or t!e i"port o# c*clo!e+ane in Pa6istan is in t!e range o# 0atc! operation to "a6e it in continuous operation range t!e "ini"u" capacit* is 4) tons/da* so 7e !ae selected it. Continuous processes are less e+pensie and product cost per unit o# ti"e is less t!an 0atc! operations. T!e #inal purit* o# product is ((.('B t!at is suita0le to "ar6et.
6ENERAL %ISC2SSION ON %ESI6N >!en
one
sees
t!e
design
results
t7o
pro"inent
#eatures
are
!ig!lig!ted. 1. As t!e capacit* selected is clai"ed #or a pilot plant t!e design di"ensions o# all
equip"ents support t!e clai" i.e. no co""ercial scale di"ensions are encountered. 2. T!e di"ensions are consistent i.e. design "et!ods/strategies 7or6 7ell and no uneenness is #ound. T!ese #eatures not onl* con#ir" t!e design strategies 0ut also usti#* t!e assu"ptions "ade in t!e design. 8econdl* alt!oug! it is a pilot plant t!ere is no need #or special #a0rication i.e. all t!e !eat e+c!angers and rotar* "ac!iner* is readil* aaila0le/#a0ricated 0* endors/#a0ricators.
$(
Production o# C*clo!e+ane #ro" ,en-ene
Chapter 0 <
ATERIAL BALANCE " ENER63 BALANCE ATERIAL BALANCE Basis 4) tons ?1(.'4 g "ole/ !r or 1'.5 6g / !r@ per da* o# c*clo!e+ane $#
Production o# C*clo!e+ane #ro" ,en-ene ,- F 1
H2
F 3.&5
?in "ol #raction @
REACTION CH J 3H2
CH12
Fro' Enc$clopedia Product co'positionD 9wt. !asis: C.H.
K
).(('' 9.C.P.
K
).)))22
,en-ene
K
1) pp"
<"purities ?CH4 J C2H etc@ K Total
).))1
K
1.))
Benene Feed Co'position 95t. !asis: ,en-ene
K
).((&'
C.H.
K
).)))1
9.C.P.
K
).)))12
<"purities
K
).)))5&
8ul#ur
K
).5 pp"
Total
K
1.))
($dro#en Feed Co'position $$
Production o# C*clo!e+ane #ro" ,en-ene ?>t. 0asis@
?9ol 0asis@
H2
K
).(111
).('&('
C)2
K
).)))2
).))))1
C$
K
CH4
K
).)''53
).)12
T$TA
K
1.))
1.))
).)))13
).))))1
BALANCE ACROSS REACTOR 9R-O1:
R-O1 Co'ponents ,en-ene C*clo!e+ane 9.C.P. <"purities
In 9;#>hr: 154'.') ).3 )1(5 1.)).
Out 9;#>hr: &' 15'3. ).4 1.&
%$ Production o# C*clo!e+ane #ro" ,en-ene
8ul#ur H*drogen Car0on dio+ide Car0on"ono+ide 9et!ane Total Te'p 9C:
Trace. 15) ).) ).)4 25 1&25 2)4.4
Trace 3 ).) ).)4 25 1&25 2)4.4
Press 9at':
35
34.25
BALANCE ACROSS REACTOR 9R-O4:
R-O4 Co'ponents ,en-ene C*clo!e+ane 9.C.P. <"purities 8ul#ur H*drogen Car0on dio+ide Car0on"ono+ide 9et!ane Total
In 9;#>hr: &' 15'3. ).4 1.& Trace 3 ).) ).)4 25 1&25
Out 9;#>hr: ).)2 1& ).4 1.& Trace 3) ).) ).)4 25 1&25 $&
Production o# C*clo!e+ane #ro" ,en-ene
Te'p 9C:
2)4.4
2&3
Press 9at':
34.25
33.
BALANCE ACROSS FLAS( %R2 98-O1:
8-O1 Co'ponents
In 9;#>hr:
,en-ene C*clo!e+ane 9.C.P. <"purities 8ul#ur H*drogen Car0on dio+ide
1.& 1.545 ).4 1.& Trace 3) ).)
Car0on"ono+ide
).)4
9et!ane
2.)
Li&uid ).)2 1.5 ).4 1.& % ).4(' % 1)+.
Out 9;#>hr: Pur#e % % % % % 1 ).)3
Rec$cle % % % % % 13.25 ).)25
1)+4.2
).)2
).)1&
1)+3
13.14
11.5
%
3%
Total 1&25 1( 3) BALANCE ACROSS STABILI*ATION COL2N 98-O4:
25
$,
Production o# C*clo!e+ane #ro" ,en-ene
8-O4 Co'ponents
In 9;#>hr:
,en-ene C*clo!e+ane 9.C.P. H*drogen Car0on dio+ide
).)2 1.5 ).4 ).(( % 1)+.
Car0on"ono+ide 9et!ane Total
Out 9;#>hr: Botto's O+erheads 5.1'1)%3 ).)14'2 1.5 ) %4 3.+1) ).3(( ).)25' ).(&)2 % ) 1)+.
1)+4.2
)
1)+3
)
1(
1.53
%
3%
1)+4.2
%
1)+3
3%
1.3'&
O8ERALL ATERIAL BALANCE
$-
Production o# C*clo!e+ane #ro" ,en-ene
$+
Production o# C*clo!e+ane #ro" ,en-ene
ENER63 BALANCE LATENT (EAT OF 8APORATION D>atson EquationL K i 0 S ?Tc IT@/?Tc IT 0@ ).3' >!ereL TK
Te"perature ?$@
Tc K
Critical te"perature #or c*clo!e+ane
K
(( R.
T 0 K
,oiling point #or c*clo!e+ane
K
3.3 R
(EAT OF REACITONDCH J 3H2 ?1@
CH12 ?g@
?g@
Su' of products (eat of for'ationG H Su' of products (eat of for'ationG (eat of reaction S% 2(43) % S11&2) J ) K %&4135.32 0tu/l0%"ol
SPECIFIC (EAT OF C3CLO(E,ANE 8APORSDro"53& R to () R C) p K ?1.'@
?%&.&)1 J125.&5+l)%3 T% 41.5'+1)% T%2@ dt ?1.'@
dt
C p K
3&.15 ,tu/l0 "ol. $*
Production o# C*clo!e+ane #ro" ,en-ene C p K 154.43 6G/ 6g%"ol. Critical pressure
K 5'' psia
Critical te"perature
K (( R
Reduced PressurePr
K ).'&
Reduced te"peratureTr K ).(. C p % C p
K (. + 1)%
8peci#ic HeatC p
K 3&.15 ,tu/l0 "ol.
8peci#ic HeatC p
K155.5 6G/ 6g%"ol.
SPECIFIC (EAT OF (3%RO6ENDC po K
?.52J).&'+l)%3TJ).l2+l)5 T%2@dt
K S?.52 T J).&'+1)%/23T2 %).12+1) 5 /T @
dt
S()%53&
C p ?1532.2 J &.1 J 1&.&54@/235 =
K .(2 ,tu / l0%"ol%o F
=28.96 6G/ 6g%"ol.
SPECIFIC (EAT OF LI72I% BEN*ENEDa C p at && K
).45 ,tu / l0%"ol%o F
0 C p at 4)) K
J.K ,tu / l0%"ol% o F
c C p
K
?).%).45@/?4))%&&@ $
Production o# C*clo!e+ane #ro" ,en-ene K
4.44+l)%4 ,tu / l0%"ol% o F
8peci#ic !eat C p =
(a + ct)dt ÷
8peci#ic !eat C p K S
).45dt J
dt
4.44/2+1) %4 Tdt VS4))%&&
K
43.&4 ,tu/l0 "ol
K
1'3.)( 6G/ 6g%"ol.
SPECIFIC (EAT OF LI72I% C3CLO(E,ANEDAerage Te"perature K
Reduced Te"p.Tr Accentric #actor W
K
434
K
).&'4
K
).214
C p apor !eat capacit* K %&.&)1 J 125.&5 + 1)%3 ?434@ % 41.5'4 + 1)% ?434@2 K
%&.&)1 J 54.543%).)2
K 4.'24 ,tu/l0 "ol. K 1(5 G/ 6g%"ol. sing 8ternling and ,ro7n relationF%
%(
Production o# C*clo!e+ane #ro" ,en-ene ?C p l % C po @/2 = ?).5 J 2.2 W@S3.& J 11.4?1%Tr @4 J ).34?1%Tr @%1 >!ereL R K 2 ,tu/ l0 "ol % ?C p l % C po @/2 K ?).(&1@ S3.& J ).)253 J 2.(35 ?C p l % C po @/2 K .44 Cp K 5(.& ,tu/ l0% "ol K 24'.1& G/ 6g%"ol.
%#
Production o# C*clo!e+ane #ro" ,en-ene
ENER63 BALANCE ARO2N% REACTORSD-
(R/MMF ( PRO%2CTS/JJF - (REACTANTS/=JJF 1.
?A@
(r/MM K &4135.32 ,tu/l0 "ol ?C.H.@ + 45.15& "oles/!r K 33&&2'.5 ,tu/!r.
4.
(PRO%2CT FRO =JJ TO JJ F
XH p K "C pXT K 45.15&+3&.15 ,tu/l0 "ol % ?5))%&&@ J3.21?5))%&&@ ?.(3@ K &)(1& J 1)145.32 K '15&2.32 ,tu/!r. <.
( reactants fro' MM to =JJ F %$
Production o# C*clo!e+ane #ro" ,en-ene (R K"CpXT K 45.45 "oles/!r + 43.&4 ,tu/l0 "ol % + ?4)) % &&@ J 1.2 + .(1 + ?4))%&&@ K 1)13)52.4 ,tu/!r.
K 3.5 + 1) ,tu/!r or 5.( + 1)4 ,tu/"in. 5.( + 1) ,tu/"in. !as to 0e re"oed 0* outer circulation.
FI,E% BE% REACTOR O2T-LET TEPERAT2REDConersion
K
(' B to 1))B
9oles conertedK 45.45 ?).)2@ K ).()( l0 "oles/!r. Heat generated at && K &3'( ,tu/!r.
K
5))
Assu"e adia0atic operationF
K
45.45 ?%&.&)1J125.&5 x1)%3 T@dt J
33.3'3?.52J ).&'+1)%3T)dt %%
Production o# C*clo!e+ane #ro" ,en-ene
3&43'.33 K S%&.&)1?T2%533@ J
?T22 I 5))2@ ?45.45@ J S.52?T2 I 5))@ J
?T22 I 5))2@?33.3'@ 3&43'.33 K S%35)T2 J 1'555.5&J2.'5T22 % '1134'l J S21&.T 2 % 11)11.3 J ).)13 &/ %3('. 3&43'.33 K %132.34 T2 J 2.'& T22 % &445)2.5 HenceL 2.'& T22 % 1 3 2 . 3 4 T 2 % &'1(4).'2 K 3&43'.33 $n soling t!e a0oe quadratic equation 7e get te"perature in o T2 K 522.55
%&
Production o# C*clo!e+ane #ro" ,en-ene
ENER63 BALANCE OF (EAT E,C(AN6ERS ENER63 BALANCE OF O2TER RECIRC2LATION COOLERD
STREA STREA 1
4
luid Entering
,en-ene
>ater
lo7%rate ?6g/!r@
2'&&.3
&(&'.&
24'.''
15).5
$utlet Te"perature )C
2)4.44
243.3
C!ange in te"perature )C
44.44
(3.3
Heat Capacit* ?G/6g @
25().3
5&(
$ulet Ent!alp*
6G/6g 6G/6g
41(.& 52)
1(1.(
()&.4
ut* o# e+c!anger ?9G/!r@ 3)(4
3)(4
ENER63 BALANCE OF CON%ENSER FOR C3CLO(E,ANE 8APORSD
Production o# C*clo!e+ane #ro" ,en-ene
PARAETERS
STREA
STREA
1
4
C*clo!e+an
>ater
PARAETERS
e J as STREA
STREA
lo7%rate ?6g/!r@
1 1&25
4 24&'.5
luid Entering
luid Entering
c*clo!e+ane 2&2.5
>ater 2.&
1( 2
11)3.2 14(
) )C
125 2)2 125 3 3.+1)
55.24 122.3 5. 3 4.1(+1)
Heat
3 3.)+1) '(1 515 3&'.53 4&4 12 ))
3 4.1(+1) &.123 12.& 51(.5 1&. 12 ))
)
C
lo7%rate ?6g/!r@ $utlet Te"perature
C
)
K 51(.5J3&'.53
'('.1236G/6g K '('.123 6G/g
ENER63 BALANCE OF O8ER(EA% CON%ENSERD
%-
Production o# C*clo!e+ane #ro" ,en-ene
K 41(.5J'4.)3
512.236G/6g K 512.5( 6G/g
ENER63 BALANCE OF PRO%2CT COOLERD
%+
Production o# C*clo!e+ane #ro" ,en-ene
PARAETERS
STREA
STREA
1
4
c*clo!e+ane
>ater
1(
')42.22
C
1'4
25
$utlet Te"perature )C
3)
43
Heat Capacit* ?G/6g @
3.)+1) 3
4.1(+1)3
233.52
41.(
2))
&5.42
&23.'5
&23.'5
luid Entering lo7%rate ?6g/!r@
6G/6g
$utlet Ent!alp*
)
6G/6g
ut* o# e+c!anger
?9G/!r@
Ent!alp*K $utlet Ent!alp* 2&5.42K2&5.42?6G/6g@
Chapter 0 = %*
Production o# C*clo!e+ane #ro" ,en-ene
%ESI6N OF E72IPENTS
REACTOR %ESI6N 5(AT IS A REACTOR %
Production o# C*clo!e+ane #ro" ,en-ene a. A container to 7!ic! reactants are #ed and products re"oed t!at proides #or t!e control o# reaction conditions. 0. A deice t!at encloses t!e reaction space and 7!ic! !ouses t!e catal*st and reacting "edia Y is designed to proide residence ti"es #or reactants so t!at c!e"ical reaction occur a"ong t!e" under proper reaction conditions.
REACTION Q
ain reaction
XH K % 214 G/"ole
Q
Q
Hig!l* e+ot!er"ic
Q
aored 0* lo7 T Y !ig! ppH2
Side reactions Q
Q Q
<"pacts #inal product qualit*
Ring opening
Q
aored 0* !ig! T
COON T3PES OF 2LTIP(ASE CATAL3TIC REACTORS 1. Fi)ed-!ed Reactors a. Pac6ed 0eds o# pellet or "onolit!s &(
Production o# C*clo!e+ane #ro" ,en-ene 0. 9ulti%tu0ular reactors 7it! cooling c. 8lo7 8lo7%" %"oi oing ng pell pellet et 0eds 0eds d. T!ree%p T!ree%p!ase !ase tric6l tric6lee 0ed 0ed reactor reactorss
4. Flu Fluidid-!ed !ed and and Slurr Slurr$$ Reacto Reactors rs a. 8tat 8tatio iona nar* r* gas% gas%p! p!as asee 0. as%p!ase c. iquid uid%p!a %p!asse i.
