Brian JR Geoffroy CHNG 3012 Part II PDF

The University of the West Indies
St. Augustine
Faculty of Engineering
Department of Chemical Engineering
CHNG 3012: Chemical Engineering Design Project

Part II:
Design of a Methyl Chloride Plant
Student: Brian Jr Brandon Geoffroy 812000719
Project Supervisor: Dr Sydney Thomas
Date Submitted: 17th April, 2015

Abstract
This report details the design of two major and two minor pieces of equipment, stemming from
the Chemical Engineering Design Project (Part I) report Design of a Methyl Chloride Plant. The
plant was designed to produce 45, 300 metric tons of methyl chloride per year. The plant aims at
primarily supplying the emerging Central and South American silicone production facilities. The
process involves the catalytic hydrochlorination of methanol with hydrochloric acid in the vapour
phase, using a gamma alumina catalyst, followed by purification, refrigeration, and storage.
The equipment designed are:
1) Absorber T-100 Sulphuric acid absorber with chemical reaction, absorbing dimethyl
ether (DME) and reacting with methanol (to form methyl bisulphate) from the gaseous inlet
stream. This was designed as an absorber with only physical absorption.
2) Heat exchanger E-107 Ethylene glycol cooler for cooling absorber T-100 top vapours.
3) Pump P-109 Ethylene glycol pump to heat exchanger E-107.
4) Tank V-117 Water sump tank for absorber T-100 bottoms dilution system.
For each piece of equipment, the report details design specifications from Chemical
Engineering Design Project (Part I), modifications and assumptions made, necessary schematic
drawings, design methodology, a specification sheet, difficulties encountered, basic control system
and instrumentation, and recommendations for improving the design. Calculations and design
considerations for each piece of equipment are appended.
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Dedicated to Akiel La Borde
(1993 2015)
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Contents
1. Introduction ............................................................................................................................. 1
2. Design of Pump P-109 ............................................................................................................ 4
2.1 Design Criteria ...................................................................................................................... 4
2.2 Modifications to the Original Design ................................................................................... 5
2.3 Assumptions.......................................................................................................................... 6
2.4 Layout ................................................................................................................................... 6
2.5 Methodology ......................................................................................................................... 7
2.6 Pump P-109 Specification Sheet ........................................................................................... 9
2.7 Difficulties Encountered ..................................................................................................... 10
2.8 Control System and Instrumentation .................................................................................. 10
2.9 Recommendations ............................................................................................................... 11
3. Design of Tank V-117 .............................................................................................................. 12
3.1 Design Criteria .................................................................................................................... 13
3.2 Modifications to the Original Design ................................................................................. 13
3.3 Assumptions........................................................................................................................ 14
3.4 Methodology ....................................................................................................................... 14
3.5 Tank V-117 Specification Sheet ......................................................................................... 16
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3.7 Tank V-117 Schematic Diagram ........................................................................................ 18
4. Design of Heat Exchanger E-107 ............................................................................................. 20
4.1 Design Criteria .................................................................................................................... 21
4.3 Assumptions........................................................................................................................ 22
4.4 Methodology ....................................................................................................................... 22
4.5 Heat Exchanger E-107 Specification Sheet ........................................................................ 24
4.7 Heat Exchanger E-107 Schematic Diagram ....................................................................... 27
5. Design of Absorber T-100 ........................................................................................................ 30
5.1 Design Criteria .................................................................................................................... 33
5.3 Assumptions........................................................................................................................ 34
5.4 Methodology ....................................................................................................................... 34
5.5 Absorber T-100 Specification Sheet ................................................................................... 37
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5.7 Absorber T-100 Schematic Diagram .................................................................................. 40
6. References ................................................................................................................................. 43
Nomenclature ................................................................................................................................ 44
Appendix A Pump P-109 Design Calculations .......................................................................... 47
Design Conditions ..................................................................................................................... 47
Pipe design ................................................................................................................................ 47
Total Suction Head ................................................................................................................... 50
Total Discharge Head ............................................................................................................... 51
Total System Head .................................................................................................................... 52
Available Net Positive Suction Head ........................................................................................ 52
Pump Type ................................................................................................................................ 53
Power Output of Pump.............................................................................................................. 54
Power Input to Pump ................................................................................................................ 54
Centrifugal Pump Specific Speed ............................................................................................. 55
Mechanical Design Specifications ............................................................................................ 55
Appendix B Tank V-117 Design Calculations .......................................................................... 57
Design Conditions ..................................................................................................................... 57
Design Capacity ........................................................................................................................ 57
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Tank Shell Dimensions ............................................................................................................. 58
Material of Construction ........................................................................................................... 58
Design of Shell Plates ............................................................................................................... 59
Design of Base Plates................................................................................................................ 59
Roof Design .............................................................................................................................. 60
Foundation ................................................................................................................................ 60
Accessories ............................................................................................................................... 60
Nozzles.................................................................................................................................. 60
Venting .................................................................................................................................. 61
Manhole ................................................................................................................................ 61
Ladder ................................................................................................................................... 61
Appendix C Heat Exchanger E-107 Design Calculations ......................................................... 62
Energy Balance and Design Conditions ................................................................................... 62
Heat Transfer Area .................................................................................................................... 63
Tube Design Specifications ...................................................................................................... 65
Number of Tubes ...................................................................................................................... 65
Tube Bundle and Shell Diameter .............................................................................................. 66
Tube-side Heat Transfer Coefficient ........................................................................................ 67
Shell-side Heat Transfer Coefficient ........................................................................................ 69
Overall Heat Transfer Coefficient ............................................................................................ 70
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Tube-side Pressure Drop ........................................................................................................... 72
Shell-side Pressure Drop ........................................................................................................... 73
