CHEMICAL ENGINEERING

DEPARTMENT
Graduation Project

MARCH 25, 2020

UOT
 University of Technology
Department of Chemical Engineering
Branch of chemical processes

By
Mariam eisa

Mohammed aleybe

Supervised
by

Dr. Jamal Manee Alrubeai

2020
 DEDICATION

For every person who was abond during all

days that were difficult ….
 Table of Contents
Content :- Page

Chapter one ( Introduction ) ............................................................................ 1

1.1 Introduction.................................................................................................. 2
1.2 Historical ..................................................................................................... 2
1.3 Uses ............................................................................................................. 3
1.4 Physical properties ......................................................................................4
1.5 Chemical properties ................................................................................... 5
Chapter Tow ( Production methods )............................................................... 8
2.1 Manufacturing process ………………………………...……………… 9
2.2 Ethylene from methane, method details ……………..………..…… 13
Chapter Three ( Material balance ) ............................................................... 16
3.1 Production capacity .................................................................................... 17
3.2 Overall material balance............................................................................ 17
3.3 Material balance on reactor ........................................................................ 22
3.4 Material balance on gas liquid separator ................................................... 26
3.5 Material balance on adsorbed …………………………...…………… 27
3.6 Material balance on absorber …………………………...…………… 28
3.7 Material balance on stripper ...................................................................... 31
3.8 Material balance on caustic wash ............................................................... 33
3.9 Material balance on distillation column ...................................................... 35
Chapter Four ( Energy balance ) .................................................................. 40
4.1 Energy balance on mixing point ................................................................ 42
4.2 Energy balance on furnace ......................................................................... 44
4.3 Energy balance on reactor .......................................................................... 46
4.4 Energy balance on first heat exchanger ..................................................... 49
4.5 Energy balance on second waste heat boiler .............................................. 51
4.6 Energy balance on partial condenser ......................................................... 51
4.7 Energy balance on absorbed ...................................................................... 54
4.8 Energy balance on stripper ........................................................................ 56
4.9 Energy balance on cooler ........................................................................... 61
4.10 Energy balance on caustic wash .............................................................. 62
4.11 Energy balance on compressor system .................................................... 64
4.12 Energy balance on distillation column ...................................................... 69
Chapter Five ( Equipment Design ) ............................................................ 73
5.1 Design of distillation column ..................................................................... 74
5.2 Design of Cooler ...................................................................................... 102
Chapter Six ( Environmental Effect ) ........................................................ 122
6.1 Environmental considerations .................................................................. 123

6.2 Waste management ..................................................................................123

6.3 Exposure limits ....................................................................................... 125

6.4 Environmental exposure .......................................................................... 125

Chapter Seven ( Discussion & Recommendations ) .................................... 127

7.1 Discussion ................................................................................................ 128

7.2 Recommendations .................................................................................... 128

References ..................................................................................................... 129

 Abstract

Ethylene appears to have been discovered by Johann J. Becher, who

obtained it by heating ethanol with sulfuric acid (1669). Joseph Priestley also
mentions the gas in his experiments (1779). The properties of ethylene were
studied in (1795) by four Dutch chemists, Johann R. Deimann, AdrienPaets van
Troostwyck, Anthoni Lauwerenburgh and Nicolas Bondt, who found that it
differed from hydrogen gas and that it contained both carbon and hydrogen.
Ethylene is the most produced petrochemical with about 140 million tones annual
production and nearly 300 million tones annual carbon dioxide emission. In
recent years, record price of crude oil – the origin of more than 50% ethylene
worldwide – has put naphtha-based producers in a very tough position, especially
the ones in region with strict emission regulation such as Europe.
Ethylene (ethene, H2C= CH2) is a colorless, flammable gas with a slightly sweet
odor. It is lightest of the olefin hydrocarbons. Due to it is double bound, it is a
highly reactive compound which is converted to a great number of intermediate
and end products or a large industrial scale by a variety of addition,
oxidation and polymerization reactions.
Ethylene is used to produced polyethylene low and high density (LDPE and
HDPE), Ethylene dichloride, Vinyl chloride, Ethylene oxide, Vinyl acetate,
Ethanol, Ethyl benzene, and Ethyl chloride.
Ethylene is produced by four manufacturing process as Ethylene from coal,
Ethylene from ethanol, Ethylene from Pyrolysis of hydrocarbons, Ethylene from
methane. The fourth process was selected in this project for these reasons as,
Availability of raw materials, High yield of ethylene, Modern process and Lower
cost.
The estimated capacity for Ethylene is 132000 ton/year which is equivalent to

654.65 Kmol/ hr =18333 Kg/hr .

CHAPTER ONE
INTRODUCTION

1
 1.1 Introduction:-

IUPIC name Ethylene (ethene, H2C = CH2 or C2H4) is

hydrocarbon a colorless, flammable gas with a slightly sweet odor. It is

lightest of the olefinic hydrocarbons. Due to it is double bound, it is a
highly reactive compound which is converted to a great number of
intermediate and end products or a large industrial scale by a variety of
addition, oxidation and polymerization reactions. Although less reactive
than acetylene, ethylene is simpler, safer, and less costly to produce and to
convert to other useful compounds and has largely replaced acetylene as
the most important building block in the chemical industry. It is the most
significant organic chemical produced today in terms of production
volume, sales value, and variety of useful derivatives. Ethylene is primarily
used for the production of such polymeric materials as fabricated plastics,
fiber, resins, adhesives, and elastomers. Other important uses of ethylene
derivatives are solvents, antifreeze, and plasticizers.[1]

2
 1.2 Historical

Ethylene appears to have been discovered by Johann Joachim

Becher, who obtained it by heating ethanol with sulfuric acid (1669).
Joseph Priestley also mentions the gas in his Experiments (1779) .

In 1866, the German chemist August Wilhelm von Hofmann proposed a

system of hydrocarbon nomenclature in which the suffixes -ane, -ene, -ine,
-one, and -une were used to denote the hydrocarbons with 0, 2, 4, 6, and 8.

The properties of ethylene were studied in (1795) by four Dutch chemists,

Johann Rudolph Deimann, Adrien Paets van Troostwyck, Anthoni
Lauwerenburgh and Nicolas Bondt, who found that it differed from
hydrogen gas and that it contained both carbon and hydrogen

3
fewer hydrogens than their parent alkane. In this system, ethylene became
ethane.
Ethylene is produced in the petrochemical industry by steam cracking of
hydrocarbons gases or liquids.
In (2006) global ethylene production was 109 million tonnes. By (2010)
ethylene was produced by at least 117 companies in 55 countries. [2]

Hofmann's system eventually became the basis for the Geneva

nomenclature approved by the International Congress of Chemists in
(1892). However, by that time, the name ethylene was deeply entrenched,
and it remains in wide use today, especially in the chemical industry.

1.3 Uses:-

1- Ethylene is used to produced polyethylenes low and high density

(LDPE and HDPE).
2- Ethylene is used to produced ethylene dichloride.

3- Ethylene is used to produced vinyl chloride.

4- Ethylene is used to produced ethylene oxide.

5- Ethylene is used to produced vinyl acetate.

6- Ethylene is used to produced ethanol.

7- Ethylene is used to produced ethyl benzene.

8- Ethylene is used to produced ethyl chloride.

9- Ethylene is used to produced polyethylene.

All uses from Ref. [3,4]

4
1.4 Physical properties:-

Ethylene is the lightest olefin. It is a colorless, flammable gas

slightly sweet odor, physical and thermodynamic properties are given in
the table below[4]:-

Table [1.1] :

The Physical properties for Ethylene

Property Unit Value

Molecular weight Kg/Kmol 28.05

0
Boiling point C -103.71

Latent heat of vaporization KJ/mol 13.548

Density of liquid mol/dm3 20.27

Specific heat of liquid J/mol.K 67.4

Specific heat of gas J/mol.K 42.84

Viscosity of liquid Pa.s 0.161

Surface tension of liquid dyn/cm 16.4

0
Critical temperature C 9.194

Critical pressure KPa 5040.8

Standard of combustion MJ/mol 1.411

Limits of flammability in air

Lower
vol%
2.7
Upper vol%
36
0
Autoignation temperature C 490

Standard heat of formation KJ/mol 52.3

Standard heat capacity J/mol.K 42.66

5
Standard entropy of formation J/mol.K 219.28

6
1.5 Chemical properties:-

Ethylene is a vary reactive intermediate and hence is involved in many

chemical reactions which are[2, 4]:

Ethylene is a planar molecular with a carbon-carbon bond distance of 0.134

nm which is shorter than the carbon-carbon bond length 0.153 nm found in
ethane.

1.5.1 Polymerization:

In industrial production polyethylene is formed b) )polymerization(

of ethylene at conditions …

60 to 350 MPa and temperature of up 350 0C by following reaction:-

n(CH2=CH2) → (-CH2-CH2-)n ............................... ( 1.1 )

n( )→

7
1.5.2 Oxidation:

Today ethylene oxide is produced by vapor phase

oxidation of ethylene with air over selective silver oxide
catalyst, typically at (200 –300) 0
C and 1 to 3 MPa
pressure by the following reaction…

C2H4 + 0.5O2 → C2H4O ………………………( 1.2 )

+ 0.5O2 →

8
1.5.3 Halogenation:

Ethylene dichloride made by the direct addition of chlorine to

ethylene at (40 – 140) 0C and 0.1 to 0.5 MPa in the pressure of ferric
chloride as catalyst by the following reaction:-

C2H4 + Cl2 → C2H4Cl ....................................... ( 1.3 )

+ Cl2 →

1.5.4 Oxychlorination:

The oxychlorination is carried out the vapor phase with copper

chloride containing potassium chloride supported on alumina silica as
catalyst at (200 – 300) 0C and 0.1 to 0.5 MPa ethylene dichloride is
produced by the following reaction:-

C2H4 + 2HCl + 0.5O2 → C2H4CH4 + H2O...............( 1.4 )

+ 2HCl + 0.5O2 →

9
1.5.5 Hydrohalogenation:

Ethyl chloride is produced by ionic addition of hydrogen chloride to

a dilute ethylene stream in the presence of aluminum chloride catalyst at
(25 – 40) 0C and 1 atm.

C2H4 + HCl → C2H5Cl .................................... ( 1.5 )

+ HCl →

1
0
1.5.6 Alkylation:

Ethylene is reacted with benzene at (80 – 100) 0C and 0.1 to 0.2 MPa
over aluminum chloride as catalyst to produced ethylbenzene by the
following reaction:-

C2H4 + C6H6 → C6H5 + C2H5 ............................... ( 1.6 )

1
1
 CHAPTER TWO
PRODUCTION METHODS

1
2
2.1 Manufacturing process:-
Ethylene is produced by the following manufacturing process:
1- Ethylene from coal.
2- Ethylene from ethanol.
3- Ethylene from pyrolysis of hydrocarbons.

4- Ethylene from methane.

2.1.1 Ethylene from coal:-

Synthesis gas derived from coal gasification can be converted to
hydrocarbons by the Fisher Tropsch (FT) process. The conventional (FT)
process produces high molecular weight saturated and olefinic
hydrocarbons and oxygenated compounds.

Ethylene can be recovered directly or after pyrolyzing the ethane and

naphtha produced as seen in fig.(2.1). In general this is not an
economical process.(4)

Reactions:

C + 0.5O2 → CO .....................................( 2.1)

C + H2O → H2 + CO .................................... (2.2)

2CO + 4H2 → C2H4 + 2H2O .............................(2.3)

2CO + 5H2 → C6H6 + 2H2O ............................. (2.4)

1
3
 Figure (2.1) : Flow sheet of Ethylene from coal

2.1.2 Ethylene from ethanol:-

The ethanol feed (95 wt% soluation) is pumped to 588 Psi.
Vaporized and superheated to 400 c and passed through a series of three
fixed bed adiabatic reactor operating at (590 – 762) F and 585 Psi as seen
in fig.(2.2).

Ethylene is produced by the following reaction over alumina catalyst.

C2H5OH C2H4 + H2O ....................... (2.5)

2C2H5OH (C2H5)O + H2O................. (2.6)

The reaction products are sent through a separation train designed to purity
of ethylene product to 99.96%.
10
 Figure (2.2) : Flow sheet of Ethylene from ethanol

2.1.3 Ethylene from pyrolysis of hydrocarbons.

Thermal cracking of hydrocarbons is accomplished in a tubular
reactor commonly know as cracking furnace. The reaction proceeds in the
pyrolysis coil of the radiant section of the furnace steam is added as diluent
to the feed. The furnace is operating at (775 – 950) oC and (2 – 3) atm. The
furnace effluent is cooled in heat exchanger and quenched with oil or water.
Uncondensed gases are compressed, dried with molecular sieve and cooled
to - 100 oC. The liquid stream is fed to series of distillation column for
purification as seen in fig.(2.3).(4)

11
Figure (2.3) : Flow sheet of Ethylene from pyrolysis of
hydrocarbons (ethane)
12
2.1.4 Manufacturing process selection:-
We select the fourth process for the following reasons : 1-

Availabity of raw materials.

2-High yield of ethylene.

3-Modern process.

4-Lower cost

2.2 Ethylene from methane, method details:-

Fresh feed of methane and oxygen are preheated to 400 0C by
heat exchanger (E-01) and mixed with recycle methane, the resulting
mixture is heated to 800 0C by furnace (F-01) and sent to the fixed bed
reactor operating at 800 0C and (5 - 6) atm contains Zeolite as catalyst
where ethylene is produced by the following exothermic reactions :-

2CH4 + O2 C2H4 + 2H2O .............................. (2.8)

4CH4 + O2 2C2H6 + 2H2O ........................... (2.9)

C2H6 C2H4 + H2 .......................................... (2.10)

CH4 + 2O2 CO2 + 6H2O .............................. (2.11)

CH4 + 3 O2 CO + 2H2O ............................... (2.12)

The heat of reactions is removed by cooling water and generation
saturation steam at 12 bar. The effluent gases from reactor are cooled to
(440, 200, 45) 0C be their heat exchanger (E- 01), (E-02), and(E-03), where
water is condensate and removed by gas-liquid separator. The cooled gases
are sent to adsorption column, unadsorption gases goes to separation unit
to remove methane which are recycle to the furnace, adsorbed gases (CH4
, C2H6 and CO2 ) are sent to the Carbon dioxide removal unit using
15 Wt% Monoethanolamine (MEA) solution as solvent, this unit

13
consist of absorber and stripper where carbon dioxide is removed
by the following reaction:

Absorber:-

2C2H7NO + H2O + CO2 (C2H5ONH3)2CO3 …(2.13)

Stripper:-

(C2H5ONH3)2CO3 2C2H7NO + H2O + CO2 …(2.14)

About 99% of carbon dioxide is removed the gases exit from the top
absorber are fed to the caustic wash column to remove remain
carbon dioxide by the following reaction:

CO2 + 2NaOH Na2CO3 + H2O ............(2.15)

the gases exit from the caustic wash column is sent to three stages
compressor with enter cooling between each stage where gases is
compressed to 35 atm and fed to distillation column (D-
01) to separate methane in the overfeed product (99.8 mol%) from
ethane from the bottom product as seen in fig.(2.4).[5-12]

14
 5
Figure (2.4) : Flow sheet of Ethylene from methane
 Chapter Three
Material Balance

16
3.1 Production capacity P = 132000 ton/year [From production of
petrochemical plant in Basra]

Ton = 1000 Kg
Year = 300 day
Day = 24 hr
Basis 1 hr
132000 ton 1000 Kg yr day
P= ∗ ∗ ∗
yr ton 300 day 24 hr

P = 18333 Kg

Composition of final product [5]

Table (3.1) : Composition of final product

(yi* Mi)
Composition (yi) mol% Mwt (Mi) Kg/Kmol
Kg/Kmol
C2H4 99.8 28 27.944
C2H6 0.20 30 0.06
∑ =100 ∑ =28.004

18333
P= = 654.6565 kmol
28.004

3.2 Overall material balance :- [5]

Methane inlet to the process = F1 kmol

Oxygen inlet to the process = F2 kmol

Hydrogen exit from process = A Kmol

Carbon monoxide exit from process = B Kmol

Carbon dioxide exit from process = C Kmol

Ethane unadsorbed = E Kmol

Final product from top of distillation column consist of 99.8 mol% C2H4 and 0.2
mol% C2H6 = P Kmol
17
Bottom product from distillation column consist of 4.96 mol% C 2H4 and 95.04
mol% C2H6 = L Kmol

Water exit from process = W Kmol

Fig. (3.1) : Overall materials balance

Reactions:

18
General material balance equation:-
In + Generation = Out + Consumption

Overall C2H4 M.B.