8lurr*
ii.
,u00le Colu"n
iii.
E0ulating 0e 0ed
SELECTION OF REACTOR T3PE 8lurr* reactors are co""onl* used in situations 7!ere it is necessar* to contact a liquid reactant or a solution containing t!e reactant 7it! a solid catal*st. To #acilitate #acilitate "ass trans#er and e##ectie catal*st utili-ation t!e catal*st is usuall* suspended in po7dered or in granular #or". T!is t*pe o# reactor !as 0een used 7!ere one o# t!e reactants is nor"all* a gas at t!e reaction conditions and t!e second reactant is a liquid e.g. in t!e !*drogenation o# arious oils. T!e reactant gas is 0u00led t!roug! t!e liquid dissoles and t!en di##uses to t!e catal*st sur#ace. $0iousl* "ass trans#er li"itations can 0e quite signi#icant in t!ose instances 7!ere t!ree p!ases ?t!e solid catal*st and t!e liquid and gaseous reactants@ re actants@ are present and necessar* to proceed rapidl* #ro" reactants to products. 8atter#ield !as discussed seeral adantages o# slurr* reactors relatie to ot!er "odes o# operation. T!e* include t!e #ollo7ing. 1. >ell%agitated >ell%agitated slurr* "a* 0e 6ept at a uni#or" te"perature t!roug!out eli"inating !ot spots t!at !ae aderse ad erse e##ects on catal*st selectiit*. selectiit*.
&#
Production o# C*clo!e+ane #ro" ,en-ene 2. T!e !ig! !eat capacit* associated a ssociated 7it! t!e large "ass o# liquid #acilitates control o# t!e reactor and proides a sa#et* #actor #or e+ot!er"ic reactions t!at "ig!t lead to t!er"al e+plosions or ot!er runa7a* eents. 3. 8ince liquid p!ase !eat trans#er coe##icients are large !eat recoer* is practical 7it! t!ese s*ste"s. 4. T!e s"all particles used in slurr* reactors "a* "a6e it possi0le to o0tain "uc! !ig!er rates o# reaction per unit 7eig!t o# catal*st t!an 7ould 0e ac!ieed 7it! t!e larger pellets t!at 7ould 0e required in tric6le 0ed reactors. T!is situation occurs 7!en t!e tric6le 0ed pellets are c!aracteri-ed 0* lo7 e##ectieness #actors. 5. Continuous regeneration o# t!e catal*st can 0e o0tained 0* continuousl* re"oing a #raction o# t!e slurr* #ro" 7!ic! t!e catal*st is t!en separated regenerated and returned to t!e reactor. . 8ince #ine catal*st particles are desired t!e costs associated 7it! t!e pelleting process are aoided and it 0eco"es possi0le pos si0le to use catal*sts t!at are di##icult or i"possi0le to pelleti-e. A "aor deterrent to t!e adoption o# continuous slurr* reactors is t!e #act t!at pu0lis!ed data are o#ten inadequate #or design purposes. 8olu0ili-ation and "ass trans#er processes "a* in#luence o0sered conersion rates and t!ese #actors "a* introduce design uncertainties. $ne also !as t!e pro0le"s o# deeloping "ec!anical designs t!at 7ill not plug up and o# selecting carrier liquids in 7!ic! t!e reactants are solu0le *et 7!ic! re"ain sta0le at eleated te"peratures in contact 7it! reactants products and t!e catal*st. A #urt!er disadantage o# t!e slurr* reactor is t!at t!e ratio o# liquid to catal*st is "uc! greater t!an in a tric6le 0ed reactor. Hence t!e relatie rates o# undesira0le !o"ogeneous liquid p!ase reactions 7ill 0e greater in t!e slurr* reactor 7it! a potential aderse e##ect on t!e process selectiit*.
T3PES &$
Production o# C*clo!e+ane #ro" ,en-ene 8lurr* reactors "a* ta6e on seeral p!*sical #or"sF t!e* "a* 0e si"ple stirred autoclaesL t!e* "a* 0e si"ple essels #itted 7it! an e+ternal pu"p to recirculate t!e liquid and suspended solids t!roug! an e+ternal !eat e+c!angerL or t!e* "a* rese"0le a 0u00le%tra* recti#*ing colu"n 7it! arious stages placed a0oe one anot!er in a single s!ell. 8ince a single slurr* reactor !as a residence ti"e distri0ution appro+i"ating a C8TR t!e last "ode o# construction gies an eas* "eans o# o0taining stage7ise 0e!aior and "ore e##icient utili-ation o# t!e reactor olu"e.
5(3 B2BBLE SL2RR3 COL2N REACTOR Q
T!e* T!e* !ae e+ce e+celle llent nt !eat !eat and "ass "ass trans# trans#er er c!aract c!aracteri eristi stics cs "eani "eaning ng !ig! !ig! !eat and "ass trans#er coe##icients.
Q
ittle it tle "ain "ainten tenance ance and and lo7 lo7 operati operating ng costs costs are requ require iredd due to lac6 lac6 o# "oing parts and co"pactness.
Q
>ide >ide range range o# possi possi0le 0le operat operating ing pressure pressures?5% s?5%15) 15)0ar@ 0ar@
Q
A0sorpt A0sorption ion o# react reaction ion !eat !eat is o0ta o0tain in so so t!at t!at isot!e isot!er"a r"all condit condition ionss are approac!ed
Q
o7 o 7 pre press ssur uree dro dropp acr acros osss rea react ctor or
Q
itt ittle le #loo #loorr spac spacee is is req requr urie iedd
Q
Hig! Hig! 7ettin 7ettingg o# e+terna e+ternall catal* catal*st st sur#ace sur#ace to to dela* dela* catal* catal*st st #ouling #ouling
Q
8olids 8olids can can 0e !andle !andledd 7it!out 7it!out sign signi#i i#ican cantt errosio errosionn or pluggi plugging ng pro0le pro0le"s "s
Q
T!e dura0i dura0ilit lit** o# t!e catal catal*st *st or ot!er ot!er pac6in pac6ingg "ateri "aterial al is !ig!. !ig!. 9oreo 9oreoer er online catal*st addition and 7it!dra7al a0ilit*
SL2RR3 B2BBLE COL2N REACTOR INTRO%2CTION A 0u00le colu"n reactor is 0asicall* a c*lindrical essel 7it! a gas distri0utor at t!e 0otto". T!e gas is sparged in t!e #or" o# 0u00les into eit!er a liquid p!ase or a liquidI &%
Production o# C*clo!e+ane #ro" ,en-ene solid suspension. T!ese reactors are generall* re#erred to as slurr* 0u00le colu"n reactors 7!en a solid p!ase e+ists.
,u00le colu"ns are intensiel* utili-ed as "ultip!ase contactors and reactors in c!e"ical petroc!e"ical 0ioc!e"ical and "etallurgical industries. T!e* are used especiall* in c!e"ical processes inoling reactions suc! as o+idation c!lorination al6*lation pol*"eri-ation and !*drogenation in t!e "anu#acture o# s*nt!etic #uels 0* gas conersion processes and in 0ioc!e"ical processes suc! as #er"entation and 0iological 7aste7ater treat"ent. 8o"e er* 7ell 6no7n c!e"ical applications are t!e #a"ous isc!erITropsc! process 7!ic! is t!e indirect coal lique#action process to produce transportation #uels "et!anol s*nt!esis and "anu#acture o# ot!er s*nt!etic #uels 7!ic! are eniron"entall* "uc! "ore adantageous oer petroleu"%deried #uels. &&
Production o# C*clo!e+ane #ro" ,en-ene
REACTOR S;ETC( " ATERIAL AN% ENER63 BALANCE
&,
Production o# C*clo!e+ane #ro" ,en-ene
%ESI6N CALC2LATIONS STEPS AFFECTIN6 T(E 6LOBAL RATE 1. ass transfer of #as fro' !u!!le to !u!!le>li&uid interface. &-
Production o# C*clo!e+ane #ro" ,en-ene
6 g K "ass trans#er coe##icient #or gas di##usion ag K gas 0u00le%liquid inter#acial area per unit olu"e o# 0u00le #ree slurr* Cg K concentration o# !*drogen in gas Cig K H2 concentration at 0en-ene%!*drogen 0u00le inter#ace ?at gas side@
4. ass transfer fro' the sta#nant li&uid fil' of !u!!le to !ul of li&uid. 6 l K "ass trans#er coe##icient #or gas a0sorption ag K gas 0u00le%liquid inter#acial area per unit olu"e o# 0u00le #ree slurr* Cil K H2 concentration at 0en-ene%!*drogen 0u00le inter#ace ?at liquid side@ Cl K 0ul6 concentration o# H2 in solution
<. i)in# " diffusion in !ul li&uid. T!e rise o# 0u00les t!roug! liquid is su##icient to ac!iee uni#or" conditions in 0ul6 liquid. Hence t!e resistance o# step 3 can 0e neglected.
=. ass transfer of dissol+ed #as fro' the !ul li&uid to the outer &+
Production o# C*clo!e+ane #ro" ,en-ene
surface of solid catal$st. 6 c K "ass trans#er coe##icient #or particles ac K e+ternal sur#ace area o# paticles Cl K 0ul6 concentration o# H2 in solution Cs K concentration o# H2at t!e e+ternal sur#ace area o# catal*st pellet
. Reaction on the catal$st and diffusion of products to li&uid phase. 6 K speci#ic reaction rate constant ac K e+ternal sur#ace area o# paticles Cs K concentration o# H2at t!e e+ternal sur#ace area o# catal*st pellet
CATAL3ST S3STE C(ARACTERISTICS Particle si-e
K
15) A ?sp!erical@
Catal*st densit*
K
'.( g/cc
Cone in solution K "cat K
).)&B
Conc. in solution + liq. densit* K
?).)))&@ ?).51@ K 3.5& +l$%4 g/cc
K 1).45 c"2/cc &*
Production o# C*clo!e+ane #ro" ,en-ene
B2BBLE %IAETER CALC2LATIONS u"ar and uloor Correlation
0 K 0u00le dia"eter c" K 6ine"atic iscosit* c"2/sec K 1.( + 1)%3
M K Vol. #lo7 rate o# gas cc/sec K 2341(.34 g K graitational constant c"/sec2 K (') 03 K 1.24& 0 K 1.)& c" K 1).& "" ag K 4 �r 2 K 3.3& c"2
B2BBLE FRE72ENC3 CALC2LATION
M K Vol. #lo7 rate o# gas K 2341(.34 cc/sec K $ri#ice dia"eter K '"" K ).' c" Z
K 8ur#ace tension.
Esti"ate t!e sur#ace tension Z using t!e generali-ed corresponding state correlation o# ,roc6 and ,ird and t!e 9iller relations!ip. T!e correlation and t!e relations!ip are as #ollo7sF
7!ere K is de#ined as #ollo7sF &
Production o# C*clo!e+ane #ro" ,en-ene
>!ere Z K sur#ace tension in d*nes/c" Pc K critical pressure 0ar Tc K critical te"perature T 0 K nor"al 0oiling point T 0 K ').1 C K 353.1 T 0r K ).3 Tr K ).'5 Pc K 4'.3 at" Z #
K K
Tc K 52.1
K ).3
.'5& d*nes/c" '1)2 ,u00les/sec.
FIN%IN6 O8ERALL RATE E72ATION 8oling all di##usion Y reaction equations si"ultaneousl* gies #inal equation o# t!e #or"
>!ere
nder t!e assu"ptionsF as is pure so Cg K Cig Catal*st is !ig!l* actie so 6 is er* large ,(
Production o# C*clo!e+ane #ro" ,en-ene Equili0riu" e+ist at 0u00le%liquid inter#ace Cig and Cil are related 0* Henr*[s a7
Cig K H Cil
As 0u00les are s"all and in large cone ?arge ag@ 7!ile ac is lo7 and poor agitation so #inal e+pression #or 6 o is
And oerall reaction rate is
LI72I% FIL %IFF2SION COEFFICIENT CALC2LATION 9ass trans#er correlations #ro" ,ul6 liquid to catal*st particle
>!ere K di##usiit* o# !*drogen K 3.' + 1)%5 Ol K iscosit* o# 0en-ene K ).))1 poise \l K densit* o# 0en-ene K ).51 g/cc Hence 6 c K ).)3)5 c"/sec
O8ERALL RATE CALC2LATION H
K
1&5.4
pp H2 K
35 at"
ac
K
1).45 c"2 /cc ,#
Production o# C*clo!e+ane #ro" ,en-ene
K '.(31 + 1)%4 g"ol/cc
r K 2.4& + 1)% "ol o# 0en-ene/cc%sec
REACTOR 8OL2E CALC2LATION
V K olu"e o# slurr* c"3 e I i K ).(5 r K 2.4& + 1)% "ol o# 0en-ene/cc%sec K 5.&4 g"ol/sec
V K 22)2431.43 c"3 K2.2) "3 Reactor olu"e is o0tained 0* 25 B incre"ent 8reactor 4.M '< Vessel is c*lindrical and in slurr* 0u00le colu"n reactors !eig!t to dia"eter ratio is #ro" 3 to . et !eig!t to dia"eter ratio 0e 4F1 so ia"eter o# essel K ).( " Heig!t o# essel
K 3.'3 "
,$
Production o# C*clo!e+ane #ro" ,en-ene
RESI%ENSE TIE CALC2LATION
Volu"e o# essel K 2.&5 "3 Volu"etric #lo7rate K ).)234 "3/sec ] K 1.(5' "in
SPAR6ER SELECTION Porous plate distri0utor is selected 0ecause Q
o7 price
Q
Eas* "anu#acturing
Q
Variet* o# spec#ications
,%
Production o# C*clo!e+ane #ro" ,en-ene
PRESS2RE %ROP CALC2LATIONS XP across sparger K ).1%).3 at" Q
et XP 0e ).2 at"
XP due to liquid !ead K ).1&5 at" Total XP K ).3&5 at"
SPECIFICATION S(EET Identification
Reactor
R%1)1
:o. required
1
Position
Vertical
,&
Production o# C*clo!e+ane #ro" ,en-ene
Function
Production o# c*clo!e+ane #ro" 0en-ene !*drogenation
Operation
Continuous
T$pe
Catal*tic 8lurr* ,u00le Colu"n Reactor
Che'ical Reaction CH J 3H2 Catal$st
CH12
^H K %214 G/"ol
Rane* :ic6el
8!ape F 8p!erical 8i-e F 15) oA 9aterial Contained
,en-ene
7ualit$ of 'aterial
8lig!tl* Corrosie
5orin# 8olu'e
2.2) "3
%esi#n 8olu'e
2.&5 "3
Residense ti'e
1.(5' "in
Te'perature 9process 2)4&.4 oC te'perature: 5orin# Pressure
35 at"
%ia'eter of 8essel
).( "
(ei#ht of 8essel
3.'3 "
(ei#ht to %ia Ratio
4F1 ,,
Production o# C*clo!e+ane #ro" ,en-ene
,-
Production o# C*clo!e+ane #ro" ,en-ene
VERT
,+
Production o# C*clo!e+ane #ro" ,en-ene T!e si-e a apor%liquid separator dru" ?or 6noc6%out pot or #las! dru" or co"pressor suction dru"@ s!ould 0e dictated 0* t!e anticipated #lo7 rate o# apor and liquid #ro" t!e dru". T!e #ollo7ing si-ing "et!odolog* is 0ased on t!e assu"ption t!at t!ose #lo7 rates are 6no7n. se a ertical pressure essel 7it! a lengt!%to%dia"eter ratio o# a0out 3 to 4 and si-e t!e essel to proide a0out 5 "inutes o# liquid inentor* 0et7een t!e nor"al liquid leel and t!e 0otto" o# t!e essel ?7it! t!e nor"al liquid leel 0eing at a0out t!e esselDs !al#%#ull leel@.
