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Group Members:

Academic Advisor

Dr. Basim Abu-Jdayil

Student name ID

Aysha Housani 200503484

Maha Al Shehhi 200509462

Hessa Al Shehhi 200509582

Mona Thabet 200521150

United Arab Emirates University

College of Engineering

Graduation Project II Course

First Semester- Fall 2010

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Introduction Problem Statement and Purpose

Objective

Process selection

Material balance

Energy balance

Detailed Design

Process Economics

Safety and environmental issues

Project Management

Conclusion
http://img.alibaba.com/photo/214447898/PVC_plastic_sheet_for_offset_printing.jpghttp://upload.wikimedia.org/wikipedia/commons/1/1e/Phthalic_anhydride-3d.pnghttp://upload.wikimedia.org/wikipedia/commons/d/d7/Phthalic_anhydride-2D-Skeletal.png

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Petrochemical Phthalic Anhydride Large Scale Industries

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Produced either by O-xylene or Naphthalene, where both of them are available from

oil industries that are extensively available in the UAE

Plasticizer industries Pigments industries

Phthalic anhydride

Phthalic Anhydride is not available in UAE

Its imported from other countries

Problem Statement And Purpose

UAEIn 2009 imported 27.5

Ton/day

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OBJECTIVE

Objective

Plant production 70 ton/day

UAE need 27.5 ton/day

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To produce PA the commonly types process are by

O-xylene Naphthalene

Liquid-phase oxidation

Fixed bed vapor-phase

oxidation

Fluidized bed vapor-phase

oxidation

Fixed bed vapor-phase

oxidation

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Process

Criteria

Oxidation of O-xylene

using a fixed bed vapor-

phase

Oxidation of Naphthalene

using fluidized bed vapor-

phase

Raw material Cost LowerHigher

(it is in an impure form)

Raw material availability More availableLess available

(coal tar naphthalene)

Safety:

1. CO2 emission2. Processing

Temperature

Less

Higher(350 to 500)

More

Lower (340 to 385)

PA YieldHigher (Complete

combustion)

Lower

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Combination

Vanadium Pentoxide [V2O5]

& Titanium Dioxide [TiO2]

Advantages:

Able to operate higher O-xylene concentration without:

Reducing the selectivity for the partial oxidation reaction which produces PA

Increasing the formation of by-products

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Steady State

Air(900 kmol/hr)

O-xylene

(25kmol/hr)

PA

(20 kmol/hr)

MA

O2 + N2 +CO2 + H2O

H2O

Compressor

Reactor Gas separator

Distillation

1

2

14

10

13

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Stream# 1 2 10 13 14

Mass F low (kg/hr) 25976.8 2654.2 25480.5 230.3 2920.2

Molar flow

(Kmol/hr)900.4 25.0 906.2 5.75 19.7

Average Molecular weight(kg/hr)

28.85 106.17 28.12 40.06 148.3

Component f lowrate

(kmol/hr)

O-xylene 0.0 25.0 0.0 0.0 0.0

Oxygen 189.1 0.0 79.4 0.0 0.0

Nitrogyn 711.3 0.0 711.3 0.0 0.0

Carbon Dioxide 0.0 0.0 35.8 0.0 0.0

Water 0.0 0.0 79.6 4.2 0.0

Maleic Anhydr ide 0.0 0.0 0.0 1.6 0.1

Phthalic Anhydride 0.0 0.0 0.0 0.0 19.7

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General equation of the energy balance

Calculation of energy balance

the amount of the energy supplied

the amount of the steams

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E-101 E-102 E-104 E-105 E-106 R-101

Q (kJ/hr) 1.87 x106

1.67x106

8.20x105

4.65x105

7.56x105

3.85x107

Utilities mps mps hps cw mpsMolten

salt

F low rate

(kg/hr)989.28 931.58 522.18 795.4 400 614,000

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Q calculated

(kJ/hr)

Q*

(kJ/hr)

% Error

Utility calculated

(kg/hr)

Utility*

(kg/hr)