1 2
0 + F1X1 + F1X2X3 = 0.998P + 0.0496L
2 4

0.5 F1 ( X1 + X2X3) = 0.998P + 0.0496L

0.5 F1 [( 0.4838 ) + ( 0.1253 + 0.80 )] = 0.998( 654.6565 ) + 0.0496L

F1 = 2237.3371 + 0.16985L ................................................. (3.1)

Overall C2H6 M.B.

2 2
0 + F1X2 = 0.9504L + 0.002P + E + F1X2X3
4 4

0.5 F1X2 (1- X3 ) = 0.9504L + 0.002(654.6565 ) + E

0.5 F1 ( 0.1253 ) (1- 0.80 ) = 0.9504L + 1.3093 + E

F1 = 75.84996L + 104.4932 + 79.8085E ................................ (3.2)

Assume 80% of C2H6 is adsorbed

C2H6 adsorbed = 0.9504L

C2H6 unadsorbed = E

0.9504L 0.80
=
E 0.20

E = 0.2376L ................................................................... (3.3)

Substitute eq. (3) in eq. (2)

F1 = 75.84996L + 104.4932 + 79.8085 (0.2376L )

F1 = 94.81246L + 104.4932 ............................................. (3.4)

Substitute eq. (4) in eq. (1)

2237.3371 + 0.16985L = 94.81246L + 104.4932

19
L= 22.5358 Kmol * 29.9 Kg/ Kmol

= 673.84 Kg

F1 = 2237.3371 + 0.16985 (22.5338 )

= 2241.1648 Kmol * 16 Kg/ Kmol

= 35858.64 Kg

E = 0.2376 ( 22.5338 )

= 5.3545 Kmol * 30 Kg/ Kmol

= 160.64 Kg

Overall H2 M.B.
2
0+ F1X2X3 = A + 0
4

0.5(2241.1648)(0.1253)(0.80) = A

A = 112.3272 Kmol * 2 Kg/ Kmol = 224.65 Kg

Overall CO M.B.

0 + F1X5 = B + 0

(2241.1648)(0.1890) = B

B = 423.5802 Kmol * 28 Kg/ Kmol

= 11860.25 Kg

Overall CO2 M.B.

0 + F1X4 = D + 0

(2241.1648)(0.2019) = D

D = 425.4918 Kmol * 44 Kg/ Kmol

= 19909.64 Kg

20
Overall H2O M.B.
2 2
0+ F1X1 + F1X2 + 2F1X4 + 2F1X5 = W + 0
2 4

F1 (X1 + 0.5 X2 + 2 X4 + 2 X5) = W

(2241.1648)[(0.4838) + (0.5 * 0.1253) + (2 * 0.2019) + (2 * 0.1890)] = W

W = 2976.8271 Kmol * 18 Kg/ Kmol

= 53582.89 Kg

Overall O2 M.B.
1 1 3
F2 - F1X1 - F1X2 - 2F1X4 - F1X5 = 0
2 2 2

F2 = F1(0.5X1 + 0.25X2 + 2X4 + 1.5X5)

F2 = (2241.1648)[(0.5 * 0.4838) + (0.25 * 0.1253) + (2 * 0.2019) + (1.5 *

0.1890)]

F2 = 2152.6948 Kmol * 32 Kg/ Kmol

= 68886.23 Kg

Fig. (3.2) : Overall materials balance

21
Total input = F1 + F2

= 35858.64 + 68886.23

= 104744.87 Kg

Total output = G + P + L + W

= 32155.18 + 18333 + 673.84 + 535828.89

= 104744.91 Kg

∴ Total input = Total output

3.3 Material balance on reactor:- [5]

Fig. (3.3) : Material balance on reactor

22
 Methane reacted
Single pass conversion of Methane = Methane inlet to reacted

CH4 reacted = 2241.1648 Kmol

CH4 inlet to reacted = 2241.1648 + R

Single pass conversion of CH4 = 30.02% [ 5]

2241.1648
0.3002
2241.1648 + R
=

R = 5224.4075 Kmol CH4 * 16 Kg/ Kmol

= 83590.52 Kg

Exit products :-
CH4 = inlet – reacted

= (2241.1648 +5224.4075) - 2241.1648

= 5224.4075 Kmol CH4 * 16 Kg/ Kmol

= 83590.52 Kg

H2 = A = 112.3272 Kmol * 2 Kg/ Kmol

= 224.65 Kg

CO = B = 423.580 Kmol * 28 Kg/ Kmol

= 11860.25 Kg

CO2 = D = 425.4918 Kmol * 44 Kg/ Kmol

= 19909.64 Kg

C2H4 = 0.998P + 0.0496L

= 0.998(654.6565) + 0.0496(22.5358)

= 654.4650 Kmol * 28 Kg/ Kmol

= 18325.02 Kg

C2H6 = E + 0.002P + 0.9504L

23
 = 5.3545 + 0.002(654.6565) + 0.9504(22.5358)
= 28.0818 Kmol * 30 Kg/ Kmol
= 842.45 Kg
H2O = W = 2976.8271 Kmol * 18 Kg/ Kmol
= 53582.89 Kg

Table (3.1) : Material balance on reactor

Input (6) Output (7)

Component Kmol Kg Kmol Kg

CH4 7465.5723 119449.16 5224.4075 83590.52

O2 2152.6948 68886.23

H2 112.3272 224.65

CO 423.5802 11860.25

CO2 425.4918 19909.64

C2H4 654.4650 18325.02

C2H6 28.0818 842.45

H2O 2976.8271 53582.89

∑= 96182671 188335.39 98721806 188335.42

∴ Total input = Total output

24
Fig. (3.4) : Material balance on gas liquid separator

Fig. (3.4) : Material balance on reactor

25
3.4 Material balance on gas liquid separator:-[5]

Fig. (3.5) : Material balance on gas liquid separator

26
3.5 Material balance on adsorbed :-[5]

Fig. (3.6) : Material balance on adsorbed

C2H6 Unadsorbed = E = 5.3545 Kmol calculated from C2H6 M.B.

28.0818 = E + K
28.0818 = 5.3545 + K
K = 22.7273 Kmol
Assume 70% of CO2 is adsorbed
Z = 0.70(452.5802)
= 316.8061 Kmol
V = 0.30(452.5802)
= 135.7741 Kmol

27
 Fig. (3.7) : Material balance on adsorbed

3.6 Material balance on absorber:- [7]

Use 15 Wt% Momoethanolamine (MEA) solution as solvent [7]

Let (C2H5ONH3)2CO3 recycle to absorber = R Kg

Fig. (3.8) : Material balance on absorber

28
Reaction:-
2C2H7NO + H2O + CO2 (C2H5ONH3)2CO3 .............. (3.1)
1 Kmol of MEA per 0.40 Kmol of CO2 is used [7]

Kmol MEA 1
=
Kmol CO2 0.40

Kmol MEA 1
=
316.8061 0.40

MEA inlet to the absorber = 792.0153 Kmol * 61 Kg/Kmol

= 48312.43 Kg
0.85
H2O inlet to the absorber = 48312.43( )
0.15

= 273773.27 Kg / 18 Kg/Kmol

= 15209.6260 Kmol

99% recovery of CO2

CO2 reacted = 0.99(316.8061)

= 313.6380 Kmol * 44 Kg/Kmol

= 13800.07 Kg

MEA reacted = 2(313.6380)

= 627.2760 Kmol * 61 Kg/Kmol

= 38263.84 Kg

H2O reacted = 313.6380 Kmol * 18 Kg/Kmol

= 5645.48 Kg

(C2H5ONH3)2CO3 formed = 313.6380 Kmol * 184 Kg/Kmol

= 57709.39 Kg

29
CO2 M.B.

Inlet – reacted = out

316.8061 - 313.6380 = Z

Z = 3.1681 Kmol * 44 Kg/Kmol = 139.40 Kg

Exit liquid

H2O = Inlet – reacted

= 273773.27 – 5645.48
= 268127.79 Kg / 18 Kg / Kmol = 14895.9880 Kmol
MEA = Inlet – reacted
= 48312.43 - 38263.84
= 10049.09 Kg / 61 Kg/Kmol = 164.7392 Kmol
(C2H5ONH3)2CO3 = Inlet – reacted
R
= (R + 57709.39) Kg / 184 Kg/Kmol = ( + 313.6380) Kmol
184

Table (3.2) : Material balance on absorber:

Input (16,23) Output (17,24)

Component Kmol Kg Kmol Kg
CO2 316.8061 13939.47 3.1681 139.40
C2H4 654.4650 18324.77 654.4650 18324.77
C2H6 22.7273 831.82 22.7273 831.82
H2O 15209.626 273773.27 14895.988 268127.79
MEA 792.0153 48312.43 164.7392 10049.09
R
R + 57709.39 +
(C2H5ONH3)2CO3 R 184
184 313.638 R

∑ 355182.26 + R 355182.26 + R

∴ Total input = Total output

30
3.7 Material balance on stripper:- [5]

Fig. (3.9) : Material balance on stripper

Reaction :-

(C2H5ONH3)2CO3 2C2H7NO + H2O + CO2 ............... (3.2)

CO2 formed = 313.6380 Kmol * 44 Kg/Kmol

= 13800.07 Kg
H2O formed = 313.6380 Kmol * 18 Kg/Kmol
= 5645.48 Kg

31
MEA formed = 2(313.6380)
= 627.2760 Kmol * 61 Kg/Kmol
= 38263.84 Kg
(C2H5ONH3)2CO3 reacted = 313.6380 Kmol * 184 Kg/Kmol
= 57709.39 Kg
99% recovery of (C2H5ONH3)2CO3
R
( + 313.6380)(0.99) = 313.6380
184
R

184
= 3.1681 Kmol

R = 582.93 Kg
Exit liquid :-
H2O = Inlet + formed
= 14895.9880 + 313.6380

= 15209.6260 Kmol * 18 Kg/Kmol

= 273773.27 Kg
MEA = Inlet + formed
= 164.7392 + 627.276

= 792.0152 Kmol * 61 Kg/Kmol = 48312.93 Kg

(C2H5ONH3)2CO3 = Inlet – reacted
R
=( + 313.6380) - 313.6380
184

= (3.1681 + 313.6380) - 313.6380

= 3.1681 Kmol * 184 Kg/Kmol
= 582.93 Kg

32
Table (3.3) : Material balance on stripper:

Input (17,21) Output (18,19,20,22)

Component Kmol Kg Kmol Kg

CO2 313.6380 13800.07

H2O 14895.9880 268127.79 15209.6260 273773.27
MEA 164.7392 10044.09 792.0152 48312.93
C2H5ONH3)2CO3 316.8061 58292.32 3.1680 582.93
∑ 15377.5313 336489.2 16318.4472 336489.2

∴ Total input = Total output

3.8 Material balance on caustic wash:- [5]

Fig. (3.10) : Material balance on caustic wash

33
Reaction:-
CO2 + 2NaOH Na2CO3 + H2O ............................. (3.3)

Use 10% excess of NaOH

In− Required
Excess % =
Required
* 100

CO2 input = 3.1681 Kmol

NaOH required = 2(3.1681)

= 6.3362 Kmol
In − 6.3362
0.10 =
6.3362

In of NaOH = 6.9698 Kmol * 40 Kg/Kmol

= 278.79 Kg
CO2 reacted = 3.1681 Kmol
NaOH reacted = 2(3.1681)

= 6.3362 Kmol * 40 Kg/Kmol

= 253.45 Kg
Na2CO3 product = 3.1681 Kmol * 106 Kg/Kmol
= 335.82 Kg
H2O product = 3.1681 Kmol * 18 Kg/Kmol
= 57.03 Kg

Exit gases
C2H4 = 654.4650 Kmol
C2H6 = 227.273 Kmol
Exit liquid
H2O = inlet + product
= 0 + 3.1681
= 3.1681 Kmol * 18 Kg/Kmol
34
 = 57.0258 Kg
NaOH = inlet - reacted
= 6.9698 - 6.3362
= 0.6336 Kmol * 40 Kg/Kmol
= 25.34 Kg
Na2CO3 = inlet + product
= 0 + 3.1681 = 3.1681 Kmol * 106 Kg/Kmol
= 335.82 Kg

3.9 Material balance on distillation column:-[5]

All streams are calculated from overall M.B.