SELECTION CRITERIA FOR 8APOR LI72I% SEPARATORS T!e con#iguration o# a apor/liquid separator depends on a nu"0er o# #actors. ,e#ore "a6ing a essel design one !as to decide on t!e con#iguration o# t!e essel 7it! respect to a"ong ot!ersF •
$rientation
•
T*pe o# #eed inlet
•
T*pe o# internals
•
T*pe o# !eads
Orientation of the 8essel T!e selection o# t!e orientation o# a gas%liquid separator depends on seeral #actors. ,ot! ertical and !ori-ontal essels !ae t!eir adantages. epending on t!e application one !as to decide on t!e 0est c!oice 0et7een t!e alternaties. Adantages o# a ertical essel areF •
a s"aller plot area is required ?critical on o##s!ore plat#or"s@ ,*
Production o# C*clo!e+ane #ro" ,en-ene
•
it is easier to re"oe solids
•
liquid re"oal e##icienc* does not ar* 7it! liquid leel 0ecause t!e area in t!e essel aaila0le #or t!e apor #lo7 re"ains constant
•
generall* t!e essel olu"e is s"aller
Adantages o# a !ori-ontal essel areF •
it is easier to acco""odate large liquid slugsL
•
less !ead roo" is requiredL
•
t!e do7n7ard liquid elocit* is lo7er resulting in i"proed de%gassing and #oa" 0rea6do7nL
•
additional to apor / liquid separation also a liquid / liquid separation can 0e ac!ieed ?e.g. 0* installing a 0oot@.
T!e pre#erred orientation #or a nu"0er o# t*pical apor / liquid separation applications areF
Application
Preferred orientation
Reactor E##luent 8eparator ?V/@
Vertical
Reactor E##luent 8eparator ?V//@
Hori-ontal
Re#lu+ Accu"ulator
Hori-ontal
Co"pressor $ ru"
Vertical
uel as $ ru"
Vertical
lare $ ru"
Hori-ontal
Condensate las! ru"
Vertical ,
Production o# C*clo!e+ane #ro" ,en-ene
8tea" isengaging ru"
Hori-ontal
Feed Inlet Inlet Nole T!e #eed no--le si-e and t!e t*pe o# #eed inlet deice ?i# an*@ !ae an i"pact on t!e apor / liquid separation t!at can 0e ac!ieed. T!e #eed no--le is nor"all* si-ed to li"it t!e "o"entu" o# t!e #eed. T!e li"itation depends on 7!et!er or not a #eed inlet deice is installed.
Inlet de+ice Various inlet deices are aaila0le to i"proe t!e apor / liquid separation. A"ong ot!ers t!e #ollo7ing inlet deices "a* 0e installedF •
a de#lector 0a##le
•
a slotted tee distri0utor
•
a !al#%open pipe
•
a () el0o7
•
a tangential inlet 7it! annular ring
•
a sc!oepentoeter
or ertical dru"s pre#era0l* a de#lector 0a##le or a !al# open pipe s!all 0e selected.
-(
Production o# C*clo!e+ane #ro" ,en-ene or !ori-ontal dru"s nor"all* a () el0o7 or a slotted dierter is installed.
a () el0o7 or a slotted dierter in case o# an all liquid or apor%liquid #eed
•
a su0"erged pipe 7!en t!e #eed is a su0cooled liquid and t!e "i+ing o# liquid and 0lan6et gas is to 0e "ini"i-ed
•
t7o () el0o7 inlets in case o# !ig! apor loads
Internals A#ter passing t!roug! t!e #eed inlet t!e apor strea" 7ill still contain liquid in t!e #or" o# droplets. T!e "a+i"u" si-e o# t!ese entrained droplets depends on t!e apor up#lo7 elocit*. A separation deice can reduce t!is entrain"ent signi#icantl*. >ire "es! de"isters are t!e "ost co""onl* used as separation deice. T!e* are used #or t7o reasonsF •
To "ini"i-e entrain"ent
$# t!e dru" serices !aing suc! a require"ent suction dru"s #or reciprocating co"pressors are t!e "ost nota0le e+a"ples •
To reduce t!e si-e o# a essel
T!e allo7a0le apor elocit* in a dru" can 0e increased signi#icantl* 0* using a 7ire "es! de"ister. 8o 7!en si-ing is goerned 0* apor%liquid separation criteria t!is 7ill result in a s"aller dia"eter o# t!e essel 9aor disadantages o# 7ire "es! de"isters areF •
T!e* are not suita0le #or #ouling serices
•
T!eir liquid re"oal decreases signi#icantl* at reduced t!roug!put -#
Production o# C*clo!e+ane #ro" ,en-ene Alt!oug! t!e si-e o# t!e essel o#ten can 0e reduced 0* appl*ing a 7ire "es! de"ister t!ere are also "an* serices 7!ere t!ere is nor"all* no de"ister installed. Re#lu+ accu"ulators #or e+a"ple seldo" !ae "ist eli"inators. T!ere are seeral ot!er t*pes o# "ist eli"inators suc! as anes c*clones and #i0er 0eds. T!e* are used 7!en conditions are not #aora0le #or 7ire "es! screens. 8election criteria #or t!ese t*pes o# internals are t!e required e##icienc* capacit* turndo7n ratio "a+i"u" allo7a0le pressure drop and #ouling resistance. T!ese t*pes !o7eer 7ill not 0e #urt!er addressed in t!is design guide.
8essel (ead 9ost essels !ae 2F1 elliptical !eads 7elded to t!e s!ell o# t!e essel. Ho7eer in so"e cases ot!er t*pes o# !eads are used. T!e "aor alternaties areF •
lat !eads
He"isp!erical !eads
A !e"isp!erical !ead s!ould 0e considered #or an e+tre"el* large !ig!%pressure essel •
A dis!ed !ead s!ould 0e considered in t!e case o# a large dia"eter lo7%pressure essel
-$
Production o# C*clo!e+ane #ro" ,en-ene
INLET STREA C.HK 1.545 6g/!r 9.C.PK ).3& 6g/!r ,en-eneK ).)1& 6g/!r <"puritiesK traces 8K traces H2K15)%12)K 3) 6g/!rJ H2R C$2K ).)32& 6g/!rJ C$2R C$K ).)2 6g/!rJ C$ R CH4K14.5 6g/!rJ CH4R
INP2TS $perating pressure F PK1) at" Vapour "ass #lo7 rateF >V K 5.)5 6g/!r -%
Production o# C*clo!e+ane #ro" ,en-ene Vapor densit* K 1.23 6g/!r iquid "ass #lo7 rate F > K 1( 6g/!r iquid densit* F K 3(. 6g/"3
8APORS H2K 3) 6g/!r C$2K ).)32& 6g/!r C$K ).)2 6g/!r CH4K2 6g/!r
LI72I% C.HK 1.545 6g/!r 9.C.PK ).3& 6g/!r ,en-eneK ).)1& 6g/!r <"puritiesK traces 8K traces
;# 'ole of 6ases H2K 15 6g "ole C$2K 1.33`1)%3 6g "ole C$K 1.42'5&`1)%3 6g "ole
-&
Production o# C*clo!e+ane #ro" ,en-ene CH4K1.25 6g "ole
8OL2E OF 6ASES
nK total "olesK1.2& 6g "ole
K 1.2&`).)'2`335/1) 6g"ole`at"`"3`6 / at"` 6g "ole`6 K "3 VK 45.& "3/ !r VK).& "3/ "in
%ensit$ of +apours
9ass K 5.1 6g/ !r K ).(35 6g/"in \
K ).(35/).& K 1.23 6g/ "3
-,
Production o# C*clo!e+ane #ro" ,en-ene
%ensit$ of li&uid nK total "olesK1(.'4 6g "ole 8peci#ic grait* K ).313 ensit* o# liquid K 31.3 6g/"3
STEPS VKA` K 6 ?b % b@/ b1/2 6 K ).)1)& "/s 7it! a "ist eli"inator AKU2/4 AKts` V 3 ts 5 KJ1.5J1.5#t
CALC2LATIONS irst 7e #ind elocit* o# gase K 6 ?b % b@/ b1/2 K ).)5&("/s :o7 7e #ind area VKA`
AK V/ --
Production o# C*clo!e+ane #ro" ,en-ene
).& "3
1 "in
sec
"in
) sec
).)5&(' "
K ).21' "2 K 2.34 #t2
%IAETER
K 1.&2 #t K 1.&5 #t
LEN6T( OF LI72I% ENTRAINE% AKts` Vf tsK 4 "in >e assu"e 5 percent o# entrain"ent o# liquid in apors VfK V` 5 B K ).()'` 5 B K ).)454 "3 / "in AKts` Vf -+
Production o# C*clo!e+ane #ro" ,en-ene Kts` Vf/ A K ).)454 `4 / ).21' "2 "3 / "in`"in`1/ " 2 K).33)2& " K 2.&3 #t K 2.&5 #t K J1.5J1.5 #t K .'&5 #t 9ini"u" lengt! s!ould 0e '.5 #t According to ertical and !ori-ontal ap liq separator design_ 8o lengt! is '.5 #t /K '.5/1.&5 K 4.'5 / N 5 #or ertical separator
-*
Production o# C*clo!e+ane #ro" ,en-ene
-
Production o# C*clo!e+ane #ro" ,en-ene
STABILI*ATION COL2N %ESI6N 8ta0ili-ation colu"n is t!e last "ass trans#er $peration in t!e production o# c*clo!e+ane.
+(
Production o# C*clo!e+ane #ro" ,en-ene Contrar* to t!is t!ere is anot!er design in 7!ic! t!e require"ent o# cold #eed "a* 0e rela+ed as t!e need o# cold strea" is #ul#illed 7it! t!e !elp o# re#lu+ing a part o# oer!ead apors. ,ut it is costl* due larger nu"0er o# au+iliar* equip"ents required. < selected Cold #eed 7it!out re#lu+ sta0ili-er colu"n .8aturated liquid #eed at 1) at" is entering at top o# t!e pac6ed colu"n ia liquid distri0utor. As t!e liquid #lo7s do7n t!e colu"n "a6ing a #il" on pac6ing an inti"ate contact o# liquid and gas p!ase 7!ic! is co"ing #ro" 0otto" re0oiler ta6es place !ence gases desor0 #ro" c*clo!e+ane 0ecause te"perature o# gas p!ase is !ig!er t!an liquidF a #aora0le condition #or gases to leae liquid p!ase. At t!e 0otto" re0oiler 0oils a portion o# 0otto" product and sends 0ac6 to colu"n to increase t!e purit* o# product to ((.('B. 8aturated stea" at 1).5 at" is entering in re0oiler[s coils. $er!ead products contains "aorl* !*drogen and trace a"ount o# ot!er products. T!is gas is used as a #uel gas and is stored a#ter cooling in oer!ead cooler.
ATERIAL BALANCED Feed Co'ponents
ol
Botto's ;#-
fraction 'ol>hr
ol
O+erheads
;#-
fractio 'ol>hr fraction n
)f
ol
;#'ol>hr
)d
)!
CK(K
).(&33
1(.'41
).((('
1(.'41
)
)
).((5
).4'51
2.+1)%5
1.(+1)%4
(.(+1)% (4
).)245
).4('
5.)+1) %4
3
2.)+1)% 1.)&+1) 2.1+1)% 1.)+1)%5
4
%&
+#
Production o# C*clo!e+ane #ro" ,en-ene
3.)+1)% CO
1.5+1)%&
)
)
3.)+1)%&
3.)+1)%
)
)
3.)+1)%&
3.)+1)%
)
)
3.5+1)%4 3.&+1)%3
3.)+1)% CO4
1.5+1)%&
3.&+1)% C(=
1.'+1)%4
3
2.1(+1) 4.3+1)% CP
2.15+1)%3
).)43
%&
2.&+1)%5
).)42(
Total
1.)
2).3'5
1.)
1(.'45
1.)
).54)
%ESI6NIN6 OF COL2N
T!e general design o# sta0ili-ation colu"n include #ollo7ing stepsF 1@ 8election o# tra* or pac6ed colu"n 2@ 8election o# pac6ing 3@ Calculation o# ia"eter and Area o# colu"n 4@ Calculation o# pressure drop 5@ Calculation o# :u"0er o# trans#er units @ Esti"ation o# !eig!t o# trans#er units &@ Heig!t o# Colu"n '@ Calculation o# iquid Hold p
+$
Production o# C*clo!e+ane #ro" ,en-ene
Step 0 1D SELECTION OF COL2NDApplication o# stripping in practical process requires t!e generation o# large contact area 0et7een liquid and gas p!ase. T!is is usuall* done 7it! t!ree 0asic tec!niques. 1- ,rea6ing up gas into s"all 0u00le into continuous liquid strea" ?Tra* Colu"n@ 4- iiding t!e liquid strea"s into nu"erous t!in #il"s t!at #lo7 t!roug! continuous as p!ase ? Pac6ed Colu"n@ <- ispersing t!e liquid as "ultitude o# discrete droplets 7it!in continuous gas p!ase? 8pra* Contactor@
Tra$ Colu'n
Paced Colu'n T!ese are pre#erred #or
non%#oa"ing and clean
corrosie liquids.
liquids. Tra* colu"ns are #or large
T!e* are e##icient in s"all
installations
installations.
or !ig! liquid to gas ratios
liquid #lo7%rates T!e* are pre#erred 7!en
pac6ed colu"n s are installed. or lo7 pressure drop application
internal cooling is required
t!e* 7or6 0est.