Mechanical Design.................................................................................................................... 74
Shell Design .......................................................................................................................... 74
Tube-side Nozzles ................................................................................................................. 74
Shell-side Nozzles................................................................................................................. 75
Design of Baffles .................................................................................................................. 76
Insulation Specification ........................................................................................................ 76
Appendix D Absorber T-100 Design Calculations .................................................................... 77
Stream Specifications................................................................................................................ 77
Absorber Type .......................................................................................................................... 78
Number of Transfer Units (NOG) .............................................................................................. 79
Diameter of Column ................................................................................................................. 81
Height of Packing ..................................................................................................................... 83
Mechanical Design.................................................................................................................... 87
Design Conditions ................................................................................................................. 87
Material of Construction ....................................................................................................... 87
Shell Thickness ..................................................................................................................... 87
Column Head Design ............................................................................................................ 88
Weight Loads ............................................................................................................................ 88
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Weight of Shell ..................................................................................................................... 88
Weight of Packing................................................................................................................. 89
Weight of Accessories .......................................................................................................... 89
Total Weight of Column ....................................................................................................... 89
Internal Accessories .................................................................................................................. 90
Column Support ........................................................................................................................ 90
List of Tables
Table 1: Original design specifications........................................................................................... 4
Table 2: Original design specifications......................................................................................... 13
List of Figures
Figure 1: Block flow diagram of the process .................................................................................. 3
Figure 2: Pump P-109 system in the process flow diagram............................................................ 4
Figure 3: P-109 system estimated plant layout ............................................................................... 7
Figure 4: General controls and instrumentation for pump P-109 ................................................. 11
Figure 5: Tank V-117 system in the process flow diagram .......................................................... 12
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Figure 6: Tank V-117 plan (top) and front elevation (bottom) ..................................................... 18
Figure 7: General controls and instrumentation for tank V-117 ................................................... 19
Figure 8: Heat exchanger E-107 system in the process flow diagram .......................................... 20
Figure 9: Heat exchanger E-107 cross-sectional view (front elevation)....................................... 27
Figure 10: Heat exchanger E-107 cross-sectional view (side view) ............................................. 28
Figure 11: General controls and instrumentation for E-107 ......................................................... 29
Figure 12: Absorber T-100 system in the process flow diagram .................................................. 32
Figure 13: Absorber T-100 cross-sectional view (front elevation) ............................................... 40
Figure 14: General controls and instrumentation for T-100 ......................................................... 41
Figure 15: Pump Selection Guide (Sinnott 2005) ......................................................................... 53
Figure 16: Centrifugal Pump Efficiency Graph (Sinnott 2005).................................................... 54
Figure 17: Centrifugal Pump Characteristic Curve (Green and Perry 2008) ................................ 56
Figure 18: Heat exchanger simulation flow sheet on Aspen HYSYS v8.6 .................................. 62
Figure 19: Temperature correction factor for one shell pass, two tube passes (Sinnott 2005) ..... 64
Figure 20: Shell bundle clearance (Sinnott 2005)......................................................................... 67
Figure 21: Tube-side heat transfer factor (Sinnott 2005).............................................................. 68
Figure 22: Shell-side heat transfer factor (Sinnott 2005).............................................................. 69
Figure 23: Tube-side friction factor (Sinnott 2005) ...................................................................... 72
Figure 24: Shell-side friction factor (Sinnott 2005) ...................................................................... 73
Figure 25: Ceramic Intalox saddle (Sinnott 2005) ........................................................................ 78
Figure 26: Number of overall gas-phase transfer units as a function of y1/y2 (Sinnott 2005) ...... 80
Figure 27: Generalised pressure drop correlation (Sinnott 2005) ................................................. 82
Figure 28: Percentage flooding correction factor graph (Sinnott 2005) ....................................... 84
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Figure 29: Factor for HG for 1 1/2 inch Berl saddles (Sinnott 2005) ............................................ 85
Figure 30: Factor for HL for 1 1/2 inch Berl saddles (Sinnott 2005) ............................................ 85
Figure 31: Skirt support welded flush with the shell (Sinnott 2005) ............................................ 91
Figure 32: Base ring: Double plate with gusset (Sinnott 2005) .................................................... 91
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1. Introduction
The Chemical Engineering Design Project (Part I) report detailed the design of a methyl chloride
production facility. Methyl chloride (CH3Cl) is a toxic, colorless, and extremely flammable gas
under room conditions. Previous use of methyl chloride as refrigerant R-40 has become obsolete
as a result of environmental and safety concerns. Its major use in recent years has been as an
intermediate in the manufacture of silicone polymers. Since silicone polymers have a variety of
vital uses in automotive, industrial coating, electronics, and lubricant manufacture and many
other industries methyl chloride is considered to be of significant importance.
The plant was designed to produce 45, 300 metric tons of methyl chloride per year, aiming
to primarily supply the emerging Central and South American silicone production facilities. A
brief process description is given below, followed by a rudimentary block flow diagram.
Methanol and hydrochloric acid (HCl) feeds are heated to their bubble points and mixed.
The mixture is sent to the feed preheater, which vaporises the feed. The stream is then compressed
to approximately 5 bar and enters the packed-bed reactor in an HCl-methanol ratio of
approximately 1:1.05.
A gaseous mixture of hydrogen chloride and methanol enters the reactor at approximately
280oC and flows through the catalyst-packed tubes before exiting the reactor at approximately
320oC. Here, two reactions take place:
1. Formation of methyl chloride and water (desired reaction)
2. Formation of dimethyl ether and water (undesired reaction)
The gaseous reactor output (methyl chloride, dimethyl ether DME, water, methanol, and
HCl) enters the quench system where the majority of the methanol and approximately all of the
1
water (with dissolved HCl and DME) is removed as liquid. Methanol, DME and some HCl is
flashed from this liquid stream, and the dilute HCl is recirculated to the quench system as a
quenching agent.
The crude methyl chloride (methyl chloride and DME, with small amounts of HCl and
methanol) enters a sulphuric acid absorption tower (Absorber T-100, designed in this report). In
the tower, 96% H2SO4 (by weight) is used to:
Absorb DME
React with methanol to produce methyl bisulphate
The liquid output enters a sulphuric acid regeneration system, where the dissolved
compounds are converted to methanol and sent to methanol storage. The purified sulphuric acid is
now recirculated to the tower.
The crude methyl chloride vapours (methyl chloride, with small amounts of HCl and DME)
enters a cooler (Heat exchanger E-107, designed in this report) and sent to an intermediate tank,
where small amounts of entrained liquids are removed. The crude vapour is now sent to a high-
pressure, extractive distillation column. Water is used as an extractant, allowing methyl chloride
vapours to be produced at the top at greater than 99% purity. This is sent to refrigeration and
storage, ready for shipping. DME and remaining methanol are collected as liquid bottoms and sent
to temporary waste storage.
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Figure 1: Block flow diagram of the process
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2. Design of Pump P-109
The objective of this section is to design pump P-109. Pump P-109 supplies heat exchanger E-107
with low-temperature ethylene glycol for the condensation of absorber T-100 top vapours (stream
49). The ethylene glycol is then returned to the sump tank V-111 after being cooled by cooler E-
108. A snapshot of this segment of the process flow diagram is shown below.
Figure 2: Pump P-109 system in the process flow diagram
2.1 Design Criteria
The following specifications are taken directly from the Design Project Part I. Modifications to
the design are presented in the following subsection.
Table 1: Original design specifications
Initial Specifications Inlet Outlet