Fig. (3.11) : Material balance on distillation column

Top product

C2H4 = 0.998(654.6568)

= 653.3472 Koml

C2H6 = 0.002(654.6568)

35
 = 1.3093 Koml

Bottom product

C2H4 = 0.0496(22.5358)

= 1.1177 Koml

C2H6 = 0.9504(22.5358) = 21.4180 Kom

Input:

C2H4 = 654.6568 Kom

C2H6 = 22.5358 Kom

Output:

C2H4 = 653.3472 + 1.1177

= 654.4650 Koml

C2H6 = 1.3093 + 21.4180

= 22.7273 Koml

Fig. (3.12) : Materials entering and leaving into the distillation and their values

36
37
 Stream
Component Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CH4 Kg 35858.6 35858.6 35858.6 119449.1 119449.1 83590.5 83590.5 83590.5 83590.5 83590.5 83590.5 83590.5
O2 Kg 68886.2 68886.2 68886.2 68886.2 68886.2
H2 Kg 224.65 224.65 224.65 224.65 224.65 224.65 224.65
CO Kg 11860.2 11860.2 11860.2 11860.2 11860.2 11860.2 11860
CO2 Kg 19909.6 19909.6 19909.6 19909.6 19909.6 5974 5974 13939
C2H4 Kg 18325 18325.0 18325.0 18325 18325 18324.7
C2H6 Kg 842.45 842.45 842.45 842.45 842.45 160.64 681.82
H2 O Kg 53582.8 53582.8 53582.8 53582.8 53582.8
MEA Kg
(C2H5ONH3)2CO3 Kg
NaOH Kg
Na2CO3 Kg
Total Kg 35858.6 68886.2 104745 104745 188335.4 188335.4 188335.4 188335.4 188335.4 188335.4 53582.8 134752.5 101810 83590.51 18059 32946
T ℃ 25 25 25 400 214.9 800 800 439.7 200 45 45 45 45 25 25 45
P atm 6 6 6 5.6 5.6 5.3 4.9 4.4 3.9 3.4 3.4 3.4 3 5.6 5.6 3

17 18 19 20 21 22 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

13800 13800 13800 13800 13800 139.4

18324.7 18324 18324 18324 18324 18324 18324 18324 31.05 18293.7
681.82 681.8 681.8 681.8 681.8 681.8 681.8 681.8 642.54 39.28
268127.8 12236.9 12236.9 12236.9 273773.3 12236.9 12236.9 273773.3 273773.3 1117.19
10049.1 48312.9 48.31 48312.9 48312.9 1115.16
58292.3 582.93 582.93 582.93
278.90 25.34
253.43
336469 26037 26037 13800 12236.9 322669 26037 13848 12236.9 322669 322669 19146 1394.1 1451 19006 19006 19006 19006 19006 19006 19006 673.59 18333
63 98 98 98 98 116 98 98 98 116 45 63 25 40 40 113 40 113 40 113 40 14 -10
2.5 1.3 1.2 1.2 1.2 3 1.2 1.2 1.2 3 3 2.7 2.7 2.5 2.5 6.205 5.875 14.582 14.252 35.37 35.04 35.2 34.9

38
 Code Equipment

R-01 Fixed bed reactor

F-01 Furnace

AD-01 Adsorber

AB-01 Absorber

ST-01 Stripper

D-01 Caustic wash column

D-02 Distillation column

V-01 Gas-liquid separator

SP-01 Separation unit

E-01 – E-11 Heat exchanger

C-01 – C-03 Compressors

T-01 Methane tank

T-02 Oxygen tank

T-03 Reflux tank

P-01 Centrifugal pump

P-02 Centrifugal pump

39
 Chapter Four
Energy Balance

40
Gas heat capacity:- [6]
Cp = a + bT + cT2 + dT3 KJ/Kmol.K

Table (4.1) : Values of Gas heat capacity :

Component a b c d

CH4 19.251 5.21*10-3 1.197*10-5 -1.131*10-8

H2 27.143 9.273*10-3 1.380*10-5 7.605*10-9

CO 30.869 -1.285*10-2 2.789*10-5 -1.271*10-8

CO2 19.795 7.343*10-2 -5.601*10-5 1.715*10-8

C2H4 3.806 1.565*10-1 -8.348*10-5 1.755*10-8

C2H6 15.409 1.781*10-1 -6.937*10-5 8.712*10-9

O2 28.106 -3.680*10-1 1.745*10-5 -1.065*10-8

H2O 31.243 1.933*10-3 1.055*10-5 -3.596*10-9

Liquid heat capacity:- [6,7]

Table (4.2) : Values of Liquid heat capacity :

Component CpL KJ/Kmol.K

H2O 4.20

MEA 2.67

(C2H5ONH3)2CO3 2.93

15 Wt% MEA 3.97

NA2CO3 1.14

20 Wt% NaOH 3.97

41
Heat of formation :- [6,8]
Table (4.3) : Values of Heat of formation:

Component ∆Hf298 K/mol.K

CH4 -74.86
CO -110.62
CO2 -393.77
C2H4 52.33
C2H6 -84.74
-24.2 Vap.
H2O
-286 Liq.
NaOH 0.55
Na2CO3 1.144

4.1 Energy balance on mixing point:-[5]

Recycle methane at 25 ℃ is mixed with fresh feeds
at 400 ℃ ( from heat exchanger ). The mixture exit at temp. = T ........ From Ref.[5]

CH4 = 35858.64 Kg/hr

O2 = 68886.23 Kg/hr
400 ℃ (673 K) CH4 = 119449.16 Kg/hr
O2 = 68886.23 Kg/hr
CH4 = 83590.52 Kg/hr T=?
25 ℃ (298 K)
Fig. (4.1) : Energy balance on mixing point

Energy Balance

Qin = Qout
Tref = 25 ℃ = 298 K

42
 298 673
Q =𝑛∫ 𝐶𝑝 𝑑𝑇 + ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
in 298 298

298
n ∫298 Cp dT = 0 for CH 4 recycle

For fresh feed CH4

35858.64
𝑛= 16
= 2241.1650 Kmol/hr

𝑇2 𝑇2
∫𝑇1 𝐶𝑝 𝑑𝑇 = ∫𝑇1 (a + bT + cT^2 + dT^3) 𝑑 .

Assume T1 = T , T2 = Tref
𝑇ref b c d
∫ 𝐶𝑝 𝑑𝑇 = [a(T – T ) + (T2 – T2 ) + (T3 – T3 )+ (T4 – T4 )]
𝑇 ref ref ref ref
2 3 4

673 5.21∗10^−3
∫ 𝐶𝑝 𝑑𝑇 = [19.251(673 – 298) + (6732 – 2982) +
1.197∗10^−5 (6733
298 2 3

−1.131∗10^−8
– 2983) + (6734 – 2984)]
4

= 17261 kJ/Kmol
673
𝑛 ∫298 𝐶𝑝 𝑑𝑇 = (2241.1650)(17261)

= 38684749 kJ/hr

Similar for O2
68886.23
𝑛= = 2152.6947 Kmol/hr
32

673 −3.680∗10^−1
∫ 𝐶𝑝 𝑑𝑇 = [28.106 (673 – 298) + (6732 – 2982) +
1.745∗10^−5 (6733
298 2 3
3 −1.065∗10^−8
- 298 ) + (6734 – 2984)]
4

= 11633 kJ/Kmol

43
 673
𝑛 ∫298 𝐶𝑝 𝑑𝑇 = (2152.6947)( 11633)

= 25042297 kJ/hr

Qin = 0 + 38684749 + 25042297

= 63727046 kJ/hr
T
Qout = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Qin = Qout
35858.64 5.21∗10^−3 1.197∗10^−5
63727046 = [19.251(T – 298) + (T2 – 2982) + (T3 –
16 2 3

1.131∗10^−8 68886.23 3.680∗10^−1

2983) - (T4 – 2984)] + [28.106 (T – 298) - (T2 –
4 32 2

1.745∗10^−5 1.065∗10^−8
2982) + (T3 – 2983) - (T4 – 2984)]
3 4

By trial and error

T = 487.9 K

= 214.9 ℃

4.2 Energy balance on furnace:-[5]

The gases are heating form 214.9 ℃ to 800 ℃

(Reaction temperature)

CH4 = 119449.16 Kg/hr

O2 = 68886.23 Kg/hr CH4 = 119449.16 Kg/hr
T = 214.9 ℃ (487.9 K ) O2 = 68886.23 Kg/hr

44
 T = 800 ℃ (1073 K )

Energy balance
Qheating
Qin + Qheating = Qout
Fig. (4.2) : Energy balance on furnace
Tref = 25 ℃= 298 K

45
 487.9
Qin = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Qin = 63727046 kJ/hr Calculate

1073
Qout = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Table (4.4) : Values of the materials entering and leaving the furnace :
1073 1073
𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
Component 298 298
. .

kmol/hr kJ/hr kJ/hr

CH4 7465.5725 43707 326297777

O2 2152.6947 25304 54471787

∑ = 380769560

∴ Qout = 380769560 kJ/hr

63727046 + Qheating = 380769560

Qheating = 317042510 kJ/hr

This heat is supplied by burning of natural gas

NHV = 49525 KJ/Kg

NHV = Net Heating Value

Qheating = m(NHV)
317042510
m= = 6420 Kg/hr
49525

46
4.3 Energy balance on reactor:-[5]
CH4 = 83590.52 Kg/ hr
H2 = 224.65 Kg/ hr
CO = 11860.25 Kg/ hr
CO2 = 19909.64 Kg/ hr
C2H4 = 18325.02 Kg/ hr
C2H6 = 842.45 Kg/ hr
H2O = 53582.89 Kg/ hr

Qcooling

CH4 = 119449.16 Kg/hr

O2 = 68886.23 Kg/hr
T = 800 ℃ (1073 K )

Fig. (4.3) : Energy balance on the reactor

Reactions:- Overall conversion
2CH4 + O2 → C2H4 + 2H2O X1 = 49.38%

4CH4 + O2 → 2C2H6 + 2H2O X2 = 12.53%

C2H6 → C2H4 + H2
X3 = 80%
CH4 + 2O2 → CO2 + 6H2O
X4 = 20.19%
3
CH4 + O2 → CO + 2H2O
2 X5 = 18.90%

47
Energy balance

Qin = Qout + Qreaction + Qcool

Tref = 25 ℃ = 298 K
1073
Qin = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Qin = 380769560 kJ/hr Calculate

1073
Qout = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Table (4.5) : Values of the materials entering and leaving the reactor :
1073 1073
𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
Component 298 298
. .

kmol/hr kJ/hr kJ/hr

CH4 5224.4075 43707 228343180
H2 112.3272 22920 2574539
CO 423.5802 24149 10229038
CO2 452.4918 37431 16937221
C2H4 654.4650 58234 38112115
C2H6 28.0818 73726 2070359
H2O 2979.827 29077 86557199
∑ = 382753290

∴ Qout = 382753290 kJ/hr

∆Hr298 = ∑∆Hf298│P – ∆Hf298│R …… From Ref.5

Reaction (1)

∆Hr1│298 = 2(-242) + (52.22) – 2(-74.86)

= -281.95 KJ/2mol CH4

= -281950 KJ/2Kmol CH4

= -140975 KJ/Kmol CH4

48
 1073
∆Hr1│1073 = ∆Hr1│ 298 + ∫298 ∆𝐶𝑝 𝑑𝑇

1073 1073 1073

∫ ∆𝐶𝑝 𝑑𝑇 = 2∫ 𝐶𝑝 𝑑𝑇│H O + ∫ 𝐶𝑝 𝑑𝑇│C H - ∫1073 𝐶𝑝 𝑑𝑇│O -
2 2 4 2
2981073 298 298 298
2∫ 𝐶𝑝 𝑑𝑇│CH
4
298

= [2(29077) + (58234) - (25304) –2 (43707)]

= 3670 KJ/2Kmol CH4

= 1835 KJ/Kmol CH4

∆Hr1│1073 = -140975 + 1835

= -139140 KJ/Kmol CH4

CH4 reacted = n1 = F1X1

= 2241.1648(0.4838)

= 1084.2755 Kmol/hr

n1∆Hr1 = (-139140)( 1084.2755)

= -150866100 KJ/hr

Similar for other reactions :-

Table (4.6) : Values of the other reactions :

1073 1073
∆Hri│298 ∫ ∆𝐶𝑝 𝑑 ∆Hri│1073 ni reacted ni∫298 ∆𝐶𝑝 𝑑𝑇
Reaction NO. 298 .

KJ/Kmol KJ/Kmol KJ/Kmol Kmol/hr KJ/hr

1 -140975 1835 -139140 1084.2755 -150866100
2 -88510 1369 -87141 280.8180 -244707161
3 137070 7428 144498 112.3272 16231056
4 -802910 1270 -801640 452.4912 -362735050
5 -519760 640 -519120 423.5802 -21988950
∑ = -741729810

49
Qreaction = -741729810 KJ/hr

380769560 = 382753290 - 741729810 + Qcool

Qcool = 7.3974608 * 108

Qcool is removed by cooling water at 30 ℃ and 12 bar to produced saturated

steam at 12 bar

Tsat = 180 ℃

λ = 1984.2 KJ/Kg

Qcool = mCp∆𝑇 + mλ

7.3974608 * 108 = m * 4.20 * (188 – 30) + 1984.2 * m

m = 279381 Kg/hr

= 77.6 Kg/s

4.4 Energy balance on first heat exchanger:-[5]

Fresh feed
CH4 = 35858.64 Kg/hr
O2 = 68886.23 Kg/hr
25 ℃ (298 K) CH4 = 83590.52 Kg/ hr
CH4 = 83590.52 Kg/ hr
H2 = 224.65 Kg/ hr
H2 = 224.65 Kg/ hr
CO = 11860.25 Kg/ hr
CO = 11860.25 Kg/ hr
CO2 = 19909.64 Kg/ hr
CO2 = 19909.64 Kg/ hr
C2H4 = 18325.02 Kg/ hr
C2H4 = 18325.02 Kg/ hr
C2H6 = 842.45 Kg/ hr
C2H6 = 842.45 Kg/ hr
H2O = 53582.89 Kg/ hr
H2O = 53582.89 Kg/ hr
CH4 = 35858.64 Kg/hr T=?
800 ℃ (1073 K)
O2 = 68886.23 Kg/hr
From reactor
400 ℃ (673 K)
To furnace

Fig. (4.4) : Energy balance on first heat exchanger

50
Energy balance

Qin = Qout

Tref = 25 ℃= 298 K
298 1073
Q = ∑𝑛𝑖 ∫ 𝐶𝑝 𝑑𝑇 + ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
in 298 298

Qin = 0 + 382753290

Qin = 382753290 KJ/hr

673 T
Q =∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 + ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
out 298 298

673
∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 = 63727096 KJ/hr
298

T
Qout = 63727096 + ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

T
382753290 = 63727096 + ∑ 𝑛𝑖 ∫298 𝐶𝑝𝑖 𝑑𝑇

T
∑ 𝑛𝑖 ∫298 𝐶𝑝𝑖 𝑑𝑇 = 319026240 KJ/hr

By trial and error

T = 721.7 K

= 439.7 ℃

51
4.5 Energy balance on second waste heat boiler:-[5]

Qcool

In Out
439.7 ℃ (717.7 K) 200 ℃ (473 K)

Fig. (4.5) : Energy balance on second waste heat boiler

Energy balance

Qin = Qout + Qcool

712
Qin = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Qin = 319026240 KJ/hr

473
Qout = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
298

Qout = 159162190 KJ/hr

319026240 = 159162190 + Qcool

Qcool = 159862190 KJ/hr

The heat is removed by cooling water at 30 ℃ and 12 bar to produced saturated

steam at 12 bar

Tsat = 188 ℃
λ = 1984.2 KJ/Kg
Qcool = mCp∆𝑇 + mλ
159862190 = m * 4.20 * (188 – 30) + 1984.2 * m

m = 60376 KJ/hr

= 16.77 KJ/s H2O

52
4.6 Energy balance on partial condenser:- [5]

Gases Gases
H2O = 53582.89 KJ/hr H2O = 53582.89 KJ/hr
Vapor Liquid
200 ℃ (473 K) 45 ℃ (318 K)

Fig. (4.6) : Energy balance on partial condenser

Energy balance

Qin = Qout + Q473

cool
Q = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 + mλ│ H O
in 2
298

712
∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 = 159162190 KJ/hr
298

mλ│ H2O = (53582.89)(2260.2)

= 12110850 KJ/hr
318
Q = ∑ 𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 + mCp∆𝑇│ H O
out 2
298

318
∑ 𝑛𝑖 ∫298 𝐶𝑝𝑖 𝑑𝑇 = 13096774 KJ/hr

mCp∆𝑇│ H2O = (53582.89)(4.2)(318 – 298)

= 4500963 KJ/hr

Qout = 13096774 + 4500963

= 17597737 KJ/hr

280270240 = 17597737 + Qcool

Qcool = 26267750 KJ/hr

53
This heat is removed by cooling water at 30 ℃ and 5 bar to produced saturated
steam at 5 bar

Tsat = 152 ℃
λ = 2106.9 KJ/Kg
Qcool = mCp∆𝑇 + mλ
26267750 = m * 4.20 * (152 – 30) + 2106.9 * m

m = 100283 KJ/hr
= 27.86 KJ/s

54
 4.7 Energy balance on absorbed :-
 Feed of gases inlet at 45℃
 15 Wt% MEA solution at 45℃ from cooler
 Exit streams outlet at temp =T

139.40 Kg/h CO2 273773.27 kg/h

18324.77 Kg/h C2H 4 48312.93 kg /h MEA

139.40 Kg/h CO2 582.93 kg/h(C2H5ONH3)2CO

T= ? 45℃

13939.47 Kg/h CO2 268127.79 Kg/h H2O

18324.77 Kg/h C2H4 10049.09 Kg/h MEA

8324.87 Kg/h C2H6 58292.32 kg/h(C2H5ONH3)2CO

45℃ (318 ) T= ?