0et7een stages
< !ae selected pac6ed colu"n 0ecause c*clo!e+ane is slig!tl* corrosie and as it is er * s"a ll sc ale pla nt. Also pac 6ed colu"ns are less e+pensie t!an plate colu"ns #or s"all colu"n dia"eter ?N). "@. A0oe t!is t!e #a0rication o# tra*s in s"all dia"eter colu"n is a di##icult o0. +%
Production o# C*clo!e+ane #ro" ,en-ene T!e "ain co"ponents o# pac6ed colu"ns are gien 0ello7F 1. 8!ell 2. Pac6ings 3. Pac6ing support 4. iquid distri0utor
igure 4.2F Pac6ed colu"n 7it! its internals
Step 0 4D SELE CTION OF PAC;IN6 T3PE DT !e distri0utor and pac6ing are t!e !eart o# t!e per#or"ance o# t!is equip"ent. T!eir proper selection entails an understanding o# pac6ing operational c!aracteristics and t!e e##ects on per#or% "ance. T !e 0road classes o# pac6ings #or apor%liquid contacting are eit!er rando' or structured. T!e #or"er are s"all !ollo7 structures 7it! large s ur #a ce p er u ni t ol u" e t !a t a re l oa de d a t r an do " i nt o t !e es se l. 8tructured pac6ings "a* 0e la*ers o# large rings or grids 0ut are "ost +&
Production o# C*clo!e+ane #ro" ,en-ene co""onl* "ade o# e+panded "etal or 7oen 7ire screen t!at are stac6ed in la*ers or as spiral 7indings.
6ENERAL CRITERIA FOR SELECTION OF PAC;IN6 F 1.
9ost co""onl* used pac6ings includeF
+,
Production o# C*clo!e+ane #ro" ,en-ene
igure 4.3 E+a"ples o# so"e pac6ing iterature sure* reeals t!at structured pac6ings !ae t!e "erits o# lo7 pressure drop good "ass trans#er c!aracteristics !ig! capacit* and !ence lo7er dia"eter o# colu"n 0ut t!e* !ae t!e de"erits o# !ig! cost and relatiel* less aaila0ilit*. Also structured pac6ings are e"plo*ed particularl* in acuu" serices 7!ere pressure drops "ust 0e 6ept lo7. $n t!e ot!er !and co"paratie anal*sis o# di##erent rando" pac6ings supports Pall rin#s 7it! respect to aaila0ilit* cost and pressure drop #eatures. Pall rings !ae open structure and !ig! #looding and loading li"its. ood liquid / gas distri0ution and !ig! "ass trans#er e##icienc*. 9etal rings are easil* 7etta0le. 9ec!anical 8trengt! o# 9etal Pall Ring Pac6ing is !ig!. $ t! er t !a n t! is i t i s "e c! an ic al l* r o0 us t a nd c an 7 it! sta nd ! ig ! te"perature o# our process !ence < selected "etal pall rings.
PAC;IN6 SI*ED
Production o# C*clo!e+ane #ro" ,en-ene ones. A0oe 5)"" lo7er cost per cu0ic "eter does not co"pensate #or lo7er "ass trans#er e##icienc*. ses o# too large si-e pac6ings in s"all dia"eter colu"n "a6e liquid distri0ution poor . Reco""ended si-es are gien 0elo7
Colu'n dia'eter
Pacin# sies
N).3"
N25""
).3%).(
25%3'""
h).(
5)%&5""
T!e design data o# di##erent rings is gien in appendi+ Fi#ure 4.1.
Step 0 it! t!e !elp o# calculated V #lo7 para"eter read alues o#
4 Y
4
/
#ro" Fi#ure =.< gien in appendi+. ++
Production o# C*clo!e+ane #ro" ,en-ene T!e #or"ulae to calculate #lo7 para"eter and percentage #looding are gien 0elo7 7it!F F L + L>89Q + > l : >!ereL K 9ass #lo7%rate o# liquid in 6g/sec K ).46g/sec V K 9ass #lo7%rate o# apor in 6g/sec K ).)143 6g/sec \ l K ensit* o# liquid 6g/" 3 K &&'6g/" 3 \ K ensit* o# apor 6g/" 3
K1.56g/" 3
V K 2.3
Percenta#e floodin# 9; = >; = > : J . ) 1JJ Assu"e pressure drop per unit !eig!t o# pac6ing to 0e 21""/" !eig!t o# pac6ing 4 K ).13 4 / K ).23 B #looding K &5B Percentage #looding is in satis#actor* range. !:
ind Vapor 9ass elocit* 6g/" 2 %sec
T!e #or"ula to 0e used is gien 0elo7L +*
Production o# C*clo!e+ane #ro" ,en-ene
\ K ensit* o# liquid6g/" 3 K &&'6g/" 3 \ l Kensit* o# apor 6g/" 3 K1.56g/" 3 l KViscosit* o# liquid :"/s 2 p K Pac6ing #actor " % 1 K 1) ?ta6en # ro" Ric!ardson and coulson Vol. @ K ).3& 6g/" 2 %sec
c: Required AreaK V/ " 2 V K ).)142 6g/sec K ).3& 6g/" 2 %sec Area AK ).)3( " 2 ia"eter K j?4+A@/3.14 K ).223" Actual area co"es out to 0eL AK U/4? 2 @ AK ). )3 ( " 2
+
Production o# C*clo!e+ane #ro" ,en-ene
Step 0 =D CALC2LATION OF PRESS2RE %ROP IN PAC;I N6 DPressure drop per unit !eig!t o# pac6ing di##er #ro" pac6ing to ot!er.
K2.41(l0/s%#t 2
\ g Kas densit* l0/#t 2 g c K 32.14 l0 " %#t/l0 # %sec 2 p K4'.4' K1.5( *(
Production o# C*clo!e+ane #ro" ,en-ene kK).)))2 ^P K ).2424 in H 2 $/#t o# pac6ing K2)"" H 2 $/" o# pac6ing Assu"ed alue 7as 21"" H2$ / " Heig!t o# pac6ing calculated alue is close to assu"ed alue so it is accepta0le.
Step 0 D CALC2LATION OF N2BER OF TRANSFER 2NITS D :u"0er o# trans#er units !as 0een calculated 7it! t!e !elp o# re"ser[s Equation gien 0elo7L N 1
9S
H S: > 9S
N1
H 1: ol fraction of solute #as stripped
T!is equation is applica0le 0ecause t!e equili0riu" data o# !*drogen desorption #ro" c*clo!e+ane is straig!t line. Equili0riu" constant !as 0een "easured 0* using grap! gien in appendi+ Ta!le =.= >!ereas no"enclature used is gien 0elo7D :K :o $# Tr ans#er nit 8K K
8tripping actor V/
K
iquid #lo7%rate6g% "ol/sec
K
5.+1) % 3 6g%"ol/sec
VK
Vapor #lo7%rate6g% "ol/sec
VK
1.5+1) % 4 6g%"ol/sec *#
Production o# C*clo!e+ane #ro" ,en-ene K
&
8K
2.)24
N
T!e nu"0er o# trans#er units #or required separation is '.
Step 0KD (EI6(T OF TRANSFER 2NI TS DHeig!t o# trans#er units is t!e !eig!t o# pac6ing t!at is required to c!ange t!e "ol #ractions o# co"ponents equialent to one t!eoretical plate in tra* colu"n colu"n.. alas #or a gien t*pe o# pac6ing "aterial t!e ratio o# HE T P to pressure drop re"ains re"ains constan cons tantt #or all si-es. si-es. Hence Hence it is not reco""e reco""ended nded to decrease decrease si-e o# p o# paa c 6 i n g t o ! a e s " a l l ! e i g ! t o # c o l u " n .
HETP/H $ K
l nS " / S "/%1
>!ere *$
Production o# C*clo!e+ane #ro" ,en-ene H $ KVapor KVapor p!ase !eig!t o# trans #er unit As rule o# t!u"0 in 7!en N).5"
MG
HETPK HETPK).233" H $
K ).54"
Step Ste p 0MD (EI6(T (EI 6(T O F COL2 N D-
* N ) ( O 6 = K Heig!t o# Pac6ing in "eters =K'+).54 = K4.32" * t * ( d ( ! Heig!t #or t!e disengage"ent region H d K).2'(" Heig!t #or t!e ,otto" H 0 K).435" = t K Total Total !eig!t o# t!e colu"n K 5.)4"
Step Ste p 0 D LI72 I% (OL% (O L% 2P CALC2 LATIONS D(Lw J.JJJ=9L'>%p:J.K
*%
Production o# C*clo!e+ane #ro" ,en-ene p Kequialent sp!erical pac6ing dia"eter ?inc!es@ " Kliquid rate ? l0/s%#t2 @ Hl7K).)5)"3/"3 o# pac6ing
PROCESS SPECIFICATION S(EET FOR STABILI*ATION STABILI*ATION COL2N
*&
1. 2 3. 4. 5.
V%)2
T*peFPac6ed
Production o# C*clo!e+ane #ro" ,en-ene
8erice :$ $ EM
C*clo!e+ane 8ta0ili-er 1
$PERAT<$: C$:T<:$8 PROCESS CON%ITIONS
.
iquid Handled iquid lo7%rate
C*clo!e+ane
&.
%"ol/!r iquid Mualit*
8lig!tl* corrosie
'.
iquid Viscosit* cP
).12
(.
Vapor Handled
C*clo!e+ane
1).
Vapor Mualit*
8lig!tl* corrosie
11.
Vapor "ol.7t
'4
12.
Te"perature
453
13.
Pressure at"
1)
2).3'5
OPERATIONAL CON%ITIONS 14.
:ature o# operation
8tripping
15.
eed no--le location
Top/8at. liquid
1.
Te"perature
1&.
Percentage looding
442 &5B
COL2N INTERNALS 1'.
Pac6ing 8i-e
25
"" 1(.
:ature o# pac6ing
2).
9aterial o# Pac6ing
21.
i id i t i0 t
Pall rings 9etallic Car0on 8teel 8
l
*,
Production o# C*clo!e+ane #ro" ,en-ene
(EAT E,C(AN6ER %ESI6N (EAT E,C(AN6ER Heat e+c!anger is a deice t!at is used to trans#er !eat 0et7een t7o #luids at di##erent te"perature.
%IFFERENT T3PES OF (EAT E,C(AN6ERS T!e principle t*pes o# !eat E+c!anger used in C!e"ical and allied industries are as #ollo7sF 1. 2. 3. 4. 5. .
ou0le Pipe !eat E+c!anger 8!ell and Tu0e Heat E+c!anger Plate and ra"e Heat E+c!anger Plate and in T*pe Heat E+c!anger 8piral T*pe Heat E+c!anger A CooledF Cooler and Condenser
SELECTION CRITERIA 8election process includes a :o. o# #actors all o# t!ese are related to t!e !eat trans#er application. 1. 2. 3. 4. 5. .
T!er"al Require"ents 9aterial Co"pati0ilit* $perational 9aintains Eniron"ental Healt! Y 8a#et* Consideration Aaila0ilit* Cost
S(ELL " T2BE (EAT E,C(AN6ER Basic Construction of Shell " Tu!e (eat E)chan#ers 8!ell and tu0e !eat e+c!angers represent t!e "ost 7idel* used e!icle #or t!e trans#er o# *-
Production o# C*clo!e+ane #ro" ,en-ene !eat in industrial process applications. T!e* are #requentl* selected #or suc! duties asF Q Q Q Q Q Q Q Q
Process liquid or gas cooling Process or re#rigerant apor or stea" condensing Process liquid stea" or re#rigerant eaporation Process !eat re"oal and pre!eating o# #eed 7ater T!er"al energ* conseration e##orts !eat recoer* Co"pressor tur0ine and engine cooling oil and ac6et 7ater H*draulic and lu0e oil cooling 9an* ot!er industrial applications
8!ell and tu0e !eat e+c!angers !ae t!e a0ilit* to trans#er large a"ounts o# !eat in relatiel* lo7 cost serica0le designs. T!e* can proide large a"ounts o# e##ectie tu0e sur#ace 7!ile "ini"i-ing t!e require"ents o# #loor space liquid olu"e and 7eig!t. 8!ell and tu0e e+c!angers are aaila0le in a 7ide range o# si-es. T!e* !ae 0een used in industr* #or oer 15) *ears so t!e t!er"al tec!nologies and "anu#acturing "et!ods are 7ell de#ined and applied 0* "odern co"petitie "anu#acturers. Tu0e sur#aces #ro" standard to e+otic "etals 7it! plain or en!anced sur#ace c!aracteristics are 7idel* aaila0le. T!e* can !elp proide t!e least costl* "ec!anical design #or t!e #lo7s liquids and te"peratures inoled. Alt!oug! t!ere e+ist a 7ide ariet* o# designs and "aterials aaila0le t!ere are co"ponents co""on to all designs. Tu0es are "ec!anicall* attac!ed to tu0e s!eets 7!ic! are contained inside a s!ell 7it! ports #or inlet and outlet #luid or gas. T!e* are designed to preent liquid #lo7ing inside t!e tu0es to "i+ 7it! t!e #luid outside t!e tu0es. Tu0e s!eets can 0e #i+ed to t!e s!ell or allo7ed to e+pand and contract 7it! t!er"al stresses 0* !ae one tu0e s!eet #loat inside t!e s!ell or 0* using an e+pansion 0ello7s in t!e s!ell. T!is design can also allo7 pulling t!e entire tu0e 0undle asse"0l* #ro" t!e s!ell to clean t!e s!ell circuit o# t!e e+c!anger.