Composition Pure Ethylene Glycol
Temperature (C) 5 5
4
Temperature (K) 278.15 278.15
Pressure (bar) 1.1 1.1
Pressure (atm) 1.09 1.09
Molar Flow (kmol/h) 122.16
Mass Flow (kg/h) 7582.33
Mass Flow (kg/s) 2.11
Volumetric flow (m3/h) 6.78
Volumetric flow (m3/s) 1.88 10-3
Volumetric flow (gal/min) 29.86
Viscosity (Pa.s) 2.82 10-2
Density (kg/m3) 1125.32
The values of viscosity and density were taken from a simulation of the inlet stream using
Aspen HYSYS v8.6.
2.2 Modifications to the Original Design
The original design was modified in the following ways:
1. In error, both the inlet and outlet streams of P-109 are labelled as stream 54. In this report,
the outlet stream of P-109 is labelled as stream 54a.
2. For the purposes of design, the following overdesign modifications were made:
a. 10% increased temperature
b. 20% increased pressure
c. 20% increased flow rate
3. P-109 outlet pressure is assigned 0.5 atm above the inlet pressure.
4. A valve in stream 54 is added (at tank V-111 outlet). This is a necessary safety and control
measure.
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5. Dimensions for this section of the plant layout are estimated.
2.3 Assumptions
The following assumptions were made for this design.
1. The estimated dimensions for the layout are valid.
2. The pump is not required to drive the fluid beyond the heat exchanger outlet.
3. The fluid will be returned to the sump tank from the heat exchanger outlet by the force of
gravity.
4. Subsequent design of other equipment in the system would have negligible effects on the
pump design.
5. Unsteady state operation will have negligible effects on the pump design.
6. Heat losses are negligible.
2.4 Layout
The following diagram shows the estimated plant layout for this design.
6
10 m
5m E-107
51
4m
54a
1m 54
V-111
P-109
Figure 3: P-109 system estimated plant layout
2.5 Methodology
The design procedure was as follows. Calculations and other design considerations are presented
in Appendix A. Calculations were done using Microsoft Excel 2013 (CD attached). Aspen HYSYS
v8.6 was also employed. Drawings were done using Microsoft Visio 2013.
1. The design conditions were calculated from the modifications made.
2. The pipe for both suction and discharge was designed as follows:
a. Calculated optimum pipe diameter.
b. Calculated required diameter using the optimum velocity method.
c. Selected the larger of the two calculated values of diameter for pipe selection.
d. Using this diameter, the next largest pipe size was selected.
e. The minimum wall thickness was calculated to confirm that the pipe can be used.
3. Calculated total suction head.
4. Calculated total discharge head.
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5. Calculated total system head.
6. Calculated the available net positive suction head, (NPSH)A, at pump suction to confirm
that cavitation will be avoided.
7. The type of pump was selected using a pump selection guide by Sinnott (2005), acquiring
a. Type of pump (centrifugal or reciprocating)
b. Pump rpm
c. Number of stages
8. Calculated power output of pump.
9. Calculated power input to pump.
a. Estimated pump efficiency using a centrifugal pump efficiency graph by Sinnott
(2005).
b. Calculated power input in kW.
c. Calculated pump energy requirements in kWh,
i. Per day,
ii. Per 28-day month, and
iii. Per 333-day year (from Design Project Part I Economic Analysis).
10. Calculated centrifugal pump specific speed (dimensionless and in rpm).
11. Mechanical design specifications were made: Impeller type, mechanical seals, casing.
The results of these calculations and design considerations are presented in the following
specification sheet.
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2.6 Pump P-109 Specification Sheet
Equipment Pump P-109