Fig. (4.7) : Energy balance on absorbed

55
Reaction:
2C2H7NO + H2O + CO2 (C2H5ONH3)2CO3
Energy balance
Qin = Qout + Qreaction
Tref. = 25C˚
318
𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇 + ∑ 𝑚𝑖 𝑐𝑝𝑖∆𝑇
Qin = ∑ 298
𝑔𝑎𝑠𝑒𝑠 𝑙𝑖𝑞

318
𝑛𝑖 ∫ 𝐶𝑝𝑖 𝑑𝑇
∑ 298 =881549 kg/h
𝑔𝑎𝑠𝑒𝑠

= [(273773.27*4.20) + (48312.93*2.67) + (582.93*2.93)(318 -298)]∑𝑚𝑖 𝐶𝑝𝑖∆𝑇

=25611025 kg/h

Qin =881549 + 25611025 =26492574 kg/h

Qreaction= n ∆Hr

Where:

n= CO2 reacted kmol/hr

Hr =heat of reaction KJ/kmol∆

= -825 Btu/lb CO2 reacted∆𝐻𝑟298

= -84252 KJ/Kmol, CO2 reacted∆𝐻𝑟298

318
=∆𝐻𝑟298 + ∫298 ∆𝐶𝑝 𝑑𝑇∆𝐻𝑟318

=∫ 318 𝐶𝑝 𝑑𝑇 318 𝐶𝑝 𝑑𝑇 -∫318 𝐶𝑝 𝑑𝑇 -2∫318 𝐶𝑝 𝑑𝑇 318

-∫ ∫ ∆𝐶𝑝 𝑑𝑇
298 (C2H5ONH3)2CO3 298 CO2 298 H2O 298 MEA 298

= [(2.93*184) - (37060) - (4.20*18) - 2(2.67*61)] [318-298] = 2004 kJ/kmol

56
Hr = -84252 + 2004 = -82248 kJ/kmol∆

CO2 reacted n =313.6380 kmol/hr

Qreaction = (313.6380) (-82248) = -25796098 kJ/kmol

𝑇 𝑚 𝑐𝑝 ∆𝑇
Qout = ∑ 𝑛𝑖 ∫298 𝐶𝑝𝑖 𝑑𝑇 + ∑ 𝑖 𝑙𝑖𝑞𝑖

𝑔𝑎𝑠𝑒𝑠

Mean heat gas capacity between (25 -62)℃

Table (4.7) : Values of heat capacity :

Component Cp Kg/Kg.K
CO2 0.86
C2H4 1.69
C2H6 1.90
𝑇
∑ 𝑛𝑖 ∫298 𝐶𝑝𝑖 𝑑𝑇 =[(13939.47*0.86) + ( 18324.77*1.69) + ( 8324.8*1.90) [T-298]
𝑔𝑎𝑠𝑒𝑠
𝑇
= 44537.264 (T-298) kg/hr∑ 𝑛𝑖 ∫298 𝐶𝑝𝑖 𝑑𝑇

𝑔𝑎𝑠𝑒𝑠
𝑚𝑖 𝑐𝑝𝑖∆𝑇
=[(268127.79*4.20) + ( 10049.09*2.67) + ( 58292.32*2.93) (T -298)]∑
𝑙𝑖𝑞
𝑚𝑖 𝑐𝑝𝑖∆𝑇
=1323764.3 (T-298) kg/hr∑
𝑙𝑖𝑞
Qout =44537.264 (T-298) + 1323764.3 (T-298) =1368301.6 (T-298) kg/hr

26492574 = 1323764.3 (T-298)-25796098

26492574+25796098
T= + 298
1368301.6

T=336 K (63℃) T assume = 62℃

57
 4.8 Energy balance on stripper :-
Operating conditions[7]

Top Bottom

T= 208 ℉ T= 240 ℉

= 98℃ =116℃

P =20 psia p =24 psia

= 137.8 Kpa =165.4 Kpa

CO2 13800.2 Kg/hr CO2

268127.79 Kg/hr H2O H2O 98 ℃ (371) K
10049.09 Kg/hr MEA

58292.32 kg/hr (C2H5ONH3)2CO

T=336 k (63℃) H2O

273773.27 kg/hr

48312.93 kg /hr MEA

582.93 kg/hr (C2H5ONH3)2CO

Fig. (4.8) : Energy balance on stripper

58
Reaction:
(C2H5ONH3)2CO3 2C2H7NO + H2O + CO2

Energy balance
Qin+Qrep = Qout+Qc + Qreaction
Tref =25℃
371 𝑐𝑝𝑑𝑇 𝑚𝑖 𝑐𝑝𝑖∆𝑇
Q =𝑛 ∫ +∑ =1323764.3 (T-298) kg/h
in 298 𝑐𝑜2 𝑙𝑖𝑞

Qin = 1323764.3 (336-298) =50303043 kg/hr

317
𝑛 ∫298 𝐶𝑝 𝑑𝑇 + ∑ 𝑚𝑖 𝑐𝑝𝑖∆𝑇
Qout = ∑ 𝑙𝑖𝑞
CO2

13800.07
n= =313.6380
44

371 𝑐𝑝𝑑𝑇
𝑛∫ = 2826.2 kg/kmol
298 𝑐𝑜2
371 𝑐𝑝𝑑𝑇
𝑛∫ =(313.6380)*(2826.2) =886404 kg/h
298 𝑐𝑜2
𝑚𝑖 𝑐𝑝𝑖∆𝑇
∑ =[(273773.27*4.20 )+(48312.93*2.67)+(582.93*2.93)][389-298]
𝑙𝑖𝑞
𝑚𝑖 𝑐𝑝𝑖∆𝑇
∑ =116530160 kg/h
𝑙𝑖𝑞
Qout=886404+116530160 =117416570 kg/h
Calculation of Qc
Assume 𝑐𝑜2 exit from to the stripper is saturated with water vapour at top
conditions 98℃ and 137.8 Kpa
𝑝
𝑦𝑤= 𝑝𝑤 ……..from Ref.[6]
𝑇

Where

𝑦𝑊=mol fraction of water vapour

59
𝑝𝑤=partial pressure of water vapour ,Kpa
𝑝𝑇=total pressure Kpa
At saturation partial pressure = vapor pressure
 𝑝𝑤=𝑝°𝑤
𝑝°𝑤
𝑦𝑤= 𝑝𝑇

𝑎𝑡 98 ℃ vapour pressure of water

𝑝𝑤
° =94.3 Kpa .......... from Ref.[10]

94.3
𝑦𝑤 = = 0.6843
137.8

𝐾𝑚𝑜𝑙 H2O
𝑦𝑤 =
𝑡𝑜𝑡𝑎𝑙 𝐾𝑚𝑜𝑙

𝑛 CO2 =313.6380 kmol/hr

𝑛𝑤
0.6843= 𝑛𝑤+313.6380

nw =679.8305 kmol/hr *18

=12236.95 kg/hr H2O
Latent heat of water at 98℃
ʎ = 2262.2 Kg/Kg ........ from Ref.[10]
Qc = mλ
Qc = (12236.95)( 2262.2) =27682428 Kg/hr
Qreaction =n∆𝐻𝑟
N =313.6380 Kmol/hr CO2
∆𝐻𝑟298 = + 825 Btu/Ib CO2
= +84252 kg/kmol CO2
389
∆𝐻𝑟389 = ∆𝐻𝑟298 +∫298 ∆𝑐𝑝𝑑𝑇

60
 389 389 389
∫389
389
∆𝑐𝑝𝑑𝑇=2∫298 𝐶𝑝 𝑑𝑇+ ∫298 𝐶𝑝 𝑑𝑇+ ∫298 𝐶𝑝 𝑑𝑇 ∫298 𝐶𝑝 𝑑𝑇
+
298
𝑀𝐸𝐴 𝐻2𝑂 𝐶𝑂2 (C2H5ONH3)2CO3

=[2(2.67*61)+(4.20*18)+(39.078)-(2.93*18)[389-298]
389
∫298 ∆𝑐𝑝𝑑𝑇= -8982 Kg/kmol
∆𝐻𝑟389 =84252-8982 =75270 Kg/Kmol
=75270 Kg/Kmol
Qreaction=(313.6380)(75270)
=23607532 Kg/h
Qrep+50303043 = 121348950+27682428+23607532
Qrep= 122335870 Kg/h
Qc= mCp ∆T│H2O
∆𝑇 H2o=10℃
Cp 27682428
m= = =65910 Kg/h
Cp ∆T│H2O 4.2∗10

= 18.31 Kg/s H2O

Qrep is suplied by saturated steam at 160 ℃
And 618 Kpa
λ= 2081.3 Kg/Kg
Qrep = m λ
Qrep 122335870
m= = =58779 Kg/h
λ 2081.3

58779 Kg/hr (16.33Kg/s) stream

61
 4.9 Energy balance on cooler:
Qcool

2737.27 Kg/h H2O 2737.27 kg/h

48312.93 kg/h MEA 48312.93 Kg/h MEA

582.93 Kg/h 582.93 Kg/h

(C2H5ONH3)2CO3 (C2H5ONH3)2CO3

110℃ (388k) F Fig. (4.9) : Energy balance on cooler 45℃ (318)

From stripper to absorber

Energy balance:
Qin = Qout+Qc
Tref =25℃
Qin =∑ 𝑚𝑖 𝑐𝑝𝑖 ∆𝑇
= 116530160 kg/h
Qout = ∑ 𝑚𝑖 𝑐𝑝𝑖∆𝑇

= 25611025 Kg/ 11653010 =25611025 + Qcool

Qcool =90919138 Kg/h

Qcool =mCp∆𝑇𝐻2𝑂

∆𝑇𝐻2𝑂=10℃ (6)

Qcool 90919138
m= = =216474 Kg/h (60.13 Kg/s 𝐻2𝑂)
cp∆𝑇𝐻2𝑂 4.2∗10

62
4.10 Energy balance on caustic wash:

18324.77 Kg/h 𝐶2𝐻4 Kg/h

278.90 Kg/hr NaOH
837.82 Kg/h C2H6
1115.16 Kg/hr H2O 40℃ (313) K

25.34 Kg/hr NaOH

139.40 Kg/h 𝐶𝑂2
18324.77 Kg/h 𝐶2𝐻2 1172.19 Kg/hr H2O
831.82 kg/h 𝐶2𝐻6 253.45 Kg/hr Na2CO3
63℃ (336 )K
40℃ (313) K

Fig. (4.10) : Energy balance on caustic wash

Reaction:-

CO2 + 2NaOH Na2CO3 + H2O

Energy balance:

Qin = Qout+Qcool + Qreaction

Tref =25℃ =298 K
Q =∑ 𝑛 ∫336 𝑐𝑝𝑖𝑑𝑇 + ∑ 𝑚𝑖𝑐𝑝𝑖∆𝑇
in 𝑖 298 𝑔𝑎𝑠𝑒𝑠 𝑙𝑖𝑞

336 𝑐𝑝𝑖 𝑑𝑇
∑𝑛 ∫ =1241430 Kg/h

𝑖 298 𝑔𝑎𝑠𝑒𝑠

𝑚𝑖𝑐𝑝𝑖∆𝑇
∑ =0 , ∆𝑇=298-298 =0 Qin=1241430+0 = 1241430kg/h
𝑙𝑖𝑞

63
 𝑐𝑝𝑖𝑑𝑇 𝑚𝑖𝑐𝑝𝑖∆𝑇
Q = ∑ 𝑛 ∫313 +∑
out 𝑖 298
𝑔𝑎𝑠𝑒𝑠 𝑙𝑖𝑞

= 483022 Kg/h∑ 𝑛 ∫313 𝑐𝑝𝑖𝑑𝑇

𝑖 298 𝑔𝑎𝑠𝑒𝑠

𝑚𝑖 𝑐𝑝𝑖∆𝑇
∑ =[(1172.19+25.34)(4.05)+(253.45*1.14][313 -298]
𝑙𝑖𝑞
𝑚𝑖 𝑐𝑝𝑖∆𝑇
∑ =77264 kg/h
𝑙𝑖𝑞
Qout=483022+77264 =560286 Kg/h
∆Hr298 =(-286)+(-1151.69)-2(469.64)-(-393.77) =-104.64 Kg/mol (-104640 Kg/Kmol)
313
∆𝐻𝑟313 = ∆𝐻𝑟298 +∫298 ∆𝑐𝑝𝑑𝑇
313 313 313 313

313 ∫298 𝐶𝑝 𝑑𝑇 ∫ 𝐶𝑝 𝑑𝑇 ∫298 𝐶𝑝 𝑑𝑇 ∫ 𝐶𝑝 𝑑𝑇

∫ ∆𝑐𝑝𝑑𝑇= + 298 -2 - 298
298
𝐻2𝑂 𝑁𝑎2𝐶𝑂3 NaOH 𝐶𝑂2

=[(4.2*18)+(1.14*106)+2(0.55*40)-(0.85*44)][313-298]=1726 Kg/h
∆𝐻𝑟313 = -104640+1726 = -102914 Kg/kmol
139.40
CO2 reacted n= =3.1682 Kmol/h
44

Qreaction =n∆𝐻𝑟 = 3.1682(-102914)= -326052 Kg/h

1241430 = 560286 – 326052+ Qcool
Qcool =1007196 Kg/h
Qcool= mCp∆𝑇𝐻2𝑂
∆𝑇𝐻2𝑂=10 ℃
Qcool 1007196
m= = =23981 Kg/h H2O
Cp∆𝑇𝐻2𝑂 4.2∗10

64
 4.11 Energy balance on compressor system:
The gases are compressed from 2.5 to 35 bar [11]

T1 =313k Comp T2 T3 Comp T4 T5 Comp T6 T7

(1) (1)
(1)
P1=2.5bar p2 p3 p4 p5 p6 p7
Fig. (4.10) : Energy balance on compressor system
Pressure drop of each heat exchanger = 0.33 bar [6]
P6=35 +0.33 =35.33 bar
P6
Compression ratio =( )1/3 from Ref.[6]
P1

35.33 1/3

=( ) = 2.418
2.5

Take compression ratio = 2.482 (trial and error )

𝑝2
= 2.482
𝑝1
𝑝2
2.5
= 2.482

P2 = 6.205 bar
p3 =p2 - ∆𝑝
p3 = 6.205 – 0.33 = 5.875 bar
𝑝4
= 2.482
𝑝3
𝑝4
5.875
= 2.482 , p4 = 14.582 bar

p5 =p4 - ∆𝑝 =14.582- 0.33 =14.152 bar

𝑝6
=2.482 , p 6 =35.373 bar
𝑝5

𝑝7 = p6 -∆𝑝

𝑝7 = 35.373 – 0.33 , 𝑝7 = 35.04 bar

65
 4.11.1 Compressor (1)