Fluid Strea' Allocations T!ere are a nu"0er o# practical guidelines 7!ic! can lead to t!e opti"u" design o# a gien !eat e+c!anger. Re"e"0ering t!at t!e pri"ar* dut* is to per#or" its t!er"al dut* 7it! t!e lo7est cost *et proide e+cellent in serice relia0ilit* t!e selection o# #luid strea" allocations s!ould 0e o# pri"ar* concern to t!e designer. T!ere are "an* trade% o##s in #luid allocation in !eat trans#er coe##icients aaila0le pressure drop #ouling tendencies and operating pressure. *+
Production o# C*clo!e+ane #ro" ,en-ene 1. T!e !ig!er pressure #luid nor"all* #lo7s t!roug! t!e tu0e side. >it! t!eir s"all dia"eter and no"inal 7all t!ic6nesses t!e* are easil* a0le to accept !ig! pressures and aoids "ore e+pensie larger dia"eter co"ponents to 0e designed #or !ig! pressure. <# it is necessar* to put t!e !ig!er pressure strea" in t!e s!ell it s!ould 0e placed in a s"aller dia"eter and longer s!ell. 2. Place corrosie #luids in t!e tu0es ot!er ite"s 0eing equal. Corrosion is resisted 0* using special allo*s and it is "uc! less e+pensie t!an using special allo* s!ell "aterials. $t!er tu0e side "aterials can 0e clad 7it! corrosion resistant "aterials or epo+* coated. 3. lo7 t!e !ig!er #ouling #luids t!roug! t!e tu0es. Tu0es are easier to clean using co""on "ec!anical "et!ods. 4. ,ecause o# t!e 7ide ariet* o# designs and con#igurations aaila0le #or t!e s!ell circuits suc! as tu0e pitc! 0a##le use and spacing "ultiple no--les it is 0est to place #luids requiring lo7 pressure drops in t!e s!ell circuit. 5. T!e #luid 7it! t!e lo7er !eat trans#er coe##icient nor"all* goes in t!e s!ell circuit.T!is allo7s t!e use o# lo7%#in tu0ing to o##set t!e lo7 trans#er rate 0* proiding increased aaila0le sur#ace.
Tu!es Tu0ing t!at is generall* used in TE9A si-es is "ade #ro" lo7 car0on steel copperAd"iralt* Copper%:ic6el stainless steel Hastallo* ?electro%resistance7elded@ tu0es e+!i0it superior grain structure at t!e 7eld. E+truded tu0e 7it! lo7 #ins and interior ri#ling is speci#ied #or certain applications. 8ur#ace en!ance"ents are used to increase t!e aaila0le "etal sur#ace or aid in #luid tur0ulence t!ere0* increasing t!e e##ectie !eat trans#er rate. inned tu0ing is reco""ended 7!en t!e s!ell side #luid !as a su0stantiall* lo7er !eat trans#er coe##icient t!an t!e tu0e side #luid. inned tu0ing !as an outside dia"eter in t!e #inned area slig!tl* under t!e un#inned or landing area #or t!e tu0e s!eets. T!is is to allo7 asse"0l* 0* sliding t!e tu0es t!roug! t!e 0a##les and tu0e supports 7!ile "ini"i-ing #luid 0*pass. %tu0e designs are speci#ied 7!en t!e t!er"al di##erence o# t!e #luids and #lo7s 7ould result in e+cessie t!er"al e+pansion o# t!e **
Production o# C*clo!e+ane #ro" ,en-ene tu0es. %tu0e 0undles do not !ae as "uc! tu0e sur#ace as straig!t tu0e 0undles due to t!e 0ending radius and t!e cured ends cannot 0e easil* cleaned. Additionall* interior tu0es are di##icult to replace "an* ti"es requiring t!e re"oal o# outer la*ers or si"pl* plugging t!e tu0e. ,ecause o# t!e ease in "anu#acturing and serice it is co""on to use a re"oa0le tu0e 0undle design 7!en speci#*ing %tu0es.
Tu!e sheets Tu0es!eets are usuall* "ade #ro" a round #lat piece o# "etal 7it! !oles drilled #or t!e tu0e ends in a precise location and pattern relatie to one anot!er. Tu0e s!eet "aterials range as tu0e "aterials. Tu0es are attac!ed to t!e tu0e s!eet 0* pneu"atic or !*draulic pressure or 0* roller e+pansion. Tu0e !oles can 0e drilled and rea"ed and can 0e "ac!ined 7it! one or "ore grooes. T!is greatl* increases t!e strengt! o# t!e tu0e oint.
T!e tu0es!eet is in contact 7it! 0ot! #luids and so "ust !ae corrosion resistance allo7ances and !ae "etalurgical and electroc!e"ical properties appropriate #or t!e #luids and elocities. o7 car0on steel tu0e s!eets can include a la*er o# a !ig!er allo* "etal 0onded to t!e sur#ace to proide "ore e##ectie corrosion resistance 7it!out t!e e+pense o# using t!e solid allo*. T!e tu0e !ole pattern or pitc! aries t!e distance #ro" one tu0e to t!e ot!er and angle o# t!e tu0es relatie to eac! ot!er and to t!e direction o# #lo7. T!is allo7s t!e"anipulation o# #luid elocities and pressure drop and proides t!e "a+i"u" a"ount o# tur0ulance and tu0e sur#ace contact #or e##ectie !eat trans#er. >!ere t!e tu0e and tu0e s!eet "aterials are oina0le 7elda0le "etals t!e tu0e oint can 0e #urt!er strengt!ened 0* *
Production o# C*clo!e+ane #ro" ,en-ene appl*ing a seal 7eld or strengt! 7eld to t!e oint. A strengt! 7eld !as a tu0e slig!tl* reccessed inside t!e tu0e !ole or slig!tl* e+tended 0e*ond t!e tu0e s!eet. T!e 7eld adds "etal to t!e resulting lip. A seal 7eld is speci#ied to !elp preent t!e s!ell and tu0e liquids #ro" inter"i+ing.
Shell Asse'!l$ T!e s!ell is constructed eit!er #ro" pipe up to 24 or rolled and 7elded plate "etal. or reasons o# econo"* lo7 car0on steel is in co""on use 0ut ot!er "aterials suita0le #or e+tre"e te"perature or corrosion resistance are o#ten speci#ied. sing co""onl* aaila0le s!ell pipe to 24 in dia"eter results in reduced cost and ease o# "anu#acturing partl* 0ecause t!e* are generall* "ore per#ectl* round t!an rolled and 7elded s!ells. Roundness and consistent s!ell < is neccessar* to "ini"i-e t!e space 0et7een t!e 0a##le outside edge and t!e s!ell as e+cessie space allo7s #luid 0*pass and reduced per#or"ance. Roundness can 0e increased 0* e+panding t!e s!ell around a "andrell or dou0le rolling a#ter 7elding t!e longitudnal sea".
(
Production o# C*clo!e+ane #ro" ,en-ene
End Channels and Bonnets End c!annels or 0onnets are t*picall* #a0ricated or cast and control t!e #lo7 o# t!e tu0e side #luid in t!e tu0e circuit. T!e* are attac!ed to t!e tu0e s!eets 0* 0olting 7it! a gas6et 0et7een t!e t7o "etal sur#aces. !ere a #ull 0undle tu0e count is required to satis#* t!e t!er"al require"ents t!is "ac!ined pass ri0 approac! "a* preent !aing to consider t!e ne+t larger s!ell dia"eter.
#
Production o# C*clo!e+ane #ro" ,en-ene
Cast !ead "aterials are t*picall* used in s"aller dia"eters to around 14 and are "ade #ro" iron ductile iron steel 0ron-e or stainless steel. T!e* t*picall* !ae pipe t!read connections. Cast !eads and tu0e side piping "ust 0e re"oed to serice tu0es. a0ricated !eads can 0e "ade in a 7ide ariet* o# con#igurations. T!e* can !ae "etal coer designs t!at allo7 sericing t!e tu0es 7it!out distur0ing t!e s!ell or tu0e piping. Heads can !ae a+iall* or tangentiall* oriented no--les 7!ic! are t*picall* A:8< #langes.
Baffles ,a##les sere t7o i"portant #unctions. T!e* support t!e tu0es during asse"0l* and operation and !elp preent i0ration #ro" #lo7 induced eddies and direct t!e s!ell side #luid 0ac6 and #ort! across t!e tu0e 0undle to proide e##ectie elocit* and !eat trans#er rates. T!e dia"eter o# t!e 0a##le "ust 0e slig!tl* less t!an t!e s!ell inside dia"eter to allo7 asse"0l* 0ut "ust 0e close enoug! to aoid t!e su0stantial per#or"ance penalt* caused 0* #luid 0*pass around t!e 0a##les. 8!ell roundness is i"portant to ac!eie e##ectie sealing against e+cessie 0*pass. ,a##les can 0e "ade #ro" a ariet* o# "aterials co"pati0le 7it! t!e s!ell side #luid. T!e* can 0e punc!ed or "ac!ined. 8o"e 0a##les are "ade 0* a punc! 7!ic! proides a lip around t!e tu0e !ole to proide "ore sur#ace against t!e tu0e and eli"inate tu0e 7all cutting #ro" t!e 0a##le edge. T!e tu0e !oles "ust 0e precise enoug! to allo7 eas* asse"0l* and #ield tu0e replace"ent *et $
Production o# C*clo!e+ane #ro" ,en-ene "ini"i-e t!e c!ance o# #luid #lo7ing 0et7een t!e tu0e 7all and 0a##le !ole resulting in reduced t!er"al per#or"ance and increased potential #or tu0e 7all cutting #ro" i0ration. ,a##les do not e+tend edge to edge 0ut !ae a cut t!at allo7s s!ell side #luid to #lo7 to t!e ne+t 0a##led c!a"0er. or "ost liquid applications t!e cuts areas represent 2)%25B o# t!e s!ell dia"eter. or gases 7!ere a lo7er pressure drop is desira0le 0a##le cuts o# 4)% 45B is co""on. ,a##les "ust oerlap at least one tu0e ro7 in order to proide adequate tu0e support. T!e* are spaced t!roug!out t!e tu0e 0undle so"e7!at eenl* to proide een #luid elocit* and pressure drop at eac! 0a##led tu0e section.
8ingle%seg"ental 0a##les #orce t!e #luid or gas across t!e entire tu0e count 7!ere is c!anges direction as dictated 0* t!e 0a##le cut and spacing. T!is can result in e+cessie pressure loss in !ig! elocit* gases.
Production o# C*clo!e+ane #ro" ,en-ene reduction in per#or"ance can 0e e+pected due to a reduced !eat trans#er rate. ,ecause pressure drop aries 7it! elocit* cutting t!e elocit* in !al# 0* using dou0le%seg"ental 0a##les results in roug!l* 1/4 o# t!e pressure drop as seen in a single%seg"ental 0a##le space oer t!e sa"e tu0e sur#ace.
STAN%AR% %ESI6N STEPS a. 0. c. d. e. #. g.
e#ine t!e dut*L Heat Trans#er Rate and Te"perature Collection o# luid P!*sical Properties Assu"e t!e alue o# Heat Trans#er Coe##icient Calculate t!e 9ean Te"perature i##erence Calculate t!e Area Required ecide t!e Heat E+c!anger a*out Calculate t!e Pressure
STREA CON%ITIONS (OT FL2I%
"c K&(( 6g/!r
P(3SICAL PROPERTIES (OT FL2I% &
Production o# C*clo!e+ane #ro" ,en-ene 8peci#ic !eat C p K2.1' 6G/6g T!er"al conductiit* 6 K).1)41 >/" ensit*
K(5.2 6g/"3
�
Viscosit* K1.'' 6g/" sec COL% FL2I% 8peci#ic Heat Cp K4.1& 6G/6g T!er"al conductiit* 6 K ).5()>/" ensit* � K ((56g/"3 Viscosit* K2.3& 6g/" sec
(EAT LOA% sing Hot luid M K " Cp ^T K5.2 `1)3 6G/!r
LO6 EAN TEPERAT2RE %IFFERENCE T1 Hot luid
1'4 C
T2 3) C
t2 Cold luid
43 C
t1 25 C
XT1 K T2%t1
XT2KT1%t2
,
Production o# C*clo!e+ane #ro" ,en-ene 9T K ?XT1% XT2@/?ln XT1/ XT2@ 9T K 41.&2
Ft Factor RK ?T1%T2@/?t2%t1@ K '.55
8K?t2%t1@/?T1%t1@
K).113 tK).(& XT"K).(&`41.&2K 3'.'4
ASS2E% O8ERALL COEFFICIENT 2 d d K1)) >/"2
APPRO,IATE AREA
AKM/d` XT"
K4).35"2
T2BE SPECIFICATIONS $utside ia o# Tu0e ?$@ K ).)1("
Pt K ).)24" K 1 ,>
Area o# a 8ingle Tu0e a K ).2(11"2 -
Production o# C*clo!e+ane #ro" ,en-ene :o o# Tu0es
A/aK13(
T2BE SI%E CALC2LATIONS 9ass lo7 rate ?"c@ K &(( 6g/!r Total Area o# Tu0es ?at@ K ).)125 "2 9ass Velocit* t K ?"c/at @ K 3&52 6g/!r."2
Calculation of Re$nolds Nu'!er Re*nold[s :u"0er ?:Re@ K t / K ? ).)1` 3&52@/2.3& K 5425.&)
T2BE SI%E (EAT TRANSFER !i K S42))?1.35J).)2t@/<).2 K 4'&&.5&>/"2
K41)&.43>/"2
S(ELL SI%E CALC2LATIONS
?Cm@ K ).))4'"
,a##le 8pacing
?,@ K ).2)35 "
FLO5 AREA +
Production o# C*clo!e+ane #ro" ,en-ene
K ?).3'&`).))4`).2)5 @/).)24 K ).)11 "2
ASS 8ELOCIT3 9ass elocit* K 1(/).)11 K 151&2&6g/!r."2
S(ELL SI%E E72I8ALENT %IAETER 8!ell 8ide Equialent ia"eter ?e @K ).)13( "
Re$nolds Nu'!er
K ?).)13(`151&2&@/1.'' K 24434.5 G! K ()
Prandtl Nu'!er *
Production o# C*clo!e+ane #ro" ,en-ene Pr
K C p/6 K ?2.1'`1.'' @/).1)4
K1.3
O2TSI%E (EAT TRANSFER COEFFICIENT
K
S()`).1)4`?1.3@1/3/).)13(
K
'&.23>/"2
CLEAN O8ERALL COEFFICIENT
K &42>/"2
ACT2AL AREA Ac
K4).&)"2
CORRECTE% 2d
K
?15`1)3@/?4).&)`3'.'4@
K
((.15 >/"2
%IRT FACTOR
Production o# C*clo!e+ane #ro" ,en-ene
irt #actor K).))'& >/"2
S(ELL SI%E PRESS2RE %ROP CALC2LATION riction #actor ?#@ K ).))51 Eq. ia"eter $# 8!ell ?e@ K ).)13(" 8peci#ic rait* ?8@ K).&( :u"0er o# crosses ?:J1@ K /,K23.(' s K 42.2&6g/sec ."2
8HE 8<E PRE88RE R$P
K &41.(':/"2
T2BE SI%E PRESS2RE %ROP CALC2LATION riction #actor ?#@
K ).))25
Production o# C*clo!e+ane #ro" ,en-ene
T,E 8<E PRE88RE R$P
K23(.45 :/"2
#(#
Production o# C*clo!e+ane #ro" ,en-ene
SPECFICATION S(EET <
8 8!ell Y Tu0e Heat E+c!anger
unction
8 8ta0ili-er Product Cooler
P Position
: :o. o# nit
Hori-ontal
: $ne 1
: :o. o# 8!ell Passes
11
:o. o# Tu0e Passes
22
Heat Trans#er Area
44).&" 2
ia"eter o# 8!ell
) ).3'&"
P Pitc! ?Triangular Pitc!@
:o. o# Tu0es
) ).)25"
1 13( #($
Production o# C*clo!e+ane #ro" ,en-ene
T T*pe o# Tu0e sed
1 1,>
T Tu0e engt!