Plant Section Absorber T-100 top vapour condensation section
Function Supplies heat exchanger E-107 with cooling fluid
Operation Continuous
Fluid Ethylene Glycol (Pure)
Type Centrifugal
No. of stages 1
Impeller type 1 inch radial impeller
Impeller speed 3500 rpm
Specific speed 4.51 10-2
(dimensionless)
Specific speed 780.81 rpm
Efficiency 66%
Power input 0.93 kW
Energy Per day 22.43 kWh
requirements Per 28-day month 628.00 kWh
Per 333-day year 7468.75 kWh
Piping 1 inch Schedule 40 Carbon Steel (1.61 ID, 1.9 OD, 0.145 Wall)
Density 1125.32 kg/m3
Viscosity 2.82 10-2 N.s/m2
Mass flow rate Normal 7582.33 (2.11) kg/h (kg/s)
Design 9098.80 (2.53) kg/h (kg/s)
Volumetric Normal 6.78 (29.86) m3/h (gpm)
flow rate Design 8.14 (35.83) m3/h (gpm)
Operating Normal 5.0 C
temperature Design 5.5 C
Suction head 8.29 m
Discharge head 33.01 m
9
System head 24.72 m
NPSHA 8.29 m
Casing Volute (carbon steel)
Seal Mechanical (carbon steel)
2.7 Difficulties Encountered

The following challenges were encountered throughout this design.
1. Design of the piping required a plant layout. However, the plant layout has not been
designed, and the plant is not in operation. Hence, the layout dimensions had to be
estimated.
2. It was assumed that subsequent design of connecting equipment would not affect the pump
design. Steady-state operation was also assumed. Difficulty lies in validating these
assumptions, as the plant is not in operation. This was addressed by using over-design
factors.
2.8 Control System and Instrumentation
Certain general control and instrumentation mechanisms are suggested below.
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Figure 4: General controls and instrumentation for pump P-109
A flow meter connected to stream 51 will be used to monitor the flow from the pump to
the heat exchanger.
The temperature of the outlet process stream of the heat exchanger (stream 50) will be
controlled by the temperature controller. The actuator will be attached to valve VLV-111,
controlling the flow of coolant. When the temperature is below the set point, the valve will close.
When the temperature is above the set point, the valve will open.
2.9 Recommendations
The following recommendations can be used for the improvement of this design.
1. Upon design of connecting equipment, it is recommended to re-evaluate this design,
taking into account factors such as dimension changes and friction losses as a result of
these equipment.
11
2. The controls and instrumentation suggested are only preliminary, and the system must
be designed by a specialist, such as a controls engineer.
3. Based on the cost of electrical utilities to the pump, the cost of pump operation can be
estimated on a daily, monthly, and yearly basis.
4. A Hazard and Operability (HAZOP) study and a Layer of Protection Analysis (LOPA)
should be done on the pump to minimise accident risk.
3. Design of Tank V-117

The objective of this section is to design tank V-117. Tank V-117 is the water sump tank for the
dilution system. It receives water from the condensation of excess steam from the acid
concentrator. This water is then reused for the dilution of absorber T-100 bottoms. If more water
is necessary, it receives this from a water utility via stream 84 (shown below). A snapshot of this
segment of the process flow diagram is shown below.
Figure 5: Tank V-117 system in the process flow diagram
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3.1 Design Criteria
Initial Specifications Value

Composition Pure Water
Temperature (C) 35
Temperature (K) 308
Pressure (bar) 1
Pressure (atm) 0.99
Molar Flow (kmol/h) 10.02
Mass Flow (kg/h) 180.6
Viscosity (Pa.s) 7.18 10-4
Density (kg/m3) 993.7
The values of viscosity and density were taken from a simulation of the tank contents using
Aspen HYSYS v8.6.
1. The calculation of required tank volume in the original report was found to be erroneous,
yielding a volumetric flow rate of 1.07 m3/h. Hence, this flow rate was recalculated.
2. The original hold-up time of 24 h was respecified to 10 days, as this is a more appropriate
time, considering the purpose of the tank.
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3. Considering points (1) and (2), the tank capacity was recalculated.
4. Valve V-117a at the tank outlet is added. This will act as the new level control actuator. It
was decided best to place the actuator at the tank outlet, rather than inlet.
3.3 Assumptions
tank design.
2. Unsteady state operation will have negligible effects on the tank design.
3. Heat losses are negligible.
3.4 Methodology
in Appendix B. Calculations were done using Microsoft Excel 2013 (CD attached). Aspen HYSYS
1. The design conditions were calculated.
2. Calculated design capacity.
3. Obtained tank shell dimensions.
a. Decided type of tank (vertical, cylindrical tank).
b. Selected nominal capacity, obtaining nominal height and diameter.
c. Calculated liquid height and freeboard.
4. Determined material of construction and corrosion protection method.
5. Designed shell plates.
a. Determined corrosion allowance.

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b. Calculated minimum shell thickness.
c. Determined shell plate arrangement and welding.
6. Designed base plates.
a. Determined base plate arrangement and welding.
b. Determined base plate thickness.
7. Designed roof.
a. Selected roof type.
b. Calculated radius of curvature.
c. Designed roof plates, arrangement, and welding.
8. Specified tank foundation.
9. Designed tank accessories.
a. Nozzles
b. Venting
c. Manhole
d. Ladder
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3.5 Tank V-117 Specification Sheet
Equipment Tank V-117