18324.77 Kg/h 𝐶2𝐻4 18324.77 Kg/h C2H4

831.82 Kg/h 𝐶2𝐻6 Compresser(1)
831.82 Kg/h 𝐶2𝐻6
j
T1 =40 ℃ (313K) T2 = ?

P1 =2.5 bar Fig. (4.11) : Energy balance on compressor (1) P2 = 6.205 bar
𝑇 𝑝
( 2 ) =( 2)m [6]
𝑇1 𝑝1

𝛼−1
m= [6]
𝛼𝐸𝑃

where
𝑐𝑝
∝=
𝑐𝑣

EP = efficiency of compressor
P1v1= n1RT
P1= 2.5 bar = 250 Kpa
n1 = 682.1834 Kmol /h
250 v1 = 682.1834(8.314) (313)
V1 = 7101 m3/h(1.97 m3/s)
For v1 =1.97 m3/s and centrifugal compressor
EP = 69% [6]
𝑐𝑝
∝= , cv = cp -R
𝑐𝑣
𝑐𝑝

∝=
cp − R
By trial and error assume exit gas temp = 115℃ (388 k) mean heat capacity of
component between (313 -388) K

66
 Table (4.7) : heat capacity:
Component 𝑐𝑝𝑖 𝑦𝑖 𝑦𝑖 𝑐𝑝𝑖
KJ/Kmol.K Mol % KJ/Kmol.K

𝐶2𝐻4 50.99 95.94 48.92

𝐶2𝐻6 61.53 4.06 2.50
100 51.42

𝑐𝑝𝑚 = ∑ 𝑦𝑖 𝑐𝑝𝑖 =51.42 KJ/Kmol .K

51.42
∝= = 1.19
51.42 −8.314

1.19
M= = 0.23
1.19∗0.69

𝑇2 6.205
=( )0.231
313 2.5

T2 =386 K(113℃) Tassume =115℃

4.11.2 Energy balance on first cooler

The gases are cooler from 113 to 40 ℃
Qcool
18324.77 Kg/h C2H4 18324.77 Kg/h C2H4

831.82 Kg/h C2H6 831. 82 Kg/h C2H6

386 K(113℃)

Fig.(4.12) : Energy balance on first cooler

67
 Energy balance
Qin = Qout+Qcool
Tref =25℃
386
Qin =∑ 𝑛𝑖 ∫298 𝑐𝑝 𝑖𝑑𝑇=3086853 kg/h

313
Q = ∑𝑛 ∫ 𝑐𝑝 𝑑𝑇 =472242 Kg/h
out 𝑖 298 𝑖

3086853 = 472242 + Qcool , Qcool =2614611 Kg/h

Qcool= mcp∆𝑇 H2o
∆𝑇 H2o=10℃
Qcool 2614611
m= = = 62253 Kg/h H2O (17.30 Kg/s )
cp∆𝑇 H2o 4.2∗10

4.11.3 Power of compressors:-

First compressor:-
𝑛
W=ZTR ( )[( 𝑃2 )^ ( 𝑛 ) - 1] [6]

1 1
𝑛−1 𝑃1 𝑛−1

Where:-
W = Work (KJ/Kmol)
1
n=
1−𝑚
1
= = 1.3
1−0.331
1 .3 6.205 1 .3

W = (1 * 313 * 8.314 )( 1.3−1 )[( 2.5

)^ ( 1.3−1 ) -1]

= (2632)(682.1834)
= 1795506 KJ/hr
= 499 KW

68
 499 = 723 KW
Actual work = 0.69

Assume equal work in each compressor

W1 = W 2 = W3

69
similar for other compressors and coolers:
compressor:
Table (4.8) : The values of Energy balance on compressors:
No Tin (K) Tout (K) Pin (bar) Pout (bar) W (KW)
1 313 386 2.5 6.205 723
2 313 386 5.875 14.582 723
3 313 386 14.252 35.37 723

Coolers:
Table (4.9) : The values of Energy balance on coolers:
No Tin (K) Tout (K) Qcool KJ/h m H2O Kg/h
1 386 313 2614611 62253
2 386 313 2614611 62253
3 386 313 2614611 62253

70
 4.12 Energy balance on distillation column:
18293.72 Kg/h C2H4
39.28 Kg/h C2H6

T= ?
P =34.9 bar

18324.77 Kg/h C2H4

831.82 Kg/h C2H6

T = 40 ℃ (313k)

P= 35.04 bar

Qr

31.05 Kg/h C2H4

792.54 Kg/h C2H6

(6)
T= ? , P= 35.04 bar

Fig.(4.13) : Energy balance on distillation column

Table (4.10 ) : The conversion of input and output at distillation

Compont XF mol% XD mol% Xw mol%

𝐶2𝐻4 95.94 97.80 4.06
𝐶2𝐻6 4.06 0.20 95.94
total 100 100 100

Top tempreture (Dew point)

Top product consist of 99.8 % 𝐶2𝐻4 and 0.2% C2H6 (by mol)

71
 (12)
Dew point = boiling point of C2H4 at top pressure =34.9 bar (506.4 psi)

(12)
Dew point = -10 ℃

Bottom temperature (Bubble point)

At bubble point ∑ 𝑦𝑖 = ∑ 𝑦𝑖 𝑥𝑖 =1 (6)

𝑝𝑖
= 𝐾
𝑝𝑇 𝑖
= 𝑘1𝑥1 + 𝑘2 𝑥2 =1 ∑ 𝑦𝑖

Bottom pressure =35.2 bar

By trial and error assume bubble point 15℃

Vapor pressure of components at 15℃

Table (4.11 ) : Summation of output conversion for distillation at T = 15℃

𝑝𝑖
component 𝑥𝑖 Pi bar = 𝐾𝑖 𝑘𝑖 𝑥 𝑖
𝑝𝑇

C2H4 0.0496 36.85 1.615 0.0801

C2H6 0.9504 35.49 1.008 0.9580
total 1.00 1.9580
∑≠1
Table (4.12 ) : Summation of output conversion for distillation at T = 14 ℃
𝑝𝑖
component 𝑥𝑖 Pi bar = 𝐾𝑖 𝑘𝑖 𝑥 𝑖
𝑝𝑇

C2H4 0.0496 55.82 1.586 0.0787

C2H6 0.9504 34.46 0.979 0.9304
total 1.00 1.0091
∑≅1

Bubble point =14℃

Top T= -10℃

72
Liquid heat capacity of components between 25-(-10℃) (12)

Table (4.13 ) : Liquid heat capacity of components between 25-(-10℃)

component Cp Cp at-10ʎ at-10 ʎ

cal/g.℃ Kg/Kg.K cal/g Kg/Kg
C2H4 1.035 4.33 60 251.20
C2H6 0.925 3.87 83 347.44

Bottom T= 14℃

Liquid heat capacity of components between 25-14℃

Table (4.14 ) : Liquid heat capacity of components between 25-14℃

component Cp Cp
cal/g.℃ Kg/Kg.K
C2H4 1.12 4.69
C2H6 1.01 4.23

Energy balance
Qin+Qreb= Qout+Qcool
Tref =25℃
313
Qin =∑ 𝑛𝑖 ∫298 𝑐𝑝 𝑖𝑑𝑇=472242 kg/h

Qout = ∑ 𝑚𝑖 𝑐𝑝𝑖∆𝑇 + ∑ 𝑚𝑖 𝑐𝑝𝑖 ∆𝑇

𝐷 𝑀
=[(18293.72*4.33)+(39.28*3.87)][263-298]+[(31.05*4.69)+(792.54*4.23)[287-4.69]

Qout= -2816213 KJ/h

Reflux ratio R= 3
𝐿𝑛
R=
𝐷

Ln =RD

73
 Vn = Ln+D =RD+D

Vn = (R+1)D =(3+1)D

Vn=4D

Qc=∑ 𝑉𝑖 ʎ𝑖

=4 ∑ 𝐷𝑖 ʎ𝑖

Qc=4[(18293.72*251.20)+( 39.28*347.44) = 18436120 KJ/h

472242+ Qreb =-2816213+18436120

Qreb = 15147665 KJ/h

Qc =is removal by saturated liquid ethylene

At =-50℃

ʎ= 86 Cal/g (360 KJ/Kg)

Qc= mʎ
𝑄𝑐 18436120
m= = =51211 Kg/h
ʎ 360

Qrep is suplied by saturated hot water at 100 ℃

Qrep = mʎ

∆𝑇H2O = 10 ℃
𝑄𝑟𝑒𝑝 15147665
m= =
ʎ 2257

m= 6711.416 Kg/h

74
 Chapter Five
Equipment Design

73
5.1 Design of distillation column:
Distillation is a physical process for the separation of liquid mixtures that
is based on differences in the boiling points of the constituent components.
Distillation is the most widely separation process used in many industries.

Distillation towers can be classified into two main categories, based on their mode
of operation. The two classes are batch distillation and continuous distillation. In
batch distillation, the feed to the column is introduced batch- wise. The column
is first charged with a ‘batch’ and then the distillation process is carried out. When
the desired task is achieved, the next batch of feed is introduced. Batch distillation
is usually preferred in the pharmaceutical industries and for the production of
seasonal products. On the other hand, continuous distillation handles a continuous
feed stream. No interruption occurs during the operation of a continuous
distillation column unless there is a problem with the column or surrounding unit
operations. Continuous columns are capable of handling high throughputs.
Besides, additional variations can be utilized in a continuous distillation column,
such as multiple feed points and multiple product drawing points. Therefore,
continuous columns are the more common of the two modes, especially in the
petroleum and chemical industries.

74
 18293.72 Kg/h C2H4
39.28 Kg/h C2H6
T = -10 𝐶𝑜
P = 34.9 bar

18324.77 Kg/h C2H4

831.82 Kg/h C2H6
T = 40 𝐶𝑜
P = 35.04 bar

31.05 Kg/h C2H4

792.54 Kg/h C2H6
T = 14 𝐶𝑜
P = 35.2 bar

Fig.(5-1): Distillation

Table (5-1): Composition of distillation:

Component 𝑋𝑓 𝑋𝑑 𝑋𝑤
Mol% Mol% Mol%

𝐶2𝐻4 95.94 99.80 4.96

𝐶2𝐻6 4.06 0.20 95.04
total 100 100 100

75
5.1.1 Calculation number of plates:
Calculation of equilibrium data:
at top T = -10 𝐶𝑜
vapor pressure of Components at T = -10 𝐶𝑜
𝐶2𝐻4𝑝0 1= 500 Psi

= 34.64 bar

𝐶2𝐻6𝑝0 2= 280 Psi

= 19.30 bar

𝑝0 1 34.64
𝛼𝑡𝑜𝑝 = = = 1.79
𝑝02 19.30

𝛼 = volatility

At Bottom T=14 𝐶 𝑜
vapor pressure of Components at T = 14 𝐶𝑜

𝐶2𝐻4𝑝0 1= 810 Psi

= 55.82 bar

𝐶2𝐻6𝑝0 2= 500 Psi

= 34.46 bar
𝑝01 55.82 = 1.62
𝛼 = =
𝑏𝑜𝑡 𝑝02 34.46

𝛼𝑎𝑣 = ( 𝑜𝑝 ∗ 𝛼𝑏𝑜𝑡)0.5

𝛼𝑎𝑣 = (1.79 ∗ 1.62)0.5 = 1.70

𝛼𝑎𝑣∗𝑋
𝑌=
1+(𝛼𝑎𝑣−1)∗𝑋

1.70∗𝑋
𝑌= 𝑒𝑞𝑢𝑖𝑙𝑖𝑏𝑟𝑖𝑢𝑚 𝑐𝑢𝑟𝑣𝑒
1+1.70∗𝑋

At X = 0.10

1.70∗0.1
𝑌= = 0.159
1+1.70∗0.1
76
 X Y
0.000 0.000
0.100 0.159
0.200 0.298
0.300 0.421
0.400 0.531
0.500 0.630
0.600 0.718
0.700 0.800
0.800 0.872
0.900 0.939
1.000 1.000
5.1.2 Calculation of feed bubble point
At bubble point ∑ 𝑦𝑖 = ∑ 𝑦𝑖 𝑥𝑖 =1

Feed pressure = 35.04 bar

By trial and error assume feed bubble point= -10℃

Table (5-2): Feed bubble point of distillation at-10 ℃

𝑝𝑖
component 𝑥𝑓𝑖 Pi bar = 𝐾𝑖 𝑘𝑖 𝑥 𝑖
𝑝𝑇
mol%
C2H4 95.04 34.5 0.985 0.9450
C2H6 4.06 19.3 0.551 0.0224
total 100 0.9674
∑≠1
Try T = -8 ℃

Table (5-3): Feed bubble point of distillation at-8 ℃

𝑝𝑖
component 𝑥𝑓𝑖 Pi bar = 𝐾𝑖 𝑘𝑖 𝑥 𝑖
𝑝𝑇
mol%
C2H4 95.04 35.3 1.022 0.9805
C2H6 4.06 20.7 0.591 0.0272
total 100 1.0077
∑≅1
Bubble point =-8 ℃feed

77
Table (5-4): Mean heat capacity of components between -8 to 40℃

component Cp Cp 𝑥𝑖 Cpi Xi
cal/g.℃ KJ/Kg.K mol% KJ/Kmol.K
C2H4 0.375 43.93 95.04 42.15
C2H6 0.530 66.53 4.06 2.70
44.85
Cpmix = ∑Cpi Xi
= 44.85 KJ/Kmol.K

Table (5-5): Latent heat of components at -8 ℃

component λ λ 𝑥𝑓𝑖 λ i 𝑥𝑖
cal/g KJ/Kmol mol% KJ/Kmol
C2H4 58 6795 95.04 6519.12
C2H6 81 10167 4.06 412.78
9632
∑λi𝑥𝑖= 9632 KJ/Kmol

5.1.3 Calculation of q-line

heat required to vaporized 1K mol of feed
𝑞=
molar latent heat of feed
Cpmix∗ Δ𝑇
𝑞= [10]
𝜆𝑚𝑖𝑥

44.85(−8−40)
= = - 0.31
6932

𝑞 −0.31
Slope of q-line = = = 0.21
𝑞−1 −0.31−1

where:

Cpmix= average molar heat capacity of feed KJ/Kmol. ℃

𝜆𝑚𝑖𝑥 = Average molar latent heat of feed KJ/Kmol

Δ𝑇 = 𝑓𝑒𝑒𝑑 𝑏𝑢𝑏𝑏𝑙𝑒 𝑝𝑜𝑖𝑛𝑡 − 𝑓𝑒𝑒𝑑 𝑡𝑒𝑚𝑝𝑎𝑟𝑎𝑡𝑢𝑟𝑒 ℃

78
From plot
𝑋𝑑
𝑅𝑚+1
= 0.463 = ∅min

0.998
𝑅𝑚+1
= 0.463

𝑅𝑚 = 1.16

R= 1.5𝑅𝑚

= 1.5*1.16 = 1.74
𝑋𝑑 0.998
= =∅
𝑅+1 1.74+1

= 0.364

5.1.4 Calculation number of plates:

 Draw the equilibrium data X vs Y.
 Draw the q-line with slope = 0.21
 Draw the top of operating line from Xdon the diagonal
𝑋𝑑
 ∅= = 0.364
𝑅+1

 Draw the bottom operating line from Xw on the diagonal to the point of
intersection of the operating line and the q-line.
 Starting at Xd step off the number of stages.
From plot No. of stage =17
No. of plate = No. of stages – 1
=17 – 1 = 16
5.1.5 Plate efficiency:-
𝐸0=0.17 - 0.616 log (∑ µ𝑖 ∗ 𝑋𝑓𝑖)

Where

𝐸0= plate efficiency

𝑋𝑓𝑖 = 𝑚𝑜𝑙 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑

µ𝑖 = viscosity of component 𝑖 cp(mN.s/m²)

79
At top T= -10 𝐶𝑜

At bottom T=14 𝐶𝑜
−10 +14
Tm = =2 Co
2

Table (5- 6) : Viscosity of components at 2 𝐶𝑜

component µ Xf
mN.s/m² mol
𝐶2𝐻4 0.07 0.9594
𝐶2𝐻6 0.05 0.0406

∑ 𝜇𝑖 𝑋𝑓𝑖 = 𝜇1𝑋𝑓1 + 𝜇2𝑋𝑓2

∑ µ 𝑖 𝑋𝑓𝑖 = (0.07 ∗ 0.9594) + (0.05 ∗ 0.0406)

=0.07 cp

𝐸0=0.17 - 0.616 log(0.07)

= 0.88 = 88 %
𝑁𝑡ℎ𝑒
𝑁𝑎𝑐𝑡 =
𝐸0

16
= = 18.2 ≅ 19 𝑝𝑙𝑎𝑡𝑒
0.88

5.1.6 Column diameter

Top
𝐿𝑛 𝜌𝑣
FL.v= ∗ ( )0.5
𝑉𝑛 𝜌𝐿

Where:

Fl.v= liquid vapor flow factor

Ln =liquid mass flow rate Kg/s

Vn= vapor mass flow rate Kg/s

𝜌v= vapour density Kg/m³

80
𝜌L=liquid density Kg/m³

D= 18293.72 + 39.28 = 18333 Kg/h

Ln=R*D=1.74* 18333 =31899.42 Kg/h

=8.861 Kg/s

Vn=Ln + D = (R+1) * D

=D(R+1)

Vn=(1.74+ 1)* 18333

= 50232.42 Kg/h = 13.953 Kg/s

Vapor density
𝑝∗𝑀𝑎𝑣
𝜌𝑣 = 𝑅∗𝑇

Where:
𝑘𝑔
𝜌𝑣 = 𝑣𝑎𝑝𝑜𝑢𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
𝑚3
P = total pressure KPa

T = absolute temperature K.