4 4.''"
< < Y $ o# tu0e
) ).)15&" ).)1()'"
!i
4 4'&&.5&>/"2
!o
' '&.23>/"2
P Pressure drop on 8!ell 8ide
& 41.(':/" 2
Chapter 0
EC(ANICAL %ESI6N
#(%
Production o# C*clo!e+ane #ro" ,en-ene
EC(ANICAL %ESI6N OF S(ELL " T2BE (EAT E,C(AN6ER S(ELL SI%E S(ELL T(IC;NESS
tsK8!ell t!ic6ness K PKesign PressureK1.51:/""2 sK
ts <.K
Allo7a0le Corrosion allo7ance C K4"" 8o t!e 8!ell T!ic6ness ts K3.5J4 K&.5""
NO**LE %ESI6N FOR S(ELL SI%E 9aterial used Car0on 8teel or 8!ell luid
#(&
Production o# C*clo!e+ane #ro" ,en-ene 9ass lo7 Rate o# 8!ell 8ide #luid K1(6g/!r ensit* o# t!e 8!ell side luidK(5.26g/"3 Velocit* o# 8!ell 8ide luidK 21'"/!r A K"/ �K ).)11"2
n K 11'"" $uter :o--le also !as t!e sa"e ia"eter
NO**LE T(IC;NESS
C K Corrosion allo7ance
K5.11""
(EA% T(IC;NESS
P K esign Pressure K 4 :/""2
R c K$uter Radius o# 8!ell K 2))"" R 6 K unc6le Radius o# 8!ell K ).)Rc K12"" >K 1.&&) #(,
Production o# C*clo!e+ane #ro" ,en-ene t! K &.2&)""
BAFFLE %IAETER
?sing 25B Cut ,a##le@
0 K s %4.'
K3'2.2""
T2BE SI%E 9aterial sed Car0on 8teel :o. o# Passes K 2 :o. o# Tu0es K 13( $utside ia"eter K ).)1(" all T!ic6ness o# Tu0eK ).15" engt! o# Tu0eK K4.''" Tu0e Pitc! Pt K).)25" >or6ing Pressure K). :/""2 esign Pressure K). :/""2
NO**LE %ESI6N FOR T2BE SI%E 9aterial sed Car0on 8teel 9ass lo7 Rate o# Tu0e 8ide luid K &((6g/!r ensit* o# Cold luid K((5 6g/"3 Velocit* o# Tu0e 8ide luid K K4).&2"/!r
#(-
Production o# C*clo!e+ane #ro" ,en-ene
K ).)125"2
n K 12.1'""
NO**LE T(IC;NESS
tn K ).51 :o--le t!ic6ness 7it! Corrosion Allo7ance tn K ).51J4 K 4.51""
Chapter 0 K
INSTR2ENTATION " PROCESS CONTROL #(+
Production o# C*clo!e+ane #ro" ,en-ene
INSTR2ENTS
INSTR2ENTATION " CONTROL OB@ECTI8E T!e pri"ar* o0ectie o# t!e designer 7!en speci#*ing instru"entation and control sc!e"es areF
8a#er Plant $peration a. To 6eep t!e process aria0le 7it!in 6no7n sa#e operation li"its 0. To detect dangerous situation as t!e* deelop and to proide alar"s and auto"atic s!ut do7n s*ste". c. To proide inter loc6s and alar"s to preent dangerous operating
procedures. Production Rate To ac!iee t!e design product output Product Mualit* To "aintain t!e product co"position 7it!in t!e speci#ied qualit* standards Cost To operate at t!e lo7est production cost co""ensurate 7it! t!e ot!er o0ecties. #(*
Production o# C*clo!e+ane #ro" ,en-ene T!ese are not separate o0ecties and "ust 0e considered toget!er. T!e order in 7!ic! t!e* are listed is not "eant to i"pl* t!e precedence o# an* o0ectie oer anot!er ot!er t!an t!at o# putting sa#et* #irst. Product qualit* production rate and t!e cost o# production 7ill 0e dependent on sales require"ents. or e+a"ple it "a* 0e a 0etter strateg* to produce a 0etter qualit* product at a !ig!er cost.
COPONENTS OF A CONTROL S3STE Process
An* operation or series o# operations t!at produces a desired #inal result is a process.
easurin# eans
$# all t!e parts o# t!e control s*ste" t!e "easuring ele"ents is per!aps t!e "ost i"portant. <# "easure"ent is not "ade properl* t!e re"ainder o# t!e s*ste" cannot operate satis#actoril*. T!e aaila0le is do-en to represent t!e desired condition in t!e process.
Anal$sis of 'easure'ents 8aria!le to !e 'easured 1. 2. 3. 4.
Pressure "easure"ents Te"perature "easure"ents lo7 Rate "easure"ents eel "easure"ents
8aria!le to !e Recorded
Controller T!e controller is t!e "ec!anis" t!at responds to an* error indicated 0* t!e error detecting "ec!anis". T!e output o# t!e controller is so"e predeter"ined #unction o# t!e error.
Production o# C*clo!e+ane #ro" ,en-ene
Final Control ele'ent T!e #inal control ele"ent receies t!e signal #ro" t!e controller and 0* so"e predeter"ined relations!ip c!anges t!e energ* input to t!e process.
CLASSIFICATION OF CONTROLLER
T!e pneu"atic controller is ar* rugged and al"ost #ree o# "aintenance. T!e "aintenance "en !ae not !ad su##icient training and 0ac6ground in electronics so 0asicall* pneu"atic equip"ent is si"ple.
ii@
T!e pneu"atic controller appears to 0e sa#er in a potentiall* e+plosie at"osp!ere 7!ic! is o#ten present in t!e petro%c!e"ical industr*.
iii@
Trans"ission distances are s!ort. Pneu"atic and electronic trans"ission s*ste" are generall* equal upto a0out 25) to 3)) #eet. A0oe t!is distance electronic s*ste"s 0egin to o##er saings.
O%ES OF CONTROL T!e arious t*pe o# control are called "odes and t!e* deter"ine t!e t*pe o# response o0tained.
Production o# C*clo!e+ane #ro" ,en-ene i@
$n%o## Control
ii@
iii@ Proportional Control i@
Rate or eriatie Control
in t!e control s*ste". T!e $n%o## controller in t!e controller 7it! er* !ig! gain.
ALARS AN% SAFET3 TRIPS AN% INTERLOC;S Alar"s are used to alert operators o# serious and potentiall* !a-ardous deiations in process conditions. e* instru"ents are #itted 7it! s7itc!es and rela*s to operate audi0le and isual alar"s on t!e control panels. T!e 0asic co"ponents o# an auto"atic trip s*ste"s areF i@
A sensor to "onitor t!e control aria0le and proide an output signal 7!en a preset ale is e+ceeded ?t!e instru"ent@.
ii@
A lin6 to trans#er t!e signal to t!e actuator usuall* consisting o# a s*ste" o# pneu"atic or electric rela*s.
iii@
An actuator to carr* out t!e required actionL close or open a ale s7itc! o## a "otor.
%
###
Production o# C*clo!e+ane #ro" ,en-ene A sa#et* trip can 0e incorporated in control loopL as s!o7n in #igure .
INTERLOC;S >!ere it is necessar* to #ollo7 t!e #i+ed sequence o# operations #or e+a"ple during a plant start%up and s!ut%do7n or in 0atc! operations%inter%loc6s are included to preent operators departed #ro" t!e required sequence. T!e* "a* 0e incorporated in t!e control s*ste" design as pneu"atic and electric rela*s or "a* 0e "ec!anical interloc6s.
%IFFERENT T3PES OF CONTROLLERS Flow Controllers T!ese are used to control #eed rate into a process unit. $ri#ice plates are 0* #ar t!e "ost t*pe o# #lo7 rate sensor. :or"all* ori#ice plates are designed to gie pressure drops in t!e range o# 2) to 2))inc! o# 7ater. Venture tu0es and tur0ine "eters are also used.
Te'perature Controller T!er"ocouples are t!e "ost co""onl* used te"perature sensing deices. T!e t7o dissi"ilar 7ires produce a "illiolt e"# t!at aries 7it! t!e !ot%unction te"perature.
Pressure Controller ,ourdon tu0es 0ello7s and diap!rag"s are used to sense pressure and di##erential pressure. or e+a"ple in a "ec!anical s*ste" t!e process pressure #orce is 0alanced 0* t!e "oe"ent o# a spring. T!e spring position can 0e related to process pressure.
Le+el Controller iquid leels are detected in a ariet* o# 7a*s. T!e t!ree "ost co""on areF
ollo7ing t!e position o# a #loat t!at is lig!ter t!e" t!e #luid.
9easuring t!e apparent 7eig!t o# a !ea* c*linder as it 0uo*ed up "ore or less 0* t!e liquid ?t!ese are called displace"ent "eters@. ##$
Production o# C*clo!e+ane #ro" ,en-ene
9easuring t!e di##erence in static pressure 0et7een t7o #i+ed eleations one in t!e apour a0oe t!e liquid and t!e ot!er under t!e liquid sur#ace. T!e di##erential pressure 0et7een t!e t7o leel taps is directl* related to t!e liquid leel in t!e essel.
Trans'itter T!e trans"itter is t!e inter#ace 0et7een t!e process and its control s*ste". T!e o0 o# t!e trans"itter is to conert t!e sensor signal ?"illiolts "ec!anical "oe"ent pressure di##erential etc.@ into a control signal 3 to 15 psig air%pressure signal 1 to 5 or 1) to 5) "illia"pere electrical signal etc.
Control 8al+es T!e inter#ace 7it! t!e process at t!e ot!er end o# t!e control loop is "ade 0* t!e #inal control ele"ent is an auto"atic control ale 7!ic! t!rottles t!e #lo7 o# a ste" t!at open or closes an ori#ice opening as t!e ste" is raised or lo7ered. T!e ste" is attac!ed to a diap!rag" t!at is drien 0* c!anging air%pressure a0oe t!e diap!rag". T!e #orce o# t!e air pressure is opposed 0* a spring.
##%
Production o# C*clo!e+ane #ro" ,en-ene
CONTROL OF (EAT E,C(AN6ER 1. T!e T!e :or" :or"al al >a* T!ee nor" T! nor"al al "et! "et!od od #or #or cont contro roll llin ingg a !eat !eat e+c! e+c!an ange gerr is to "eas "easur uree e+it e+it te"perature o# t!e process #luid and adusts input o# !eating or cooling "ediu" to !old t!e desired te"perature. 2. Casc Cascad adee Cont Contro roll T!e control o0ectie is to 6eep t!e e+it te"perature o# strea" 2 at a distance alue. T!e secondar* loop is used to co"pensate #or t!e c!anges in t!e #lo7 rate o# strea" 1.
CONTROL SC(EE
T!e #igure s!o7s a cascade control in 7!ic! t!e !ot #luid te"perature is constantl* "easured 0* t!e te"perature trans"itter. T!e te"perature is "atc!ed 7it! t!e set point 7!en t!e te"perature c!anges t!e deiations are co""unicated to t!e secondar* controller 7!ic! is t!en adusted t!e #lo7 rate o# t!e cold #luid.
##&
Production o# C*clo!e+ane #ro" ,en-ene
Chapter 0 M
(A*OP ST2%3 INTRO%2CTION A HA=$P sure* is one o# t!e "ost co""on and 7idel* accepted "et!ods o# s*ste"atic qualitati qualitatiee !a-ard anal*sis. anal*sis.
##,
Production o# C*clo!e+ane #ro" ,en-ene T!e o0ecties o# a HA=$P stud* can 0e su""ari-ed as #ollo7sF 1@
To ide ident nti#* i#* areas areas o# t!e t!e desi design gn t!a t!att "a* "a* posse possess ss a sig signi ni#i #ica cant nt !a!a-ard ard poten potenti tial al..
2@
To iden identi ti#* #* and and stud* stud* #eatu #eature ress o# t!e t!e desi design gn t!at t!at in#l in#lue uenc ncee t!e t!e pro0a pro0a0i 0ili lit* t* o# o# a !a-ardous incident occurring.
3@
To #a"il #a"ilia iariri-ee t!e t!e stud* stud* tea" tea" 7it! 7it! t!e t!e desi design gn in#o in#or" r"at atio ionn aai aaila la0l 0le. e.
4@
To ensu ensure re t!a t!att a s*st s*ste" e"at atic ic stu stud* d* is is "ade "ade o# t!e t!e are areas as o# sig signi ni#i #ica cant nt !a!a-ar ardd potential.
5@
To ide ident nti#* i#* perti pertine nent nt desi design gn in#o in#or" r"at atio ionn not curren currentl tl** aai aaila la0l 0lee to t!e t!e tea" tea"..
@
To pro proid idee a "ec "ec!a !ani nis" s" #or #or #ee #eed0 d0ac ac66 to t!e t!e cli clien entt o# t!e t!e stu stud* d* tea" tea"Ds Ds det detai aile ledd co""ents.