Plant Section Acid concentration part of the acid regeneration system
Function Water sump tank for dilution system
Fluid Water (Pure)
Type Vertical, cylindrical
Material High grade A-36 galvanised carbon steel plates
Water load 47678.4 kg
Density 993.7 kg/m3
Viscosity 7.18 10-4 N.s/m2
Internal 1 atm
Operating
Pressure
Mass flow rate 180.6 kg/h
Volumetric 0.18 m3/h
flow rate
Hold-up time 10 days
Capacity Normal 43.62 m3
Design 47.98 m3
Operating Normal 35 C
temperature Design 45 C
Vessel volume 50 m3
Shell diameter 4 m
Shell height 4 m
Liquid height 3.82 m
Shell plate 5 mm
thickness
Shell design All courses truly vertical. Plates welded together; seams shall be butt joints.
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Base plate 8 mm
thickness
Base design Rectangular and sketch plates; lapped and welded with minimum lap 60 mm.
Roof plate 7 mm
thickness
Roof design Fixed, self-supporting dome roof. 6 m radius of curvature. Plates lapped and
welded together with minimum lap of 25 mm.
Foundation Square concrete slab; concrete of minimum compressive strength 3000 psi.
Sand cushion at least 1 inch thick. Edge of slab at least 3 inches from base of
tank, neatly rounded for drainage away from tank. Concrete below ground at
least 12 inches deep.
Manhole 500 mm diameter. Tight-gasket, bolted cover.
Ladder Vertical, welded to tank, close to manhole. Safety cage 4 m above base.
Nozzles inch Schedule 40 Carbon Steel (0.364 ID, 0.54 OD, 0.088 Wall)
1. The flow through the tank was very low (0.18 m3/h). With a low hold-up time, this would
have resulted in an unusually small tank. The hold-up time was estimated to give a small
tank that was still reasonably large.
2. It was also difficult estimating the tank hold-up time. As mentioned above, this was
addressed by using a hold-up time to give a desirable size.
3. It was assumed that subsequent design of connecting equipment would not affect the tank
design. Steady-state operation was also assumed. Difficulty lies in validating these
assumptions, as the plant is not in operation. This was addressed by using over-design
factors.
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3.7 Tank V-117 Schematic Diagram
Figure 6: Tank V-117 plan (top) and front elevation (bottom)
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Figure 7: General controls and instrumentation for tank V-117
The tank level will be controlled by the level controller. The actuator will be attached to
valve VLV-117a. When the level is above the set point, the valve will open. When the level is
below the set point, the valve will close. The water level will be monitored with the level meter.
3.9 Recommendations
1. The main standard used, BS 2654 (BSI 1989) was superseded by BS EN 14015:2004
in 2005. If necessary, it is recommended to obtain this improved standard, and adjust
calculations and specifications to suit this standard.
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2. Upon more detailed design of the connecting equipment, it is recommended to re-
evaluate this design.
should be done on the tank to minimise accident risk.
4. Design of Heat Exchanger E-107

The objective of this section is to design heat exchanger E-107. Heat exchanger E-107 uses low-
temperature ethylene glycol to cool absorber T-100 top vapours (stream 49). A snapshot of this
segment of the process flow diagram is shown below.
Figure 8: Heat exchanger E-107 system in the process flow diagram
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4.1 Design Criteria
Initial Shell Side Tube Side

Specifications IN OUT IN OUT
Stream number 49 50 51 52
Fluid Process Stream Ethylene Glycol
Temperature (C) 43.5 15.2 5.0 13.0
Pressure (bar) 1.4 1.3 1.1 1.0
Molar Flow (kmol/h) 125.20 122.20
Mass Flow (kg/h) 6317.60 7573.90
Process Stream composition Methyl Chloride: 99.5%
Dimethyl Ether (DME): 0.4%
Methanol: 0.1%
1. For accuracy, the energy balance across the heat exchanger was recalculated by simulating
the heat exchanger in Aspen HYSYS v8.6. The energy balance is used to calculate the
required flow rate of ethylene glycol.
2. The original design stated that E-107 is a condenser, condensing methanol and DME. These
values are considered small enough to be neglected in this design. Hence, the design will
not account for condensation (see Assumptions).
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4.3 Assumptions
1. The process stream is assumed to be 100% methyl chloride, a logical approximation for
this design.
2. The cooling fluid is pure ethylene glycol.
3. Negligible condensation will take place.
heat exchanger design.
5. Unsteady state operation will have negligible effects on the heat exchanger design.
4.4 Methodology
in Appendix C. Calculations were done using Microsoft Excel 2013 (CD attached). Aspen HYSYS
1. Simulated heat exchanger in Aspen HYSYS v8.6 to carry out energy balance. The
simulation file is included in the attached CD.
a. Obtained ethylene glycol flow rate.
b. Obtained other values such as heat transferred and properties of the fluids.
2. Calculated heat transfer area.
a. Calculated log-mean temperature difference.
b. Calculated temperature correction factor.
c. Estimated true mean temperature difference.
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d. Estimated overall heat transfer coefficient (initial estimate was recommended by
Aspen HYSYS v8.6).
e. Calculated heat transfer area.
3. Specified tube dimensions.
4. Calculated number of tubes.
a. Specified number of passes.
b. Calculated number of tubes per pass.
5. Calculated tube bundle and shell diameters.
6. Calculated tube-side heat transfer coefficient.
7. Calculated shell-side heat transfer coefficient.
8. Calculated overall heat transfer coefficient.
9. Repeated steps (2) to (8) using the calculated overall heat transfer coefficient.
10. Calculated tube-side pressure drop.
11. Calculated shell-side pressure drop.
12. Mechanical design calculations and specifications were made.
a. Sized the shell as a standard steel pipe.
b. Designed the tube-side and shell-side nozzles.
c. Calculated number of baffles and baffle diameter.
d. Specified insulation type.
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4.5 Heat Exchanger E-107 Specification Sheet
Equipment Heat exchanger E-107