Mav= ∑ 𝑀𝑖 ∗ 𝑋𝑑𝑖

Mav= (28 *0.9980) + (30 *0.0020)

=28 kg/kmol

Table (5-7) : The critical temperature and critical pressure of Components:

yi Tci Pci Tci*yi Pci*yi

Component
Mol% K bar K bar
𝐶2𝐻4 99.8 282.4 50.4 281.8 50.3
𝐶2𝐻6 0.20 305.4 48.8 0.61 0.10
Tc = ∑Tci*yi =282.41 K

Pc = ∑Pci*yi = 50.40 bar

Tr = 𝑇 [6]
𝑇𝑐

81
Pr = 𝑃
𝑃𝑐

T = - 10 = 263 K

P = 34.9 bar = 3490 kPa

263
Tr = = 0.93
282.41

34.9
Pr = = 0.69
50.40

For Tr = 0.93andPr = 0.69

Z = 0.55 ( Fig. 3.8 ) [6]

3490∗28
𝜌𝑣 = = 81.26 Kg/m3
0.55∗8.314∗263

Liquid density

Table(5:8) : Liquid Density of components at T= -10℃

Component Xd 𝜌𝐿
wt% Kg/m³
𝐶2𝐻4 99.8 380
𝐶2𝐻6 0.20 445
𝜌𝐿 = ∗ 𝑋𝑑𝑖 [6]

= (380 ∗ 0.998) + (445 ∗ 0.0020) = 380 𝐾𝑔/m3

8.861 81.26
FL.v= ( )0.5 = 0.25
13.953 380
𝜌𝐿−𝜌𝑣 0.5
Uf =K1( ) [6]
𝜌𝑣

Where:

Uf= vapour flooding velocity m/s

K1= Constant

Select tray spacing = 0.45m [6]

For FL.v=0.29 and tray spacing =0.45m

82
K1 =0.056 Fig. 12.27 [6]
380−81.26 0.5
Uf =0.056( ) =0.11 m/s
81.26

U=85% Uf[6]

U=0.85*0.11 =0.09 m/s

m= 𝜌𝑣 ∗ 𝑈 ∗ 𝐴𝑛 [6]

Where:

m= vapour mass flow rate kg/s

𝑘𝑔
𝜌= 𝑣𝑎𝑝𝑜𝑢𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
𝑚3
𝑚
𝑈 = 𝑣𝑎𝑝𝑜𝑢𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝑠
𝐴𝑛 = 𝑛𝑒𝑡 𝑎𝑟𝑒𝑎 𝑚2

An = 𝑚
𝜌𝑣∗𝑢

m=Vn=13.953 Kg/s
13.953
An=
13.953 ∗0.09
= 1.908 𝑚²

Down comer area =12% of total column cross sectional area [6]

An= (1- 0.12) Ac

An=0.88 * Ac

Ac=cross sectional area of column m²

Ac=An/0.88

=1.908 /0.88=2.168 m²

Ac = 𝜋 𝐷𝑐2 [6]
4

Dc=1.66 m

Bottom

83
 𝐿𝑚 𝜌𝑣 0.5
FL.v= ( ) [6]
𝐿𝑛 𝜌𝐿

Lm=Ln + q*F [6]

18324.77 831.82
F= +
28 30

= 682.183 𝐾𝑚𝑜𝑙/ℎ

Ln=31899.42 = 1139.65 𝐾𝑚𝑜𝑙 /ℎ

28

q = 0 feed is saturated vapor

Lm= Ln = 1139.65 Kmol/h

𝑀𝑎𝑣 = ∑ 𝑀𝑖 ∗ 𝑋𝑤𝑖

𝑘𝑔
𝑀𝑎𝑣 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑎𝑡 𝑏𝑜𝑡𝑡𝑜𝑚
𝑘𝑚𝑜𝑙
= (28 * 0.0496) + (30 *0.9504)

=29.90 Kg/Kmol

Lm=1139.65 * 29.90

=34064.02 kg/h=9.462 kg/s

Lm= Vm + W [6]
31.05 792.54
W= + = 27.527 kmol/h
28 30

Vm = Lm - W

Vm= 1139.65 – 27.527 =1111.738 Kmol/h

Vm=1111.738 * 29.90 = 33240.97 Kg/h=9.234 kg/s

Vapor density
𝑃 ∗ 𝑀𝑎𝑣
𝜌𝑣 =
𝑅∗𝑇

P= 35.2 bar

T=14℃
84
Table (5-9) : The critical temperature and critical pressure of Components:

yi Tci Pci Tci*yi Pci*yi

Component
Mol% K bar K bar
𝐶2𝐻4 4.96 282.4 50.4 14.1 2.50
𝐶2𝐻6 95.04 305.4 48.8 290.3 46.4
Tc = ∑Tci*yi =304.4 K

Pc = ∑Pci*yi = 48.9 bar

Tr = 𝑇 [6]
𝑇𝑐

Pr = 𝑃
𝑃𝑐

T = - 10 = 263 K

P = 34.9 bar = 3490 kPa

287
Tr = = 0.94
304.4

35.2
Pr = = 0.72
48.9

For Tr = 0.94andPr = 0.72

Z = 0.54 ( Fig. 3.8 ) [6]

3520∗29.9
𝜌𝑣 = = 81.68 Kg/m3
0.54∗8.314∗287

Liquid density
Table (5.10): Liquid density of components at 14 ℃ [ 6]

components Bottom 𝑋𝑤 𝜌
Kg/h Wt% Kg/m³
𝐶2𝐻4 31.05 3.77 210
𝐶2𝐻6 792.54 96.23 380

𝜌𝐿 = ∑ 𝜌𝑖 ∗ 𝑋𝑤𝑖
= (210*0.0377) + (380*0. 9623) =374 Kg/m³

85
 9.462 81.68 0.5
FL.v= ( )
9.234 374
= 0.48

For FL.v= 0.48 and tray spacing = 0.45m

K1=0.048 Fig. 11.27 [6]

374−81.68 0.5
Uf=0.075( ) = 0.09 m/s
81.68

U=85% Uf[6]

U=0.85*0.09 = 0.08 m/s

m = 𝜌𝑣 ∗ 𝑢 ∗ 𝐴𝑛 [6]

m = Vm = 9.234 kg/s
9.234
An = 𝑚 = = 1.414 m²
𝜌𝑣∗𝑢 81.68∗0.08

𝐴𝑛 1.413
Ac = = = 1.606 m²
0.88 0.88

Ac =𝜋Dc²
4

Dc= 1.43 m

At top Dc=1.66

At bottom Dc=1.43m

Select high value of column diameter

Dc=1.66 m

5.1.7 Plate Design [6]

Column diameter Dc=1.66m

Column area Ac=2.168 m2

Down comer area Ad=12% Ac=0.12*2.168 = 0.260 m²

Net area An= Ac-Ad =2.168 - 0.260 = 1.908 m²

86
Active area Aa=Ac - 2Ad=2.168 -2*0.260 =1.648 m²

Holes area Ah=10%Aa as first trial

=0.10*1. 648 =0.165 m²

5.1.8 Weir length

For Ad/Ac=12%
𝑙𝑤
= 0.77 Fig.11.31 [6]
𝐷𝑐
𝑙𝑤
=0.77
1.66

𝑙𝑤 =1. 28 m weir length

Weir height [6]

hw=40 to 90 mm

hw=50mm

5.1.9 hole size[6]

dh = 2.5 to 12.5mm
dh = 5mm

plate thickness =5mm

5.1.10 Check weeping

𝐿𝑛
how=750( )2/3[6]
𝜌𝑙∗𝑙𝑤

Where:

how = height of the liquid over the weir mm.

Ln = liquid mass flow rate Kg/s

𝜌𝐿 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝐾𝑔/𝑚³

87
𝑙𝑤 = 𝑤𝑒𝑖𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 𝑚.
8.861
how=750( )2/3= 52 mm
380∗1.28

𝑘2−0.9(25.4−𝑑ℎ)
umin= [6]
𝜌𝑣0.5

Where:

umin= minimum vapor velocity through the hole m/s

K2= constant

dh=hole size mm

for (hw + how)=50+52=102 mm

K2=31 Fig.11.30 [6]

31−0.9(25.4−5)
umin= =1.40 m/s
(81.26)0.5
𝑉
Úmin=
𝜌𝑣∗𝐴ℎ

Úmin= actual minimum velocity through the hole m/s

𝑘𝑔
𝑉 = 𝑣𝑎𝑝𝑜𝑢𝑟 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
𝑠
𝑘𝑔
𝜌𝑣 = 𝑣𝑎𝑝𝑜𝑢𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
𝑚3
𝐴ℎ = ℎ𝑜𝑙𝑒𝑠 𝑎𝑟𝑒𝑎 𝑚2
13.959
Úmin = = 1.04 m/s
81.26∗0.165

1.04 m/s<1. 40 m/s

∴ Operating rate above weep point

Check entrainment
For 85% flooding and FL.v=0.29

𝜑 = 0.01 Fig.11.29 [6]

88
5.1.11 Plate pressure drop
Dry plate drop
𝑢ℎ 𝜌𝑣
hd=51( )2∗ [6]
𝑐 𝜌𝑙

where :

hd=dry plate drop mm

uh= actual vapour velocity through the holes m/s

c̊ = constant =0.81 Fig.(11.34) [6]

For plate thickness/hole diameter =5/5=1 and An/Aa=5%

2.09 2∗ 81.26
hd=51( ) = 73 mm
0.81 380

Residual heat
12.5∗103
hr = [6]
𝜌𝑙

Where:

hr = residual head mm
12.5∗103
hr = =32 mm
380

Total plate pressure drop

ht= hd + (hw + how) + hr [10]

ht=total pressure drop mm

ht=72+ (50+52)+32=207 mm=0. 207m/plate

∆𝑝 = 𝜌𝑔ℎ

∆𝑝 = 380 * 9.81 * 0. 207m/plate =772 Pa/plate= 0.772 kPa/plate

5.1.12 Plate layout

Allow 100 mm unperforated strip round plate edge

89
100 mm wide calming zone

Fig.(5-2) : Dimension of plate

For Lw/Dc=77%

= 99̊ Fig 11.32 [6]

𝛼 = 180 − 99 = 81
81
Mean length of unperforated edge strips = (1.66 - 2*0.100)*𝜋 ∗ ∗2
360

=2.06 m

Area of unperforated edge strips =2.06 * 0.100 =0.206 m²

Area of calming zone = (1.28 - 2*0.100)*0.100*2=0.216 m²

Total area available for perforation Ap

Ap=1.648 - 0.206 - 0.216=1.226 m²

Ah/Ap=0.165/1.648 =0.10

For Ah/Ap =0.10

Lp/dh = 2.9 Fig.11.33[6]

Lp /5 =2.7

Lp =14.9 mm hole pitch

90
5.1.13 Number of holes
Area of one hole =𝜋 𝑑ℎ² =𝜋 ∗ 0.0052 = 1.96 ∗ 10−5 m²
4 4

No. of holes =holes area/area of one hole= 0.165/1.96 ∗ 10−5 =8418

5.1.14 Height of column

H =N*z *1.15 [10]

Where:

H=height of column m

N=no. of plates

Z=plate spacing m

H= 19*0.45 * (1.15)

= 9.38

5.1.15 Mechanical design

Shell
𝑃𝑖 𝐷𝑖
e= +C [6]
2𝑓−𝑃𝑖

Where:

e =Thickness of shell mm

Di=Shell inside diameter mm

Pi=Design pressure N/mm²

f=Design stress N/mm²

C=Corrosion constant mm

Di=1.66 m=1660 mm

Operating pressure =35.2 bar

91
Design pressure =1.1*operating pressure[6]

Pi=1.1 * 35.2 = 38.72 bar =3.872 N/mm²

C=2 mm[6]

At T=14℃ Design stress of Carbon steel

f =135 N/mm² Table 13.2[6]

3.872∗1660
e=
2∗135−3.872
+ 2 = 26 𝑚𝑚

5.1.15.1 Ellipsoidal head:-

𝑃𝑖 𝐷𝑖
e= +𝐶 [6]
2𝐽𝑓−0.2𝑃𝑖

Where:

e =Thickness of ellipsoidal head mm

J=Joint facto=0.85
3.872∗1660
e=
2∗0.85∗135−0.2∗3.872
+ 2 = 28 𝑚𝑚

5.1.15.2 Supports:-
Weight loads

Weight of vessel (Shell)

Wv=240CvDm(Hv+0.8Dm)t [6]

Where:

Wv=Total weight of vessel excluding internal fittingN

Cv=Constant

Hv=Height or length of shell m

t =e=26 mm

Cv= 1.15 [6]

Dm = (Di+t*10−3)[6]
92
 = (1.66+26*10−3) = 1.686 m

Hv = 9.83 m

Wv = 240 * 1.15 * 1.686 * (9.83 + 0.8*1.686) * 26

=135249 N

5.1.15.3 Plates:-
Weight of plates including liquid loading=1.2 KN/m² [6]

Wp = 1.2 Ac N

Where:

Wp =Total weight of plates KN

Ac =Cross sectional area of column m²

N=Number of plates

N = 19 Ac = 2.168 m²

Wp = 1.2 * 2.168 * 19 = 49.430 KN= 49430 N

W =Wv+Wp

W =total weight KN

W =135249 + 49430 = 184679 N

5.1.15.4 Design of skirt:-

𝐹𝑤 𝐻2
𝑀𝑠 = [6]
2

Where:

𝑀𝑠 = 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡 𝑎𝑡 𝑏𝑎𝑠𝑒 𝑜𝑓 𝑠𝑘𝑖𝑟𝑡 𝑁𝑚.