BASIC PRINCIPLES OF (A*OP ST2%3 T!e 0asic concept o# t!e !a-ard and opera0ilit* stud* is to ta6e a #ull description o# process and to question eer* part p art o# it to discoer 7!at deiation #ro" t!e intention o# t!e design can occure and 7!at can 0e t!eir causes and consequences. T!e seen guide 7ords reco""ended in t!e c!e"ical industries association ?C
##-
Production o# C*clo!e+ane #ro" ,en-ene
Ta!leD (A*OP 6uide 5ords and eanin#s 6uide 5ords :o
eanin# :egation o# design intent
ess
Muantitatie decrease
9ore
Muantitatie increase
Part o#
Mualitatie decrease
As 7ell as
Mualitatie
Reerse
ogical opposite o# t!e intent
$t!er t!an
Co"plete su0stitution
T!ese guide 7ords are applied to #lo7 te"perature pressure liquid leel co"position and an* ot!er aria0les a##ecting t!e process. T!e consequences o# t!ese deiations on t!e process are t!en assessed and t!e "easures needed to detect and correct deiations are esta0lis!ed. A HA=$P stud* is conducted in t!e #ollo7ing stepsF 1@
8peci#* t!e purpose o0ectie and scope o# t!e stud*. T!e purpose "a* 0e t!e anal*sis o# a *et to 0e 0uilt plant or a reie7 o# t!e ris6 o# an e+isting unit. ien t!e purpose and t!e circu"stances o# t!e stud* t!e o0ecties listed a0oe can !e "ade "ore speci#ic. T!e scope o# t!e stud* is t!e 0oundaries o# t!e p!*sical unit and also t!e range o# eents and aria0les considered. or e+a"ple at one ti"e HA=$PDs 7ere "ainl* #ocused on #ire and e+plosion endpoints 7!ile no7 t!e scope usuall* includes to+ic release o##ensie odor and eniron"ental end%points. T!e initial esta0lis!"ent o# purpose o0ecties and scope is er* i"portant and s!ould 0e precisel* set do7n so ##+
Production o# C*clo!e+ane #ro" ,en-ene t!at it 7ill 0e clear no7 and in t!e #uture 7!at 7as and 7as not included in t!e stud*. T!ese decisions need to 0e "ade 0* an appropriate leel o# responsi0le "anage"ent. 2@
8elect t!e HA=$P stud* tea". T!e tea" leader s!ould 0e s6illed in HA=$P and in interpersonal tec!niques to #acilitate success#ul group interaction. As "an* ot!er e+perts s!ould 0e included in t!e tea" to coer all aspects o# design operation process c!e"istr* and sa#et*. T!e tea" leader s!ould instruct t!e tea" in t!e HA=$P procedure and s!ould e"p!asi-e t!at t!e end o0ectie o# a HA=$P sure* is !a-ard identi#icationL solutions to pro0le"s are a separate e##ort.
3@
Collect data. T!eodore1 !as listed t!e #ollo7ing "aterials t!at are usuall* neededF
Process description
Process #lo7 s!eets
ata on t!e c!e"ical p!*sical and to+icological properties o# all ra7 "aterials inter"ediates and products.
4@
Piping and instru"ent diagra"s ?PY<s@
Equip"ent piping and instru"ent speci#ications
Process control logic diagra"s
a*out dra7ings
$perating procedures
9aintenance procedures
E"ergenc* response procedures
8a#et* and training "anuals
Conduct t!e stud*. sing t!e in#or"ation collected t!e unit is diided into stud* nodes and t!e sequence diagra""ed in igure is #ollo7ed #or eac! node. ##*
Production o# C*clo!e+ane #ro" ,en-ene :odes are points in t!e process 7!ere process para"eters ?pressure te"perature co"position etc.@ !ae 6no7n and intended alues. T!ese alues c!ange 0et7een nodes as a result o# t!e operation o# arious pieces o# equip"entD suc! as distillation colu"ns !eat e+c!anges or pu"ps. Various #or"s and 7or6 s!eets !ae 0een deeloped to !elp organi-e t!e node process para"eters and control logic in#or"ation. >!en t!e nodes are identi#ied and t!e para"eters are identi#ied eac! node is studied 0* appl*ing t!e speciali-ed guide 7ords to eac! para"eter. T!ese guide 7ords and t!eir "eanings are 6e* ele"ents o# t!e HA=$P procedure. Repeated c*cling t!roug! t!is process 7!ic! considers !o7 and 7!* eac! para"eter "ig!t ar* #ro" t!e intended and t!e consequence is t!e su0stance o# t!e HA=$P stud*. 5@
>rite t!e report. As "uc! detail a0out eents and t!eir consequence as is uncoered 0* t!e stud* s!ould 0e recorded. $0iousl* i# t!e HA=$P identi#ies a not i"pro0a0le sequence o# eents t!at 7ould result in a disaster appropriate #ollo7%up action is needed. T!us alt!oug! ris6 reduction action is not a part o# t!e HA=$P t!e HA=$P "a* trigger t!e need #or suc! action.
##
Production o# C*clo!e+ane #ro" ,en-ene
T!e HA=$P studies are ti"e consu"ing and e+pensie. Gust getting t!e P Y <Ds up to date on an older plant "a* 0e a "aor engineering e##ort. 8till #or processes 7it! signi#icant ris6 t!e* are cost e##ectie 7!en 0alanced against t!e potential loss o# li#e propert* 0usiness and een t!e #uture o# t!e enterprise t!at "a* result #ro" a "aor release.
#$(
Production o# C*clo!e+ane #ro" ,en-ene
(A*OP ST2%3 OF 6AS>LI72I% SEPARATOR %e+iation fro'
E+ents cause
Conse&uence of
Operatin#
de+iation
%e+iation
Notes
conditions Le+el 1.
1. o7ering o#
C!ec6 #or an*
stops
pressure
ale #ailure
2. te"p rises
2. 8eparator dries
C!ec6 condenser #$#
Production o# C*clo!e+ane #ro" ,en-ene
out Less
te"p rise
3. Pressure
3. eed to
8ee t!e ent
lo7ers
8ta0ili-er
ale
interrupted 4. Vent on
4. Purge
Condenser is
co"position
uncontrolled
c!anges
C!ec6 t!e purge co"position ea6age detection
5. Re#lu+ is
5. eed to
C!ec6 #or an*
interrupted
8ta0ili-er
ale #ailure
interrupted 1. Te"p drops
ore
1. Pressure
Consider #or
increases
colu"n
2. Pressure
2. 8eparator oer%
increased
loaded
3. eed
3. 9ore
apori-ed
apori-ing stea"
s!ut do7n C!ec6 re#lu+ quantit*
plugged 4. Hig! te"p o#
8ee re#le+
re#lu+ condenser
condenser
No
8a"e as less Te'perature 1. 8u0cooling in 1. ess #las!ing condenser 2. Pressure
C!ec6 #lo7 #ro" condenser
2. Purge / rec*cle
Vent/purge #$$
Production o# C*clo!e+ane #ro" ,en-ene
Less
drops.
co"position c!ange
3. Re#lu+ te"p
3. eel 0uilds%up
drops
co"position anal*sis C!ec6 #lo7 #ro" condenser
ore
$pposite to less
No
8a"e as less Pressure 1. Purge ale
1. Co"position o#
openned/uncontr purge / rec*cle
Less
C!ec6 #or gas co"position
olled
c!anged
2. Te"p drops
2. Muanit* to #eed
ollo7 t!e
#ro" condenser
apori-er c!anges
process conditions
3. Te"p drops
3. Co"position o#
Consider t!e
#ro" re#lu+ed
purge / rec*cle
apori-er Y
condenser
c!anged
co"pressor s!ut do7n
ore
$pposite to less
No
8a"e as less
#
%$ Production o# C*clo!e+ane #ro" ,en-ene
Chapter 0
EN8IRONENTAL IPACTS OF C3CLO(E,ANE PLANT C!e"icals can 0e released to t!e eniron"ent as a result o# t!eir "anu#acture processing and use. EPA !as deeloped in#or"ation su""aries on selected c!e"icals to descri0e !o7 *ou "ig!t 0e e+posed to t!ese c!e"icals !o7 e+posure to t!e" "ig!t a##ect *ou and t!e eniron"ent 7!at !appens to t!e" in t!e eniron"ent 7!o regulates t!e" and 7!o" to contact #or additional in#or"ation. EPA is co""itted to reducing eniron"ental releases o# c!e"icals t!roug! source reduction and ot!er practices t!at reduce creation o# pollutants.
(O5 I6(T I BE E,POSE% TO C3CLO(E,ANE C*clo!e+ane is a colorless #la""a0le liquid.
Production o# C*clo!e+ane #ro" ,en-ene 0en-ene c*clo!e+anone and nitroc*clo!e+ane. C*clo!e+ane can 0e added to lacquers and resins paint and arnis! re"oers and #ungicides.
5(AT (APPENS TO C3CLO(E,ANE IN T(E EN8IRONENT C*clo!e+ane eaporates 7!en e+posed to air. e can in 0rie# asses t!e i"pacts o# c*clo!e+ane producing plant in t!e #ollo7ing "aor areas o# ecolog* and sociolog*.
(2AN (EALT(
C*clo!e+ane is not a !ig!l* to+ic c!e"ical. or )) to &)) pp" e+posure no c!ronic e##ects !ae 0een o0sered. T!e reco""ended t!res!old li"it #or c*clo!e+ane is 3)) pp" 0* olu"e. E+posure ti"e is also i"portant. suall* seeral da*s are needed #or 0ot! !u"an and ani"als to cause an* pro0le" at t!ese pp"s.
A. Phar'acoinetics 1. A0sorption % C*clo!e+ane is a0sor0ed #ollo7ing in!alation and no"inall* 0* t!e s6in. 9assie applications o# t!e c!e"ical to t!e s6in o# ra00its !ae produced #$,
Production o# C*clo!e+ane #ro" ,en-ene "icroscopic c!anges in t!e lier and 6idne*s. 8*ste"ic to+icit* o0sered in ani"als e+posed orall* to c*clo!e+ane indicates t!at gastro% intestinal a0sorption o# t!e c!e"ical also occurs. istar rats to
concentrations
o# c*clo!e+ane ranging #ro" 3))%2))) pp" perirenal #at concentrations o# t!e c!e"ical 7ere 23% to 3'%#old greater t!an 0rain concentrations a#ter one 7ee6 o# e+posure and 5)% to ')%#old greater t!an 0rain concentrations a#ter t7o 7ee6s. :o in#or"ation 7as #ound regarding distri0ution to ot!er organs. 3. 9eta0olis" % C*clo!e+ane is "eta0oli-ed ia t!e !epatic ascular and renal s*ste"s. 9icroso"al !*dro+*lases o+idi-e c*clo!e+ane to c*clo!e+anol in t!e presence o# :APH and o+*gen. $t!er "eta0olites identi#ied in "a""alian s*ste"s include trans%c*clo!e+ane%12%diol c*clo% !e+anone and adipic acid.
B. Acute Effects C*clo!e+ane !as lo7 acute to+icit* producing e*e irritation in !u"ans and neurological s*"pto"s ot!er organ e##ects and deat! in ani"als at er* !ig! doses. 1. Hu"ans % According to one source c*clo!e+ane is detecta0le 0* odor and is irritating to t!e e*es at 3)) pp"L anot!er source suggested 25 pp" as t!e odor t!res!old ?ACit!in 1 to 1.5 !ours let!al doses to ani"als produced seere diarr!ea ascular da"age and collapse !epatocellular degeneration and to+ic glo"erulonep!ritis. E+posure o# ra00its to 333) pp" ?duration not gien@ produced no #$-
Production o# C*clo!e+ane #ro" ,en-ene e##ectL 1'5)) pp" #or ' !ours 7as non%let!alL and 2)) pp" #or 1 !our 7as let!al. Application o# 1.55 g/da* o# c*clo!e+ane to t!e s6in #or 2 da*s produced "ini"al irritation.
C. Su!chronic>Chronic Effects C*clo!e+ane ad"inistered su0c!ronicall* is o# lo7 to+icit* producing neurological e##ects ocular gastrointestinal and respirator* e##ects in ani"als at er* !ig! let!al concentrations. 1. Hu"ans % :o in#or"ation 7as #ound #or t!e su0c!ronic/c!ronic to+icit* o# c*clo!e+ane in !u"ans in t!e secondar* sources searc!ed. 2. Ani"als % :o e##ects 7ere o0sered in ra00its e+posed to 434 pp" c*clo!e+ane #or #i#t* %!our periods or in r!esus "on6e*s e+posed to 1234 pp" under identical e+posure conditions. Concentrations o# &445 pp" to ' !ours/da* #or 2 to 2 7ee6s 7ere let!al to ra00its producing neurological e##ects as 7ell as closure o# t!e e*es conunctial in#ection saliation la0ored respiration c*anosis and diarr!ea prior to deat!. Rats e+posed 0* in!alation to 15)) or 25)) pp" c*clo!e+ane #or (%1) !ours/da* 5 da*s/7ee6 #or & 14 or 3) 7ee6s e+!i0ited no aderse e##ects.
%. Carcino#enicit$ 1. Hu"ans % :o in#or"ation 7as #ound in t!e secondar* sources searc!ed regarding t!e carcinogenicit* o# c*clo!e+ane in !u"ans. 2. Ani"als % :o in#or"ation 7as #ound in t!e secondar* sources searc!ed regarding t!e carcinogenicit* o# c*clo!e+ane in ani"als.
E. 6enoto)icit$ C*clo!e+ane 7as negatie #or iral en!anced cell trans#or"ation in 8*rian !a"ster e"0r*o ?8A&/8HE@ cells and #or !istidine reerse gene "utation in 8al"onella t*p!i"uriu".
#$+
Production o# C*clo!e+ane #ro" ,en-ene
F. %e+elop'ental>Reproducti+e To)icit$ 1. Hu"ans % :o in#or"ation 7as #ound in t!e secondar* sources searc!ed regarding t!e deelop"ental/reproductie to+icit* o# c*clo!e+ane in !u"ans. 2. Ani"als % :o in#or"ation 7as #ound in t!e secondar* sources
searc!ed
regarding t!e deelop"ental/reproductie to+icit* o# c*clo!e+ane in ani"als.
6. Neuroto)icit$ T!e central nerous s*ste" is a "aor target organ #or t!e to+icit* o# c*clo!e+ane. Hig! concentrations o# t!e c!e"ical produce arious e##ects ranging #ro" tre"0ling to deat!. 1. Hu"ans % At !ig! concentrations c*clo!e+ane is a central nerous s*ste" depressant and "a* cause di--iness and unconsciousness. 2. Ani"als % 9ice e+posed to 5) "g/ ?145)) pp"@ #or 2 !ours e+!i0ited "ini"al narcotic e##ects. E+posure to 1'))) pp" produced tre"0ling 7it!in "inutes distur0ed equili0riu" 7it!in 15 "inutes and co"pletes recu"0enc* 7it!in 3) "inutes. C*clo!e+ane caused an e+citation o# t!e esti0ulo%oculo"otor re#le+ ?t!res!old 0lood leel 1.1 ""ole/@. Concentrations o# &445 pp" to ' !ours/da* #or 2 to 2 7ee6s 7ere let!al to ra00its producing conulsions tre"ors narcosis and paresis o# t!e legs.
LAN%
ta6e place. Various concrete and "etal du"ping and digging etc. are "aor costs.