Plant Section Absorber T-100 top vapour condensation section
Function Cooler for crude methyl chloride vapours exiting T-100
Description Shell and tube
Counter-current flow
Split-ring, floating head
One shell pass
2 tube passes
Equilateral triangular pitch arrangement
Segmented baffles
Number of tubes 490
Number of tubes per pass 245
Design conditions SHELL SIDE TUBE SIDE
IN OUT IN OUT
Stream 49 50 51 52
Fluid Methyl Chloride Ethylene Glycol
kg/h 6342.28 7788.37
Flow rate kmol/h 125.62 125.48
m3/h 6.93 7.01
Temperature C 43.5 15.2 5.0 13.0
Pressure bar 1.4 1.1
Density kg/m3 2.68 2.74 1125.32 1119.54
Viscosity Pa.s 1.09E-05 9.92E-06 2.82E-02 2.08E-02
Specific heat kJ/kgK 0.87 0.84 2.39 2.47
Thermal conductivity W/mK 1.28E-02 1.12E-02 0.25 0.25
Latent heat of vaporisation kJ/kg 422.56 424.33 807.56 812.15
Heat transferred (Q) kJ/h 153038.05
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Pressure drop bar 0.21 0.44
Heat transfer coefficient W/m2K 22.47 318.50
Overall heat transfer coefficient W/m2K 20.44
Tube specifications Stainless steel, OD 16 mm, ID 12.8 mm, thickness 1.6 mm,
pitch 20 mm, length 5 m
Tube bundle diameter m 0.50
Baffle spacing m 0.11
Baffle diameter m 0.56
Number of baffles 45
Shell design specifications 24 inch Schedule 40 Carbon Steel pipe (OD 24 inch, ID
22.624 inch, thickness 0.688 inch)
Tube-side nozzles 1 inch Schedule 40 Carbon Steel pipe (OD 1.9 inch, ID
Shell-side nozzles inch Schedule 40 Carbon Steel pipe (OD 0.84 inch, ID
Insulation Cotton with metal foil finish

1. It was noticed that the amount of material condensing would have been incredibly small,
and design for condensation would have consumed time to achieve unnecessarily small
differences. This was addressed by assuming negligible condensation. The process fluid
was still allowed to flow through the shell, to account for potential condensation.
2. It was difficult estimating an overall heat transfer coefficient for initial calculations. A
value suggested by the simulation led to a 51.3% error when the value was actually
calculated. Hence, an iterative procedure was needed to obtain a value with a sufficiently
small error.
25
3. Mechanical design instructions were difficult to obtain, especially for designing the shell.
Green and Perry (2008) suggested designing the shell as a standard pipe.
4. Insulation was considered difficult to design in detail, and was only specified as cotton
with a metal foil finish, upon consulting Green and Perry (2008).
5. It was assumed that subsequent design of connecting equipment would not affect the heat
exchanger design. Steady-state operation was also assumed. Difficulty lies in validating
these assumptions, as the plant is not in operation.
26
4.7 Heat Exchanger E-107 Schematic Diagram
Clearance 65 mm
Shell-side inlet
Tube length 5 m ID 15.8 mm
16 mm OD
Shell OD 0.61 m
Tube-side inlet Shell-side outlet Tube-side outlet

ID 40.9 mm ID 15.8 mm Baffle spacing 110 mm ID 40.9 mm
Figure 9: Heat exchanger E-107 cross-sectional view (front elevation)
27
574.6 mm
20 mm
17.5 mm
12.8 mm
Figure 10: Heat exchanger E-107 cross-sectional view (side view)
28
Figure 11: General controls and instrumentation for E-107
The temperature of each stream (process streams 49 and 50, and coolant streams 51 and
52) will be monitored using the thermometers shown (symbol: T).
The temperature of the outlet process stream of the heat exchanger (stream 50) will be
controlled by the temperature controller. The actuator will be attached to valve VLV-111,
controlling the flow of coolant. When the temperature is below the set point, the valve will close.
When the temperature is above the set point, the valve will open.
29
4.9 Recommendations
1. The mechanical design of the heat exchanger can be done in greater detail using 9th
Edition TEMA Standards or BSIs BS EN 3274:2010 standards.
2. More detailed design is recommended for the insulation.
3. Upon more detailed design of the connecting equipment, it is recommended to re-
should be done on the heat exchanger to minimise accident risk.
5. Design of Absorber T-100

The objective of this section is to design absorption tower T-100. T-100 is an absorber with a
chemical reaction taking place, commonly called a reactive absorber.
After the vaporised feed reacts in the reactor, the majority of the water vapour produced is
removed via the quench system. This gaseous stream is now sent to absorber T-100. T-100 uses
concentrated sulphuric acid to:
Absorb DME
React with methanol to produce methyl bisulphate
Sulphuric acid enters the column at a concentration of 90% by weight and leaves at 75%,
where its DME absorption capacity is exhausted.
30
The reaction between methanol and sulphuric acid is as follows:
CH3OH + H2SO4 (CH3)HSO4 + H2O
Methyl bisulphate also called methyl hydrogen sulphate and methyl sulphuric acid is a
mono-methyl ester of sulphuric acid, and is a liquid under the process conditions. Hence, it leaves
at the bottom of the column.
A snapshot of this segment of the process flow diagram is shown below. The crude methyl
chloride vapours enter via stream 48, and the sulphuric acid enters via stream 95. The top vapours
(stream 49) are carried further along in the purification process, while the bottoms liquid (stream
59) goes to the acid regeneration system. The regenerated acid will then be returned to the column
via stream 95.
31
Figure 12: Absorber T-100 system in the process flow diagram
32
5.1 Design Criteria
Liquid in Liquid out Gas in Gas out