Fw=loading per linear meter N/m.

H=total height m

Fw=Pw * Def[6]

93
Where:

Pw=wind pressure =1280 N/m²

Def=effect tower diameter m

Def=Di + 2t * 10-3

=1.66 + 2 * 26* 10-3 =1.712 m

Fw= 1280 * 1.712 = 2191 N/m

Take skirt height =1m[6]

H= 9.83 +1=10.83 m
2191 ∗ 10.832
=
2
=128490 Nm=128.490 * 10-3Nmm
𝑠 4𝑀
𝜀𝑏𝑠 = 𝜋(𝐷𝑠+𝑡𝑠)𝑡𝑠𝐷𝑠 [6]

Where:

𝜀𝑏𝑠 = 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑠𝑘𝑖𝑟𝑡 𝑁/𝑚𝑚2

Ds=inside diameter of the skirt at the base mm

Ts = skirt thickness mm

As the first trial take the skirt thickness as the same of the shell thickness

ts = 26mm

Base angle of conical skirt normally 80° to 90°

Take skirt angle 𝜃 = 85° [6]

ℎ𝑠
tan 𝜃 = 1
(𝐷𝑠−𝐷)
2

Where:

hs = height of skirt m

Ds = inside diameter of skirt in the base m

94
D = tower diameter m
1
tan (85) = 1
(𝐷𝑠−1.660)
2

Ds=1.835 m =1835 mm
4 ∗ 128.49 ∗ 106
𝜀𝑏𝑠 =
(1835 + 26)(26 ∗ 1835)

=1.84 N/mm2
𝑊𝑡
𝜀𝑤𝑠 =
𝜋(𝐷𝑠 + 𝑡𝑠)𝑡𝑠
Where:

𝜀𝑤𝑠 = 𝑡ℎ𝑒 𝑑𝑒𝑎𝑑 𝑤𝑒𝑖𝑔ℎ𝑡 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑠𝑘𝑖𝑟𝑡 N/mm2

Wt=total weight of the vessel and contents N

Wd = 𝜋 𝐷2ℎ 𝜌 𝑔
4

Wd=dead weight N

D=tower diameter m

h =tower height m

𝜌 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 = 1000𝐾𝑔/𝑚3

g = 9.81 m/s2

Wd=𝜋 1.662 ∗ 9.83 ∗ 1000 ∗ 9.81

4

=208703 N

Wt = W + W d

Where:

Wt=total weight N

Wt = 184679 + 208703 = 393382 N

95
 393382 = 2.59 𝑁/𝑚𝑚2
𝜀𝑤𝑠 (𝑡𝑒𝑠𝑡) =
(1835 + 26)(26)

𝜀𝑠 (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) = 𝜀𝑏𝑠 + 𝜀𝑤𝑠

= 1.84 + 2.59 = 4.43𝑁/𝑚𝑚2

𝜀𝑠 (𝑡𝑒𝑛𝑠𝑖𝑙𝑒) = │𝜀𝑏𝑠 − 𝜀𝑤𝑠 │

= │1.84 – 2.54│= 1.16 𝑁/𝑚𝑚2

εs (tensile) > 𝑓𝑠𝐽𝑠𝑖𝑛𝜃 [6]

𝜀𝑠 (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) > 0.125𝐸 ( 𝑡𝑠 ) 𝑠𝑖𝑛𝜃 [6]

𝐷𝑠

Where:

fs = design stress N/𝑚𝑚2 at 20℃ = 135 𝑁/𝑚𝑚2

J = joint factor = 0.85

E=young modulus =200000 N/𝑚𝑚2

1.16> 135 ∗ 0.85 sin(85)

1.16> 114.3 OK
26
4.43> 0.125 ∗ 200000 ∗ 𝑠𝑖𝑛85
1835

4.43> 352.9 𝑂𝐾

Added 2mm for corrosion

Skirt thickness = 26 + 2 = 28mm

96
 Fig.(5-3) : Dimension of skirt

Table (5.11):Dimension of skirt

Height (m) 1
Top diameter (m) 1.660
Bas diameter (m) 1.835
Angle 850
Thickness ( mm) 28

97
5.1.16 Cost estimation
Vessel

Height h = 9.83 m

Diameter D = 1.66 m

Pressure p = 35.2 bar

Material of construction: carbon steel

Cost= 30000 $ Fig 6.5b[6]

Pressure factor =1.6 Fig 6.5b[6]

Material factor =1 Fig 6.5b [6]

Cost = 30000 * 1.6 * 1 = 48000$

Plates:-

Diameter D = 1.66 m

Type: sieve

No. = 19

Material factor =1

Cost = 400 $ Fig 6.7b[6]

Total cost of plate =400 * 19 * 1

=7600 $

Total cost of column = 48000 + 7600 = 55600 $ in 2004

𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2016
Cost in 2016 = (Cost in 2004)*( )[6]
𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2004

Cost index in 2004=444.2 [19]

Cost index in 2016=826.76 [19]

Cost in 2016= 55600 * (826.76) = 103485 $

444.2

98
5.1.17 Data sheet

Column
Type plate
Height (m) 9.83
Top temperature (°C) -10
Bottom temperature 14
(°C)
Top pressure (bar) 34.5
Bottom pressure
34.7
(bar)
plate
Type Sieve
Area (m2) 2.168
Down comer area 0.260
(m2)
Active area (m2) 1.648
Holes area (m2) 0.165
No.of plate 19
Plate spacing 0.45
No. of holes 8418
Martial of cons C.S

99
5.1.18 Control

Fig. (5-4) : Control System of distillation column

100
5.2 Design of cooler
The transfer of heat to and from process fluids is an essential part
of most chemical processes. The most commonly used type of heat-
transfer equipment is the ubiquitous shell and tube heat exchanger.
The principal types of heat exchanger used in the chemical process and
allied industries, are listed below:
1. Double-pipe exchanger: the simplest type, used for cooling and
heating.
2. Shell and tube exchangers: used for all applications.
3. Plate and frame exchangers (plate heat exchangers): used for heating
and cooling.
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled: coolers and condensers.
7. Direct contact: cooling and quenching.
8. Agitated vessels.
9. Fired heaters.
We used the shell and tube exchanger for the following reasons:
1. The configuration gives a large surface area in a small volume.
2. Good mechanical layout: a good shape for pressure operation.
3. Uses well-established fabrication techniques.
4. Can be constructed from a wide range of materials.
5. Easily cleaned.
6. Well-established design procedures.[6]

102
273773.27 Kg/h H2O

48312.93 Kg/h MEA

582.93 Kg/h(C2H5ONH3)2CO3 721580 Kg/h H2O

T1 = 116℃ t1 =15℃

273773.27 Kg/h H2O 721580 Kg/hH2O

T2 = 45℃ t2 = 45℃

48312.93 Kg/h MEA

582.93 Kg/h(C2H5ONH3)2CO3

Fig.(5-5): Design of cooler

Tube side (15 wt% MEA)

= 15℃𝑡1

= 45℃𝑡2

Shell side H2O

= 116℃𝑇1

=45℃𝑇2

Q =UA∆𝑇𝐿𝑚𝐹

Where

Q = heat transfer per unit time (w)

U = overall heat transfer coefficient W/m2.℃

A =heat transfer area m2

= they mean temperature difference ℃∆𝑇𝐿

103
F= conversion factor

From energy balance Q = 90919138 Kg/h

1000𝐽 ℎ
Q = 90919138 Kg/h* * = 25255316 W
𝐾𝑔 3600𝑠𝑒𝑐

=(𝑇1−𝑡2)−(𝑇
𝑇1−𝑡21−𝑡1) = (116−45)−(45
116−45 −15) = 47.6℃∆𝑇𝐿𝑚
ln( ) ln( 45 )
𝑇2−𝑡1 − 15

Use one shell and two tube side t1 =116℃

𝑇 𝑇 116 40
R = 𝑇1−𝑡 2 = −
= 2.37 T=40℃
2− 1 45−15
t= 45℃
𝑡2−𝑡 1 45−15
S= = T1= 5℃
𝑇1−𝑡1 116−15

For R= 2.37 and S= 0.29

(6)
F= 0.86

(6)
U = 800 – 1500 W/m2.℃

By trial and error assume U= 900 W/m2.℃

𝑄 2525316
A= = = 685.5 m2
𝑈𝐴∆𝑇𝐿𝑀𝐹 900∗47.6∗0.88

Tube length L =16 ft = 4,88 m

(6)
Tube outside d ° =25 mm

Tube thickness = 2mm

= d ° -2× thickness𝑑𝑖

= 25 -2×2 =21 mm =0.021 m

Surface area of one tube =πdL = π×0.025 × 4.88 =0.383 m2

𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎
No. of tubes =
𝑎𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 𝑡𝑢𝑏𝑒

= 6.585 =1790 tube 𝑁

0.383 𝑡
104
Tube side coefficient ℎ𝑖
+𝑡2
Mean shell temperature = 𝑡1 =𝑇𝑚
2

15+45
= =30℃𝑇
2 𝑚

Physical properties of water at 30℃

= 0.996 g/cm3 (996 kg/m3)

=0.801 cp (8.01×10-4 kg/ m.s)

K= 146×10-5 cal/cm.s℃

= 0.611 w/m.℃

=4.20 kg/kg.℃𝑐𝑝

Tube side coefficient ℎ𝑖

= 𝐽ℎ Re𝑃𝑟 0.33 ( )0.14 (6)𝑁

𝑢
𝜇
𝜇𝑤

Where

ℎ𝑖 𝑑𝑖
= Nusselt number = 𝑁
𝑘 𝑢

𝜌𝑢𝑑𝑖
Re = Reynold number =
𝜇

𝑐𝑝𝜇
= prandttle number = 𝑃𝑟
𝑘

= inside fluid film coefficient W/m2.℃ℎ𝑖

= inside tube diameter m𝑑𝑖

K = fluid thermal conductivity W/m2.℃

=fluid density Kg/m3𝑝

= fluid viscosity Kg/m.s𝜇

= fluid heat capacity J/kg.℃𝑐𝑝

105
u= velocity m/s

= tube side heat transfer factor . 𝐽ℎ

No .of tube passes=2

No .of tubes =1790 tube

1790
No .of tube per pass= = 895
2

Total Mass flow rate = 721580 kg/h =200.44Kg/s

200.44
Mass flow rate per tube m = = 0.224 𝑘𝑔𝑙𝑠
895

m = 𝜌𝑢A

Where

m=fluid mass flow rate kg\s

P=fluid density kg\m2

U=fluid velocity m\s

A=Cross-sectional area of tube

𝜋
A= 𝑑𝑖 2
4
𝜋 2 -5 2

A= (0.021) =3.46*10 m
4

𝑚
u=
𝑝𝐴
0.224
u= 996×3.46×10−5 = 0.65 m\s small uis(1-2 m\s)

Tube number of passes = 4

1790
No .of tube per pass= = 448
4

0.447
u = 996×3.46×10−5 = 1.30 𝑚\𝑠

𝜌𝑢𝑑𝑖 996×1.30×0.021
Re= = =33946
𝜇 8.01×10
106
 4.88
For.𝑅𝑒 = 33946 and L /𝑑𝑖 = = 232
0.021

= =3.6 × 10-3 (6)

𝐽ℎ

𝑐𝑝𝜇
= 𝑃𝑟
𝑘

4.2×103×8.01×10−4
= 0.611
=5.506𝑃𝑟
𝜇
=1
𝜇𝑤
=3.6× 10-3× 33946(5.506) 0.33 (1) 0.14 =214.57𝑁𝑢

𝑚𝑖×𝑑𝑖
= 𝑘
𝑁𝑢
ℎ𝑖 𝑑 𝑖
= 𝑘
𝑁𝑢
ℎ𝑖 ×0.021
214.57 =
0.611
=6243 W/m2.℃ℎ𝑖

5.2.1 Shell side coefficient

𝑡1+𝑡2
Mean shell Temp. 𝑡𝑚 =
2

116+45
= 2
= 81℃𝑡𝑚

Physical properties of 15wt%

MEA solution at 81℃

Density

Sp.gr = 0.974

=9741g/m3𝜌

Viscosity

=0.43 c.p 𝜇

=0.43×0.924
107
=0.42 CP

=42×10-4 Kg/m.s

Heat capacity

Q = m𝐶𝑝∆ 𝑇
Q
= 𝐶
m∆ 𝑇 𝑝
9091913.8
= 𝐶𝑝
322669.13(116−45)

=3.096 kg\kg.℃

thermal conductivity

for H2O

K1=158×10-5 Cal\cm.S.℃

=0.661 w\m.c0

For MEA
Log k2 =A+B(1-𝑇) 2\7
𝐶

Where

K2= thermal conductivity of MEA w\m.c0

A,B,C = constants

A =- 1.3743

B = 1.0185

C= 638

T=81℃= 354k
354 2\7
Log k2=-1.3743+1.0185(1- )
638

= 0.27 W\m.c0

108
K=∑ 𝑋𝑖 𝐾𝑖

K=thermal conductivity of mixture w/m. ℃

=thermal conductivity of component i w/m. ℃𝐾𝑖

=weight fraction of component i𝑋𝑖

K= (0.661×0.85)+(0.27×0.15) = 0.602 w/m. ℃

=𝐽𝑅 𝑝 0.33( )0.14 𝑁
ℎ 𝑒 𝑟 𝜇𝑤 𝑢

Where
= Nusselt number=ℎ𝑜𝑑𝑒𝑁
𝑘 𝑢

= Reynold number = 𝑓𝑠𝑢𝑠𝑑𝑒𝑅

𝑚 𝑒

= prandtle number = 𝑐𝑝𝑚𝑃

𝑘 𝑟

=outside fluid film coefficient w/m2℃𝐻°

= equivalent diameter m.𝐷𝑒

K = fluid thermal conductivity w/m. ℃

= fluid density kg/m3𝐹𝑠

M = fluid viscosity kg/m.s

= fluid heat capacity J/kg. ℃𝐶𝑝

Us = fluid velocity m/s

Jh = shell heat transfer factor.