5ATER POLL2TION #$*
Production o# C*clo!e+ane #ro" ,en-ene >ater is e+tensiel* used #or cooling and #or ot!er purposes in t!e plant so 7ater leel o# localit* and sur#ace concentrations o# arious salts "a* distur0. T" alues #or #is! range #ro" 32 to 5&.& "g/ indicating t!at t!e c!e"ical is "oderatel* to+ic to aquatic organis"s in acute tests. C*clo!e+ane is e+pected to 0e o# lo7 to+icit* to terrestrial organis"s and !as a s"og%#or"ing potential.
A. To)icit$ to A&uatic Or#anis's T" alues #or #is! ?24%( !r@ are 43%32 "g/ ?Pi"ep!ales pro"elas #at!ead "inno7@ 43%34 "g/ ?epo"is "acroc!irus 0luegill@. 9ussel larae ?9*tilus edulis@ e+posed to 1 to 1)) pp" ?"g/@ c*clo!e+ane e+!i0ited a 1)%2)B increase in gro7t! rate. T!e t!res!old concentration o# c*clo!e+ane in t!e cell "ultiplication in!i0ition assa* "easured in t!e proto-oa rone"a parduc-i C!atton%7o## 7as h5) "g/.
B. To)icit$ to Terrestrial Or#anis's ,ased on t!e lo7 to+icit* o# c*clo!e+ane to la0orator* ani"als t!e to+icit* o# t!e c!e"ical to terrestrial ani"als is e+pected to 0e lo7.
C. A!iotic Effects i"ited in#or"ation indicates c*clo!e+ane "a* !ae potential to contri0ute to t!e #or"ation o# p!otoc!e"ical s"og. T!e o-one%#or"ing potential #or c*clo!e+ane !as 0een "easured as 2 on a scale o# 5. $-one%#or"ing potential is an indicator o# t!e s"og% #or"ing potential o# a c!e"ical.
AIR POLL2TION Purge #ro" t!e plant can 0e 0urned in 0oiler #urnace 0ut 0lo7%do7ns and
#ugitie e"issions ?#or" ale etc.@ "a* pollute air si"ilarl* !ig! te"peratures inoled "a* also 7ar" t!e at"osp!ere.
#$
Production o# C*clo!e+ane #ro" ,en-ene
C2LT2RAL ACTI8ITIES E+tensie cultural actiities are inoled in erection and production p!ases o# t!e
proect. Also a lot o# econo"ical actiit* is inoled. T!ese can a##ect cultural social and "orale o# t!e people inoled.
ECONOICS " B2SINESS A !uge a"ount o# #inances are spent as #i+ed and 7or6ing capital o# t!e proect.
:e7 "ar6ets 7ill 0e e+plored and captured. E+isting #inancial actiit* ?i"ports etc.@ 7ill 0e a##ected. Also t!e liing status o# t!e people inoled 7ill 0e c!anged.
POP2LATION T(IC;ENIN6 EFFECTS
<# t!e plant is to 0e installed near to a t!ic6l* populated area t!e necessities li6e acco""odation transportation sc!ooling etc. "a* get seer .
#%(
Production o# C*clo!e+ane #ro" ,en-ene
Chapter 0 U
ATERIAL OF CONSTR2CTION An* engineering design particularl* #or a c!e"ical process plant is onl* use#ul 7!en it can 0e translated into realit* 0* using aaila0le "aterials o# construction co"0ined 7it! t!e appropriate tec!niques o# #a0rication can pla* a ital role in t!e success or #ailure o# a ne7 c!e"ical plant.
IPORTANT ATERIAL A8AILABLE 9aterial o# construction "a* 0e diided into t7o general classi#ications o# "etals and non%"etals. Pure "etals and "etallic allo*s are included under t!e #irst classi#ication.
1:
Iron and Steel Alt!oug! "an* "aterials !ae greater corrosion resistance t!an iron and steel cost aspects #aor t!e use o# iron and steel. As a result t!e* are o#ten used as a "aterial o# construction 7!en it is 6no7n t!at so"e corrosion 7ill occur. <# t!is is done t!e presence o# iron salts and discoloration in t!e product can 0e e+pected and periodic replace"ent o# t!e equip"ent s!ould 0e anticipated.
4:
Stainless Steel
#%#
Production o# C*clo!e+ane #ro" ,en-ene T!ere are "ore t!an 1)) di##erent t*pes o# stainless steels. T!e "ain reason #or t!e e+istence o# stainless steels is t!eir resistance to corrosion. C!ro"iu" is t!e "ain allo*ing ele"ent and t!e steel s!ould contain at least 11B. C!ro"iu" is a reactie ele"ent 0ut it and its allo*s passiate and e+!i0it e+cellent resistance to "an* eniron"ents. A large nu"0er o# steels are aaila0le. 8o stainless steel contains c!ro"iu" nic6el iron and also containing s"all a"ount o# ot!er essential properties. T!e* !ae e+cellent corrosion resistance and !eat%resistance properties.
<:
Nicel and its Allo$ :ic6el e+!i0its !ig! corrosion resistance to "ost al6alies.D :ic6el%clad steel is used e+tensiel* #or equip"ent in t!e production o# caustic soda and al6alies. T!e strengt! and !ardness o# nic6el is al"ost as great as car0on steel.
=:
Copper
:
Alu'iniu' T!e lig!tness and relatie ease o# #a0rication o# alu"inu" and its allo*s are #actors #aoring t!e use o# t!ese "aterials. Alu"iniu" resists attac6 0* acids 0ecause a sur#ace #il" o# inert !*drated alu"iniu" o+ide is #or"ed. T!is #il" ad!eres to t!e #%$
Production o# C*clo!e+ane #ro" ,en-ene sur#ace and o##ers good protection unless "aterials 7!ic! can re"oe t!e o+ide suc! as !*drogen acids or al6alies are present.
K:
Lead Pure lead !as lo7 creep #atigue resistance 0ut. its p!*sical properties can 0e i"proed 0* t!e addition o# s"all a"ounts o# siler copper anti"on* or telluriu". ead%clad equip"ent is in co""on use in "an* c!e"ical plants. ead s!o7s good resistance to sul#uric acid and p!osp!oric acid 0ut it is suscepti0le to attac6 0* acetic acid and nitric acid.
M:
(astello$ T!e 0ene#icial e##ects o# nic6el c!ro"iu" and "ol*0denu" arc co"0ined in
Hastello* C to gie an e+pensie 0ut !ig!l* corrosion%resistant "aterial. A t*pical anal*sis o# t!is s!o7s 5B nic6el 1& "ol*0denu" 1B c!ro"iu" 5B iron and 4B tungsten 7it! "anganese silicon car0on p!osp!orus and sul#ur "a6ing up t!e 0alance. Hastello* C is used 7!ere structural strengt! and good corrosion resistance are necessar* under conditions o# !ig! te"perature. T!e "aterial can 0e "ac!ined and is easil* #a0ricated.
:
Coatin#s ,re7eries are large consu"er o# qualit* coatings not onl* #or tan6age 0ut also #or structural steel #looring and ot!er 7or6ing areas. T!e coating used range #ro" !ig! !eat silicones #or stac6s to special super resistant grouts #or #loor paers.
:
Floor aterials Considera0le gia-od tile is used in 0re7eries and special e+po+ies 7it! good ad!esion to er* s"oot! sur#aces !ae e"plo*ed to coat gla-ed cera"ic tile in order to preent cra-ing ?crac6ing@. ,acterial conta"ination deep in t!e pores o# t!e concrete is a co""on occurrence. <# #loors are not properl* sealed corrosion o# concrete re0ars and structural steel can result 7it! eentual crac6ing and spalling o# concrete. #%%
Production o# C*clo!e+ane #ro" ,en-ene
1J:
Plastics or corrosion control point o# ie7 plastics "aterials are er* use#ul t!ere#ore
t!e* !ae #ound application in 0re7eries 7ater treat"ent tan6s acid storage roo#ing and gutters are application #or plastics t!at are co""on to "ost industrial actiit*. i0erglass and pol*in*l c!loride are a"ong t!e plastics t!at !ae 0een e"plo*ed. 8"all pol*prop*lene tan6s #or *east culture and ot!er specialt* serice !ae so"e record o# use.
E72IPENT
ATERIAL OF CONSTR2CTION
8torage tan6 #or 0en-ene
Car0on steel
8torage tan6 #or c*clo!e+ane
Car0on steel
8lurr* !*drogenation reactor
31 8tainless 8teel
i+ed ,ed C*clo!e+ane Reactor
31 8tainlees 8teel
as/iquid 8eparator
Car0on 8teel
8ta0ali-ation Colu"n
Car0on 8teel
Chapter 0 1J
#%&
Production o# C*clo!e+ane #ro" ,en-ene
COST ESTIATION An accepta0le plant design "ust present a process t!at is capa0le o# operating under conditions 7!ic! 7ill *ield a pro#it.
ESTIATION OF E72IPENT COST STORA6E TAN; T%1
K
3.1 + 1) rupees
T%2
K
3.54 + 1) rupees
P%)1
K
3.54 1)5 rupees
P%)2
K
2.'' + 1)5 rupees
P%)3
K
.4+l)4 rupees
P2PS
COPRESSORS #%,
Production o# C*clo!e+ane #ro" ,en-ene C%)1 K
5.&.+1) rupees
(EAT E,C(AN6ERS E%)1
K
1.45 +l$5 rupees
E%)2
K
&.2&+l)5 rupees
E%)3
K
5.'+1)5 rupees
E%)4
K
5.'+l)5 rupees
E%)5
K
2.2+l)5 rupees
E%)
K
(.25 +l$5 rupees
R%)1
K
3.&+l$5 rupees
R%)2
K
(.5+l)4 rupees
V%)1
K
3.3 + 1)5 rupees
V%)2
K
l.l+l$5 rupees
8ESSELS
STABALI*ER 98-J<: K
3.54+l$5 rupees
Pac6ing cost K
1.(4 + 1)4rupees
Total cost
3.&3+l$5 rupees
8!ell cost
K
Total purchased e&uip'ent cost
K
Rs. 2.5+l)& rupees
ESTIATION OF TOTAL CAPITAL IN8ESTENT #%-
Production o# C*clo!e+ane #ro" ,en-ene
•
%irect Cost 9Rs:
K
4.1+1)5 rupees
Piping installed
K
1.15+1)5 rupees
Electrical installed
K
.4 +l$4rupees
,uilding process Y au+iliar*
K
1.2' + 1)rupees
8erice #acilities Y *ard i"proe"ent K
•
.4 + 1)5 rupees
1.'+1)5 rupees
and
K
1.53 + 1) rupees
Total direct cost
K
'.' + 1)rupees
Indirect Cost Engineering Y superision
K
1.514+1) rupees
Construction Y contractorDs #eeK
1.5+1) rupees
Contingenc*
K
1.33 + 1)& rupees
Total indirect costs
K
4.41 + 1)& rupees
Total fi)ed capital in+est'ent
K
1.31+1)& rupees
5orin# capital
K
3.3+1) rupees
Total capital in+est'ent
1.K=)1J M rupees
#%+
Production of 'yclohexane from enzene
REFERENCES 1@ ud7ig E.E Applied Process esign_ 3rd ed ol. 2 ul# Pro#essional Pu0lis!ers 2))2. 2@ 9cetta G. G. Enc*clopedia o# C!e"ical Processing and esign_ E+ecutie ed ol. 1 9arcel e66er ile* and 8ons illia" . u*0en C!e"ical Reactor esign and Control_ &@ Peters 9.8. and Ti""er!aus .. Plant esign and Econo"ics #or C!e"ical Engineering_ ourt! ed 9cra7 Hill 1((1. '@ ,oc6!urst G.. and Har6er G.H Process Plant esign_ Heine"ann Educational ,oo6s td 1(&3. (@ G.9.8"it! C!e"ical engineering 6inetics_. 1)@ Coulson G.". and Ric!ardson G.. C!e"ical Engineering_ 4t! ed Vol.2 ,utter7ort! He"inann 1((1. 11@ E.,ruce :au"an C!e"ical Reactor esignopti"i-ation and scaleup_. 12@ C!arles .HillGR An
#%*
Production of 'yclohexane from enzene 13@ Peacoc6 .. Co ulson Y Ric!ardson[s C!e"ical Engineering_ 3rd ed ol ,utter7ort! Heinenann 1((4. 14@ 8innot R.. Coulson and Ric!ardson[s C!e"ical Engineering_ 2nd ed ol ,utter7ord Heine"ann 1((3. 15@ ern .M. Process Heat Trans#er_ 9cra7 Hill . nit $perations o# C!e"ical Engineering_ 5t! Ed 9cra7 Hill . reen ?eds@F Perr*[s C!e"ical Engineering Hand0oo6 &t! edition 9cra7 Hill :e7 kor6 1((&. 1'@ P!ilip Hall Ho7ard. Hand0oo6 o# Eniron"ental ate and E+posure ata #or $rganic C!e"icals_. 1 (@ C le "e nt T! o"o n 8e ni e% at %$ is e ? t o < ns tit ut e o # ra nc ais e d u petrol@.8. Patent 32)2&23 Au g.24 1(5. 2 )@ 9 au ri ce 8 te 7a rt E "u ls io n a nd $ il Tr ea ti ng E qu ip "e nt s o l. 5L u l# Pro#essional Pu0lis!ers1(&2. 2 1@ o! l . an d R ic !a rd :e ls on , . as Pu ri# ic at io ns ol. 5L u l# Pro#essional Pu0lis!ers1((&. 2 2@ >ala s. 8 9. C !e "ic al P ro ce ss E qu ip "e nt 8 el ec ti on a nd es ig n Re ed Pu0lis!ers 1(('. 2 3@ R ic !a rd so n. G. Y C olu so nG .9 . C !e "i ca l E ng in ee ri ng ol.L9cra7 Hill :e7 kor6 1((&. 2 4@ E rn es t.E . App lied Pr oces s es ign or C! e"ic al An d Petroc!e"ical Plantsedit.3Lol.2L ul# Pro#essional Pu0lis!ers. 2 5@ R ic !a rd so n. G. Y C olu so nG .9 . C !e "i ca l E ng in ee ri ng ol.L9cra7 Hill :e7 kor6 1((&. 2 @ E rn es t.E . App lied Pr oces s es ign or C! e"ic al An d Petroc!e"ical Plantsedit.3Lol.2L ul# Pro#essional Pu0lis!ers.
#%
Production of 'yclohexane from enzene
APPEN%I, igure 4.1
igure 4.2 #&(
Production of 'yclohexane from enzene
igure 4.3 #&#
Production of 'yclohexane from enzene
igure 4.4 #&$
Production of 'yclohexane from enzene
#&%