Streams
95 59 48 49
Methanol (mol %) 0 0 1.5 0.1
Water (mol %) 37.7 41.6 0 0
Methyl Chloride (mol %) 0 0 97.8 99.5
Dimethyl Ether (mol %) 0 1.5 0.6 0.4
Sulphuric Acid (mol %) 62.3 49.7 0 0
Methyl Bisulphate (mol %) 0 7.2 0 0
Temperature (C) 85 37 50.4 43.5
Pressure (bar) 1.1 1.5 1.1 1.4
Molar flow (kmol/h) 10 11 127.4 125.2
Mass flow (kg/h) 124.6 722.3 6391.8 6317.6
1. The absorber will not be designed to accommodate the chemical reaction between
sulphuric acid and methanol. Instead, it will be designed to physically absorb both DME
and methanol (see Assumptions). This simplifies the design procedure. Modelling reactive
33
absorption is complex, and limited data is available for modelling this particular reaction
in an absorber. That and time constraints make the design difficult to accomplish.
2. The original liquid flow rate was found to be unusually small, resulting in challenges in the
calculations. It was respecified to 4000 kg/h. This is explained in the Difficulties
Encountered, and Appendix D Diameter of Column calculation.
5.3 Assumptions
1. For the design, it is assumed that the sulphuric acid will not react with methanol. Instead,
it will absorb both DME and methanol normally. This assumption is indeed valid, because
methanol can instead form hydrogen bonds with the acid, rather than reacting with it.
Hydrogen bonding in sulphuric acid-methanol-water systems has been studied in detail by
Rozenberg et al. (2015) and published in the Journal of Physical Chemistry A.
Additionally, due to the efficiency of the reactor and the quench system, only a small
amount of compounds are absorbed, so accuracy is still maintained.
absorber design.
3. Unsteady state operation will have negligible effects on the absorber design.
5.4 Methodology
in Appendix D. Calculations were done using Microsoft Excel 2013 (CD attached). Aspen HYSYS
1. The absorber was specified as a packed bed column.

34
2. Packing specifications were made.
a. Selected type of packing.
b. Selected size of packing.
3. Calculated number of transfer units.
4. Calculated column diameter.
a. Specified pressure drop per unit height of packing.
b. Used a generalised pressure drop correlation to calculate gas mass flow rate per unit
column cross-sectional area.
c. Using total gas mass flow rate, calculated cross-sectional area of column.
d. Calculated column diameter.
e. Column diameter was rounded up, and cross-sectional area was recalculated.
5. Used Cornells method to estimate height of an overall gas-phase transfer unit.
a. Guessed a value for height of packing.
b. Calculated height of a liquid film transfer unit.
c. Calculated height of a gas film transfer unit.
d. Calculated height of an overall gas-phase transfer unit.
6. Found the height of packing.
a. Calculated height of packing using number of transfer units and the height of an
overall gas-phase transfer unit.
b. When the calculated height of packing was close to the guessed height of packing
from Cornells method, this value was selected as the height of packing.
7. Mechanical design was done.
a. Column shape was specified cylindrical with torispherical head.
35
b. Design temperature and pressure were calculated.
c. Material of construction was specified.
d. Shell thickness was calculated.
e. Column head was designed.
8. Weight loads were calculated.
a. Calculated weight of shell.
b. Calculated weight of packing.
c. Calculated weight of accessories.
d. Found total weight of column.
9. Specified internal accessories.
a. Packing support.
b. Liquid distributor.
c. Liquid redistribution considerations.
d. Hold-down plate.
10. Made specifications for column support.
a. Specified straight cylindrical skirt support and welding arrangement.
b. Described base ring design.
c. Made specifications for anchor bolts.
36
5.5 Absorber T-100 Specification Sheet
Equipment Absorber T-100

Plant Section Absorption section
Function Uses concentrated sulphuric acid to remove methanol and
DME from the quench system outlet process stream.
Description Packed bed absorber
Cylindrical with torispherical head
Packing Random packing
Ceramic Intalox saddles
Size: 2 inch (51 mm)
Bulk density: 609 kg/m3
Surface area: 108 m2/m3
Volume required: 4.71 m3
Design conditions LIQUID GAS
IN OUT IN OUT
Stream 95 59 48 49
kg/h 4000 4069 6391.8 6317.6
Flow rate
kmol/h 58.91 60.95 127.4 125.2
Methanol mol % 0 2.93 1.5 0.1
Water mol % 37.7 36.43 0 0
Methyl Chloride mol % 0 0 97.8 99.5
Dimethyl Ether mol % 0 0.42 0.6 0.4
Sulphuric Acid mol % 62.3 60.22 0 0
Stream temperature C 85 37 50.4 43.5
Stream pressure bar 1.1 1.1 1.1 1.1
Density kg/m3 1667 1639 2.079 2.108
Viscosity Pa.s 9.18 10-3 1.12 10-2 1.10 10-5 1.08 10-5
Diameter of column m 1.0
37
Column cross-sectional area m2 0.79
Percentage flooding % 35.3
Height of packing m 6
Design temperature atm 1.1
Design pressure C 93.5
Material of construction Type 304 Stainless Steel
Shell thickness mm 7
Torispherical head thickness mm 4.7
Head crown radius m 1.0
Head knuckle radius m 0.06
Weight of shell kN 13.24
Weight of packing kN 28.15
Weight of accessories kN 2.16
Total weight of column kN 44 (rounded up)
Internal accessories Packing support: Wide-spaced grids
Liquid distributor: Central pipe with spray nozzle
Hold down plate required
No liquid redistributor necessary
Column support Straight cylindrical skirt support, welded flush with the shell.
Base ring: Double plate with gusset
Anchor bolts specifications:
1. Minimum bolt diameter 25 mm (1 in.).
2. No less than 8 bolts.
3. Use bolts in multiples of 4.
4. Bolt pitch should not be less than 600 mm (2 feet).
38
1. The original design of a reactive absorber is the design of a reactor, as opposed to an
absorber. Time constraints and complexity made this difficult to accomplish. This was
taken care of by designing for only physical absorption, whilst maintaining accuracy. The
specifications of the tops product of the absorber were maintained.
2. The liquid inlet flow rate was found to be unusually small (124.6 kg/h). It was not possible
to estimate the column diameter using the column liquid-vapour factor method (see
Appendix D Diameter of Column). This was addressed by increasing the liquid flow rate
to a more suitable value (4000 kg/h).
3. Cornells method was used to estimate the height of an overall gas-phase transfer unit.
Equations and figures were only given for Berl saddles the design uses Intalox saddles.
However, the literature stated that, though the mass-transfer efficiency of Intalox saddles
would be higher than that of Berl saddles, the method could still be used to make
conservative estimates for Intalox saddles. (Sinnott 2005)
4. It was assumed that subsequent design of connecting equipment would not affect the
absorber design. Steady-state operation was also assumed. Difficulty lies in validating
these assumptions, as the plant is not in operation. This was addressed by using over-design
factors and rounding up certain figures
39
5.7 Absorber T-100 Schematic Diagram
Crown R 1 m
Gas outlet Knuckle R 0.06 m
Liquid inlet
Liquid distributor
(Spray nozzle)
Hold down plate
Packing height 6 m
Packing (4.71 m3 2" ceramic