% Error

E-101 1.87 x10

6

1.97x10

6

5.08 989.28 1,010 2.05

E-102 1.67x106 1.84x106 9.24 931.58 948 1.73

E-104 8.20x105 7.23x105 13.42 522.18 445 17.34

E-105 4.65x105 4.80x105 3.13 795.4 - -

E-106 7.56x105 7.76x105 2.58 400 - -

R-101 3.85x107 3.74x107 2.94 614,000 - -

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DETAILED DESIGN

Compressor Design

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DETAILED DESIGN

Compressor Type

1.5x104 CFM

3

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DETAILED DESIGN

Compressor Power

Work (kJ/hr) 2,901,560Efficiency % 75

Shaft Power (kW) 1075

Fluid power (kW) 806

Stream : 1

1=900.4 kmol/hr

T 1=25 C

P1=1 atm

Stream : 3

3 = 900.4kmol/hr

P3 = 3 atm

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DETAILED DESIGN

Pump Design

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DETAILED DESIGN

Pump Power

O-xylene flow rate (Kg/hr) 2654.2

Density (kg/m3) 877.5

P1 (Pa) 100,000

P2 (Pa) 300,000

Specific Work (J/kg) 231

Fluid Power (kW) 0.17

Pump Type Reciprocating pump

Efficiency % 80

Shaft Power (kW) 0.212

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DETAILED DESIGN

Heat exchanger

heater condenser vaporizerRe-boiler

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DETAILED DESIGN

Heat exchanger

Shell and tube heat exchanger

Easily cleanedThe configuration gives a large surface area in small

volume

The construction of shell and the tubes can bemade of different materials

The variation of the pressure and pressure drops

over a wide range

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Type of design U-tube Fixed tube sheet

Temperature High temperature differential which may

require

High temperature

difference required at

extremes of about 93 0C

Clean Cleaning chemically and difficult to clean

mechanically

Cleaning chemically

and mechanically

Number of tube pass Any particle even number possible Normally no limitation

Suitable for : For any application that the fluid

should be free of suspended particle

Clean service or easily cleaned

condition in both tube side and shell

side.

Condenser , liquid-

liquid , gas gas , gas

liquid cooling or

heating , re-boilling

Cost Relatively cheap Relatively expensive

Heat exchanger

DETAILED DESIGN

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DETAILED DESIGN

Heat exchanger

3 5

Saturated steam

condensate steam

air

4 6

Saturated steam

condensate steam

O-oxylene

Saturated steam

condensate steam

mixture

Mixture : MA , PA , water

E-101 E-102 E-104

13 14

Fixed tube sheet Double pipeU-tube

Steam : condensation Steam : condensationSteam : condensation

O-oxylene : vaporization mixture : vaporizationAir : heating (one phase)

Carbon steel

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DETAILED DESIGN

U Estimated

Heat exchanger

To find Heat transfer area (A)

F Obtained from charts

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DETAILED DESIGN

Heat exchanger

Standard E-101 E-102 E-104

OD (m) 0.0254 0.019 0.019

Tube passes 4 2 2

Shell passes 2 1 1

ID (m) 0.0170 0.016 0.016

triangle spacing (m) 0.0254 0.0254 0.0254

L (m) 4.9 4.9 4.9

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DETAILED DESIGN

Heat exchanger

Heat transfer coefficient

condensate

Tube-side coefficient

shell-side coefficient

One phase


vaporization


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DETAILED DESIGN

Heat exchanger

Calculating U

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DETAILED DESIGN

Heat exchanger

Heat Exchanger E-101 E-102 E-104

Range of U

(W/m2.oC)30300 300900 300900

hi(W/m2.oC) 1,093.86 17,452.33 3770.89

ho(W/m2.oC) 49.47 1,797.09 2,867.57

U (W/m2.oC) 45 685 675

Area (m2) 375.18 12.53 3.55

Number of tubes 1,023 43 13

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DETAILED DESIGN

Reactor Design

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DETAILED DESIGN

Reactor Design

OHCOOHC

COOHOHCOHC

OHOHCOHC

222108

223242108

23482108

585.103

445.72

331

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DETAILED DESIGN

Reactor

Assumptions:

Rate constant independent of Temperature

second order based onO-xylene

Oxygen

1

2

Effect of pressure drop on the flow rates is neglected

3

steady state

4

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DETAILED DESIGN

Reactor

Mole balance equations

Stoichiometry equation of each reactant component

Conversion profile with the weight of the catalyst

Temperature change with the weight of catalyst

POLYMATH 6.1 software

Catalyst weight

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DETAILED DESIGN

Conversion profile with the weight of the catalyst

W=8,725 kg

x=1

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DETAILED DESIGN

Temperature profile with the weight of the catalyst

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DETAILED DESIGN

Reactor size

where

steel type 316

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Reactor size

Reactor design specif ication value

Vpacking(m3) 8.9

Vreactor(m3) 11.125

Dtube(m) 1.68

L tube(m) 5.03Number of tubes 5,495

P (atm) 0.1

DETAILED DESIGN

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Distillation Column

DETAILED DESIGN

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DETAILED DESIGN

Distillation column

Trayed column Packed column

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Trayed Column

Selection of column internals are:

Liquid loads are high1

1 Multiple liquid phases including water

Types of tray:

Sieve tray.Bubble Cap tray.

Valve tray.

Others like :Dual flow tray , Baffle tray.

Selection the type of tray based on:

Liquid flow rate.

Pressure exerted by the gas.

DETAILED DESIGN

S G

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Calculating the minimum number of theoretical stages using the

Fenske equation

XLD : mole fraction of light key(MA) in distillate.

XLW : mole fraction of light key(MA) in bottom.

XHD : mole fraction of heavy key (PA)in distillate. Nmin= 7

)(/].[ .min avLHD

LD

HD

LD Logx

x

x

xLogN

5.0

... )( wLDLavL

Distillation column

DETAILED DESIGN

DETAILED DESIGN

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DETAILED DESIGN

Minimum Reflux Ratio

)1/(]).([

min ABAB

FB

DB

FA

DA

Fx

Dx

Fx

Dx

F

L

4.4min

L

76.0min

min

D

LR

14.195.0.

actR1.2 Rmin

Ractual

1.5 Rmin

Distillation column

DETAILED DESIGN

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To estimate the maximum allowable superficial vapor

velocity and the column area :

Distillation column

DETAILED DESIGN

DETAILED DESIGN

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Plate Spacing : 1.37 m

Vapor Velocity in the column: 0.0504 m/s

The maximum vapor rate: 0.052 0.06 m3/s

m1.2-1.15.

.4

v

wc

u

VD

Calculating Diameter

DETAILED DESIGN

Distillation column

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DETAILED DESIGN

Distillation Column

31*)1( spacingplateNHeightactual

trayactualtower P.NP

bar007.0Ptray

Calculating Height of tower:

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DETAILED DESIGN

Distillation Column

Tray Spacing (m) 1.37

Type of Trayssieve

Internals 17 tray

Column Diameter (m) 1.15 1.2

Column Height (m) 26

P (Tower) (bar) 0.119

MOC316 SS

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PROCESS ECONOMICS

Cost

Capital Cost Operating Cost

Capital Cost

1

2

12I

ICC

Where:

C1 purchased cost of the equipment in a past record

C2 purchased cost of the equipment for the current time

I1 chemical engineeringpurchase index in a past record

I2 chemical engineeringpurchase index for the current time

CAPCOST

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PROCESS ECONOMICS

Where:

C total purchased cost of the equipment in a current time Lang factor

Capital Cost

=3.1 for predominantly solids processing plant

= 4.7 for predominantly fluids processing plant

= 3.6 for a mixed fluids-solids processing plant

has different values depend on the type of process plant

2 CfC

PROCESS ECONOMICS

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PROCESS ECONOMICS

Capital Cost

Equipment TypePur chased Equipment

Cost($)

C-101 624,000

E-101 79,500

E-102 20,400

SC-101 159,835

E-104 3,960

E-105 & E-106 18,510

E-107 40,500P-101 14,500

R-101 202,500

T-101 61,700

Total Purchased Cost ($) 1,225,405

Capital Cost ($) 4,448,222

15% of the total cost

30% of the

distillation tower

cost

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PROCESS ECONOMICS

Operating Cost

Fixed costs Variable costs Maintenance (labour and

materials) Raw materials

Operating labour. Miscellaneous operating

materials.

Laboratory costs. Utilities (Services)

Supervision. Shipping and packaging

Plant overheads. Capital charges.

Rates (and any other local taxes).

Insurance.

Licence fees and royalty

payments.

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PROCESS ECONOMICS

Operating Cost

Cost of manufacture

COM: Cost of Manufacture.

CRM: Cost of Raw Material.CWT: Cost of Waste Treatment.