Use square tube pitch pt = 1.25 𝑑°

1.27
De = ( 𝑝𝑡 - 0.785 𝑑°2)
𝑑°

Where

de , 𝑑° and pt in mm
109
pt = 25 mm

pt = 1.25 (25) = 31.25 mm

1.27
de = (31.252 -0.785× (0.252) = 24.7 mm = 0.0247m
25

D=𝑑 𝑁𝑡 1 /
𝑛 (6)

b °(𝐾 ) 1
1

Where

Db = bundle diameter mm

= total number of tubes 𝑁𝑡

K1 , n1 = constant

For square tube pitch and four tube passes

(6)
K1 = 0.158

n1 = 2.263
1790 1 /
Db= 25( ) 2.263 = 1547 mm
0.158

For Db =1547 mm and split ring floating head tube

Ds – Db = 8mm

Ds – 1547 = 88

Ds = 1635 mm = 1-633 m shell diameter

𝑝𝑡−𝑑°
As= ( ) (Ds+ LB )
𝑝𝑡

Where

As = cross .flow area m2

LB = baffle spacing m
(6)
LB = (0.20 ) * shell diameter

LB = 0.3 Ds = 0.3 * (1.635 ) = 0.491 m2

110
 31.25−25 ) (1.635+0.491) = 0.160 m2
As = (
25

𝑊𝑠
Gs =
𝐴𝑆

Where

Gs = mass velocity kg/m2.℃

= mass flow rate kg/s𝑊𝑠

= 322669.13 kg/h (89.63 kg/s)

89.63
Gs= = 560.2 kg/ m2.s
0.160

U=
𝐺𝑠
=
560.2 = 0.58 m/s
s 974
𝜌𝑠

𝜌𝑠𝑢𝑠𝑑𝑒 974∗0.58∗0.0247
Re = = =33223
𝜇 4.2∗10−4

For Re =33223 and 25% baffle cut

= 3.4*10-4 (6)𝐽
ℎ

𝑐𝑝𝑚 3.096×10−3 ×4.2 ×10−4

= = = 2.16𝑃𝑟
𝑘 0.602

= 3.4×10-3 (33223)(2.16)0.33(1)0.14 = 145.64 𝑁𝑢

=
ℎ°𝑑𝑒
=145.64 =
ℎ° ×0.0247 , ℎ = 3550 w/m2.℃ 𝑁
𝑘 0.602 ° 𝑢
(6) 1 1
= +
1
+
𝑑° ln( 𝑑°/𝑑𝑖)
+
𝑑°
∗
1
+
𝑑°
∗
1

𝑈𝑜 ℎ° ℎ𝑖𝑑 2 𝐾𝑤 𝑑𝑖 ℎ𝑖𝑑 𝑑𝑖 ℎ𝑖

𝑈𝑜 = over all heat transfer coefficient W/m 2.℃

ℎ° = outside fluid film coefficient W/m2.℃

= inside fluid film coefficient W/m2.℃ℎ𝑖

ℎ°𝑑= outside dirt coefficient (fouling factor) w/m2.℃

ℎ𝑖𝑑 = inside dirt coefficient (fouling factor) w/m2.℃

Kw = thermal conductivity of tube wall material w/m2.℃

111
di = inside tube diameter m
do : outside tube diameter m

= inside tube diameter m𝑑𝑖

ℎ°𝑑 =5000 w/m2.℃

ℎ𝑖𝑑 =5000 w/m2.℃

thermal conductivity of carbon steel

(6)
tw =45 w/m2.℃

1 1 1 25 ∗ 10−3 ln( 25/21) 25 1 25 1

= + + + ∗ + ∗
𝑈𝑜 3550 5000 2 ∗ 45 21 5000 21 6243

Uo = 955 w/m2 .℃

Assumed U=900 W/m2.℃

25255316
A= = 646.02 m2
955∗47.6∗0.86
646.02

Nt = 0.383 = 1688

Tube side coefficient ℎ𝑖

1688
No. of tube passes = = 422
4

200.44
M= = 0.472 Kg/s
422

0.475
u =996∗3.46∗10−4 = 1.38 m/s
996∗1.38∗0.021
𝑅𝑒 = = 36035
8.61∗10−4
𝐿 4.88
For 𝑅𝑒 = 36035 and = = 232
𝑑𝑖 0.021

𝑗ℎ = 3.5*10-3 (6)

112
Nu = 3.5 *10-3(36035)(5.506)0.33(1)0.14 =221.45
ℎ𝑖∗0.021
221.45 =
0.611

ℎ𝑖 = 6443 w/m2.℃
shell side coefficient ho
1
Db =25 ∗ ( 1688 ) 2.263 =1507 mm
0.158

For Db and spilt ring floating heat

Ds – Db = 87 mm (6)

Ds -1507 =87 =1594mm (1.594m)

LB = 0.3(1.594) = 0.478 m

(31.25−25)(1.594∗0.478)
As = = 0.152m2
31.25
89.63
𝐺𝑆 = 0.152
= 589.67 kg/m2.s

589.67
us = = 0.61 m/s
974

974∗0.61∗0.0247
Re = =34941
4.2∗10−4
For Re = 34941 and 25% baffle

Jh =3.3*10-3 (34941)(2.16)0.33(1)0.14

Nu = 148.67
ℎ°∗0.0247
148.67 =
0.602

ℎ° = 3623 W/m2.℃
1 1 1 0.075 ln( 25/21) 25 1 25 1
= + + + ∗ + ∗
𝑈° 3623 5000 2 ∗ 45 21 5000 21 6443

𝑈° = 966 w/m2 .K

Assumed U=955 W/m2.C

966−955
Error = 955
*100% = 1%

113
5.2.2 Pressure drop
tube side pressure drop

∆𝑝t = NP[8jf(L/𝑑𝑖)(𝜇/𝜇𝑤)-0.14 +2.5][𝜌*𝑢𝑡2/2] (6)

Where

∆𝑝t = tube side pressure drop N/m2

Np = number of tube passes

L =tube length m

𝑑𝑖 = tube inside diameter m

𝜌= fluid density Kg/m3

𝑢𝑡 =tube side velocity m/s

jf = fraction factor
𝜌𝑢𝑖𝑑𝑖
Re = = 996*1.38*0.021/8.01*10-4 =36035
𝜇

For Re = 36035

jf =3.4*10-4 (6)

∆𝑝t = 4[8*3.4*10-3(4.88/0.021)(1)-0.14 +2.5][996*1.382/2]

∆𝑝t =33462N/m2(33.462KPa)(4.86 psi) (6)

Shell side pressure drop

∆𝑝s = [8jf(Ds/𝑑𝑒)(𝐿/𝑙𝐵][𝜌*𝑢𝑠2/2] (𝜇/𝜇𝑤)-0.14 (6)

Where

∆𝑝s = shell side pressure drop N/m2

de = equivalent diameter m

𝑙𝐵 =baffle spacing m

L =tube length m

114
𝐷𝑠 = shell diameter m

𝜌= fluid density Kg/m3

𝑢𝑠 =shell side velocity m/s

jf = fraction factor
𝜌𝑠𝑢𝑠𝑑𝑒
Re = = 974*0.61*0.0247/4.2*10-4 =34941
𝜇

For Re = 34941

jf =4*10-2 (6)

∆𝑝s = [8*4*10-2(1.594/0.0247)(4.88/0.478)(974*(0.61)2/2)(1)-0.14

∆𝑝t =38205N/m2(38.205KPa)(5.54 psi) (6)

115
5.2.3 Data sheet

Tube Shell
Length m 4.88 Length m 4.88
Inside dia. Mm 21 Baffle spacing 0.491
m
Outside dia. 25 Baffle cut % 25
Mm
Surface area m2 646.02 Inlet temp ℃ 116
No. of tubes 1688 Outlet temp ℃ 45
No. of passes 4 Pressure drop 0.38
bar
Inlet temp ℃ 15 fluid MEA
H2O
Outlet temp ℃ 45 H.T.C W/m2.℃ 3623
Pressure drop 0.33 Material of St.St
bar const.
Fluid H2O
H.T.C W/m2.℃ 6443
Material of St. St
const.

116
 1.653m
4.88m

5.2.4 Mechanical design

Shell
𝑃𝑖 𝐷𝑖
e= +C [6]
2𝑓−𝑃𝑖

Where:

e =Thickness of shell mm

Di=Shell inside diameter mm

Pi=Design pressure N/mm²

f=Design stress N/mm²

C=Corrosion constant mm

Di=1.594 m=1594 mm

Design pressure must be taken as 0.345 MN/m2 [6]

Pi=0.345 MN/m2 = 0.345 N/mm²

C=2 mm [6]

At T=116 ℃ Design stress of stainless steel

f =130 N/mm² Table 13.2 [6]

0.345∗1594
e=
2∗130−0.345
+ 2 = 4 𝑚𝑚

117
5.2.4.1 Ellipsoidal head:-
𝑃𝑖 𝐷𝑖
e= +𝐶 [6]
2𝐽𝑓−0.
2𝑃𝑖

Where:

e =Thickness of ellipsoidal head mm

J=Joint factor =0.85 [6]

0.345∗1594
e=
2∗0.85∗130−0.2∗0.345
+ 2 = 4.5 𝑚

5.2.4.2 Supports:-

Weight loads

Weight of vessel (Shell)

Wv= 𝜋𝜌𝑚CvDmg(Hv+0.8Dm)t*10-3 [6]

Where:

Wv=Total weight of shell including internal fitting N

Cv=Constant

Hv=Height or length of shell m

Dm = mean diameter of shell m

T = wall thickness mm

𝜌𝑚 = density of wall material Kg/m3

t =e=4 mm

Cv= 1.15 [6]

Dm = (Di+t*10−3) [6]

= (1.594+4*10−3) = 1.598 m
Density of stainless steel 𝜌𝑚 = 7800 Kg/m3 Wv = 1.15 𝜋 *
7800*1.594*9.81*(4*10-3) (4.88 + 0.8*1. 594)

=10850 N
118
5.2.4.3 Weight of tubes
Weight of plates including liquid loading=1.2 KN/m² [6]

Wt = 𝜋𝜌doLtgN

Where:

Wt =Total weight of tubes KN

L = length of tube m

t = tube thickness m

N=Number of tubes

Wp = 𝜋 * 0.025 * 4.88*0.002*7800*9.81*1688 = 49.430 KN= 99009 N

5.2.4.4 Weight of fluid

Wf =( 𝜋𝜌gLD2)/4 [6]

Where:

Wt =Total weight of fluid KN

L = length m

𝜌 = density of water Kg/m3

Wf =( 𝜋*(1.594)2 * 4.88 * 996 * 9.81)/4

= 95151 N

W= Wv + W t + Wf

Where:

W =Total weight KN

= 10850 + 99009 + 95151

= 205010 N

= 2050.10 KN

119
5.2.5 Cost estimation

Surface area A = 646 m2

Pressure p = 1.5 bar

Material of construction: stainless steel

Type : Floating head

Cost= 400000 $ Fig 6.5b [6]

Pressure factor =1 Fig 6.5b [6]

Material factor =1 Fig 6.5b [6]

Cost = 400000 * 1* 1 = 400000 $ in 2004

𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2016
Cost in 2016 = (Cost in 2004)*( ) [6]
𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 𝑖𝑛 2004

Cost index in 2004=444.2 [15]

Cost index in 2016=826.76 [15]

Cost in 2016= 400000 * (826.76) = 74449 $

444.2

111
0
Control on cooler

120
 Chapter Six
Environmental Effect

122
6.1 Environmental considerations:
Vigilance is required in both the design and operation of process plant to
ensure that legal standards are met and that no harm is done to the
environment. Consideration must be given to:
1. All emissions to land, air, water.
2. Waste management.
3. Smells.
4. Noise.
5. The visual impact.
6. Any other nuisances.
7. The environmental friendliness of the products. [6]

6.2 Waste management:

Waste arises mainly as byproducts or unused reactants from the process,
or as off specification product produced through mis-operation. There will also
be fugitive emissions from leaking seals and flanges, and inadvertent spills and
discharges through mis-operation. The designer must consider all possible
sources of pollution and, where practicable, select processes that will eliminate
or reduce waste generation. the waste from process can be use as raw material
for another process.[6]

6.2.1 Gaseous wastes:

Gaseous effluents which contain toxic such as Carbon monoxide caustic
soda and MEA or noxious substances will need treatment before discharge into
the atmosphere. Gaseous pollutants can be removed by absorption or
adsorption. Flammable gases can be burnt, The gases leaving an incinerator may
be scrubbed and acid gases neutralized. [6]

6.2.2 Aqueous wastes:

The principal factors which determine the nature of an aqueous industrial
effluent and on which strict controls will be placed by the responsible authority
are:
1. pH.
2. Suspended solids.
3. Toxicity.
4. Biological oxygen demand.
The pH can be adjusted by the addition of acid or alkali. For some effluents it will
be possible to reduce the toxicity to acceptable levels by dilution. Other
effluents will need chemical treatment.[6]

123
6.2.3 Treatment of waste gases:

Fig. (6-1) : Treatment of waste gases [6]

6.2.4 Treatment of waste liquids:

Fig. (6-2) : Mixer of Treatment of waste liquids [6]

6.2.5 Treatment of aqueous waste:

Fig. (6-2) : Thickener of Treatment of waste slurry [6]

124
6.3 Exposure limits:
ACGIH-TLV(TWA) 100 PPm

ACGIH-TLV(STEL) above 19.5% in air

OSHA-PEL(TWA) above 19.5% in air

OSHA-PEL(STEL) above 19.5% in air [14]

6.4 Environmental exposure controls :

Emissions from ventilation or work process equipment should be
checked to ensure they comply with the requirements of environmental
protection legislation. In some cases, fume scrubbers, filters or engineering
modifications to the process equipment will be necessary to reduce emissions
to acceptable levels.[14]

121
25
 Chapter Seven
Discussion &
Recommendations

127
7.1 Discussion :

Use monoethanolamine solution (15%MEA) to absorption of

carbon dioxide because its high action liquid , which gives small packing
size and column height . monoethanolamine is the preferred solvent for gas
streams containing relatively low concentration of carbon dioxide
,and essentially no minor contaminants such as CO2 and CS2 .
In the design of heat exchanger the heat transferred is very high which
gives high number of tubes and shell diameter.

7.2 Recommendations:

1- The by product (ethane) can by used as raw material for others processes
such as production of ethylene by dehydrate_ nation or use as fuel.

2- The plant must be establishes near from others plants used ethylene as
raw material such polyethylene, ethylene oxide, ethanol, ethane.

3- The plant must be establishes near from raw material(refineries).

Cylinders should be stored in dry well ventilated areas away from

sources of heat, flames, sparks, ignition and direct sunlight. Do not allow
area where cylinders are stored to exceed 52℃. Isolate from oxidizers
gases such as oxygen, chlorine or fluorine. Post no smoking or open
flame sings in storage and areas. Use with adequate ventilation to
maintain oxygen levels above 19.5% in the work place.

128
References:-

1- Mecketta and John J, Encyclopedia of Chemical processing and

Design, 2nd Edition, Vol.5, Marcel Dekker, New York (1998).
2- Ethylene Wikipedia, the free

encyclopedia. 3-WWW. Qenos.

Com.

4- Kirk-Othmer, Encyclopedia of Chemical Technology , 4th Edition,

Vol.20, John Wily, New York (1998).
5- Vorgelegt Von, M.Sc. thesis, Ethylene Production by oxidation
Coupling of Methane, Technischen University, Berlin (2014).
6- Coulson J.M and Richardson J.F, Chemical Engineering
Design,Vol.6,4th Edition, Butter worth Heinemann, Oxford (2005).

7- Kohl A.L and Riesenfeld F.C, Gas purification, 3 nd Edition, Gulf

publishing CO., London (1979).
8-Perry R.H and Don Green, Chemical Engineers Handbook, 7 th Edition,
McGraw
–Hill, New York (1973).

9- Nelson W.L, Petroleum Refinery Engineering, 4th Edition, Mc Graw –

Hill,New York (1958).
10- Smith J.M and Van Ness H.C, Introduction to Chemical
Engineering, Thermodynamics, 6 th Edition, Mc Graw –Hill,
New York (2001).

11- Faith, Keyes and Chlark , Industrial chemistry, 2 nd Edition ,John

Wily; New York (1975).

12- Gallant W.R, Physical properties of Hydrocarbons, 2 nd Edition, Gulf

Publishing Company, Texas (1974).

13- Kern Q.D, Principles of Corporate Finance, 1st Edition, McGraw-

Hill, New York (1980).
14- https://www.airgas.com.