CUT: Cost of Utilities.

COL: Cost of Operating Labor.

FCI: Fixed Capital Investment.

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PROCESS ECONOMICS

Operating Cost

Cost of raw material

Raw materialPrice of each

kg* ($/kg)Amount (kg/hr) Pri ce ($/hr)

Air 1.78x10-4 25976.80 4.62

O-xylene 0.8122 2654.20 2152.05

CRM 17,003,223$/yr

OC SS CONO ICS

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PROCESS ECONOMICS

Operating Cost

Cost of utilities

CUT 920,275.75$/yr

Utility Electricity MP steam HP steam Cooling water

Each unit

Price0.06 Kw 0.01371 $/kg 0.01664 $/kg 0.0148 $/kg

Amount 1,074.167 Kw 2,320.86 kg/hr 522 kg/hr 795.4 kg/hr

Total Price

$/hr64.450 31.820 8.686 11.770

PROCESS ECONOMICS

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PROCESS ECONOMICS

Operating Cost

Cost of operating labour

PROCESS ECONOMICS

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PROCESS ECONOMICS

Operating Cost

Cost of waste treatment

waste water includes Maleic anhydride

treated using an activated sludge process

CWT 107.4 $/yr

PROCESS ECONOMICS

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PROCESS ECONOMICS

Operating Cost

cost of manufacture

PROCESS ECONOMICS

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PROCESS ECONOMICS

Feasibility Study

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SAFETY AND ENVIRONMENTAL ISSUES

HAZOP study

Hazard and Operability study (HAZOP)

a study conducted to prevent any damages or to overcome andrespond on any sudden changes.

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HAZOP study

Hazard and Operability study (HAZOP)

a study conducted to prevent any damages or to overcome andrespond on any sudden changes.

HAZOP outcome

Operating procedures for the equipments


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HAZOP study

Guide Word Definition Example

Deviations

Way in which the process conditions

may depart from their process

intent.

(less/More of: Flow

rate, pressure,

Temperature

CausesWhy, and how, the deviations could

occur.

Valves failure,

leaking, blockage

Consequences

The results that follow from the

occurrence of Deviations

Process failure,

reduced product flowrate

Action

Required

What Should be done to overcome

the Consequences

Installing Warning

instruments, closing

valves


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Reactor

Deviation Possible Causes Consequences Action required /Safeguards

No flow

Blockage in the

reactor inlet pipe.

Pressure build up in

reactor

Install pressure gage.

Shutdown if blockage doesnot clear itself

Rupture in the pipe

of the reactor.

Release of explosive

mixtures to

atmosphere

Regular checking of the

pipe.

Emergency shutdown.

Less F low Low feed rate. Process

inconvenience but no

hazard.

No action required

More F low High feed rate. Increased duty

downstream Install controller for feed.

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Reactor

Deviation Possible Causes Consequences

Action required

/Safeguards

More

TemperatureInadequate cooling.

Coolant (Molten

salt) temperature

rises.

Install temperatureindicators in reactor.

Increase molten salt

flow rate.

Lowtemperature

Low feedtemperature

More by-productsfrom reaction.

Install temperatureindicators in reactor.

More

pressure

Partial blockage of

reaction tubes.

Increased

pressure

downstream.

Install pressure gage.

Shutdown and clean

PROJECT MANAGEMENT

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PROJECT MANAGEMENT

CONCLUSION

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CONCLUSION

Missing information

to determine the

Detailed design.

No sufficient time to

complete each task.

Finding the actual

amount of PA needed

in UAE.

PhthalicAnhydride

Rawmaterialamount

Mass &EnergyBalance

Equipmentsizing

Cost

HAZOPstudy

Problem faced:

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DETAILED DESIGN

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DETAILED DESIGN

Heat exchanger

F obtained from charts

E-101

4 tube passes 2shell passes

E-102 , E-104

2 tube passes 1shell pass

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Compressor

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Pump

DETAILED DESIGN

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DETAILED DESIGN

Heat exchanger

condensate


where


DETAILED DESIGN

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DETAILED DESIGN

Heat exchangerOne phase


DETAILED DESIGN

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DETAILED DESIGN

Heat exchangervaporization


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Reactor

Component A:

Component B:

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Reactor

Component C:

Component D:

Component E:

Component F:

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Reactor

Conversion profile

Temperature change

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