Intalox saddles)
Shell diameter 1 m
Gas inlet
Cylindrical skirt
Liquid outlet Packing support grids
Base ring
Figure 13: Absorber T-100 cross-sectional view (front elevation)
40
49
Gas Analyser
PC
VLV-110 T-100
95
48
LC
59
VLV-112
Figure 14: General controls and instrumentation for T-100
A gas analyser will monitor the composition of the tops product stream (stream 49).
The column pressure will be controlled by the pressure controller. The actuator will be
attached to valve VLV-110, controlling the flow of feed vapour. When the pressure is below the
set point, the valve will open. When the pressure is above the set point, the valve will close.
The height of liquid in the column will be controlled by the level controller. The actuator
will be attached to valve VLV-112, controlling the outlet flow of liquid. When the column is above
the allowed flooding set point, the valve will open. When the liquid level is below the set point,
the valve will close.
41
5.9 Recommendations
1. It is recommended to repeat this design in its original form as an absorber with
chemical reaction taking place.
2. Heat effects should be taken into consideration.
3. An attempt should be made to simulate this absorber in Aspen HYSYS or similar
simulation software, such as Aspen Plus or CHEMCAD. The absorber can also be
modelled with mathematical modelling software like MATLAB.
4. Upon more detailed design of the surrounding equipment, it is recommended to re-
should be done on the absorber to minimise accident risk.
42
6. References
AK Steel. 2007. 304/304L Stainless Steel Data Sheet. Accessed April 14th, 2015.
http://www.aksteel.com/pdf/markets_products/stainless/austenitic/304_304l_data_sheet.p
df
BSI (British Standards Institution). 1989. BS 2654:1989 Specification for Manufacture of vertical
steel welded non-refrigerated storage tanks with butt-welded shells for the petroleum
industry. London: BSI.
Central Valley Tank of California, Inc. (CVT). 2015. Above Ground and Underground Carbon
Steel Tanks Fabricated for your needs. Accessed March 14, 2015.
http://www.centralvalleytank.com/carbon-steel-tanks.html
CST Industries, Inc. (CST). 2015. Vulcan Tank. Accessed March 14, 2015.
http://www.cstindustries.com/products/galvanized-storage-tanks/
FM Approvals. 2011. Approval Standards for Steel Tanks for Fire Protection. MA: FM Approvals
Green, Don W., and Robert H. Perry. 2008. Perry's Chemical Engineers' Handbook. 8th ed. NY:
McGraw-Hill.
Rosenberg, Mark, Aharon Lowenschuss, and Claus J. Nielsen. 2015. Hydrogen Bonding in the
Sulfuric Acid-Methanol-Water System: A Matrix Isolation and Computational Study.
Journal of Physical Chemistry A 119 (11):2271-2280
Scheiman, A. S. 2963. Short cuts to anchor bolting and base ring sizing. Hyd. Proc. And Pet.
Ref. 42:130.
Sinnott, R. K. 2005. Coulson and Richardsons Chemical Engineering, Volume 6: Chemical

Engineering Design. 4th ed. Oxford: Elsevier.
Seader, J. D., Earnest J. Henley, and D. Keith Roper. 2010. Separation Process Principles:
Chemical and Biochemical Operations. 3rd ed. MA: Wiley.
Walas, Staney M. 1990. Chemical Process Equipment: Selection and Design. Boston:
Butterworth-Heinemann.
43
Nomenclature
a Surface area d, optimum Optimum pipe diameter
A Cross-sectional area dreq Required pipe diameter
Areq Required cross-sectional area e Minimum shell thickness
AS Single tube surface area e/d Relative roughness
AX Tube cross-sectional area FVL Column liquid-vapour factor
c Corrosion allowance FP Packing factor
C Sum of corrosion allowances FT Temperature correction factor
Cp Fluid specific heat capacity f Design stress
Cs Stress concentration factor for f Fanning friction factor
torispherical heads
Cv Factor to account for weight of G Mass flow rate
fittings
Db Tube bundle diameter Gm Molar gas flow rate per unit
cross-sectional area
Dc Column diameter Gs Shell-side mass velocity
DL Liquid diffusivity g Acceleration due to gravity
Dm Mean diameter of vessel H Total system head
DV Vapour diffusivity hi Tube-side heat transfer
coefficient
Ds Shell diameter hid Inside dirt coefficient (fouling
factor)
d Column diameter HG Height of a gas film transfer
unit
de Shell-side equivalent diameter HL Height of a liquid film transfer
unit
di Internal diameter HOG Height of overall gas-phase
transfer unit
do Outside diameter hod Outside dirt coefficient
(fouling factor)
44
hs; ho Total suction head; Shell-side heat LW* Liquid mass flow rate per unit
transfer coefficient column cross-sectional area
hsh Static head of liquid above pump m Slope of equilibrium line
hsf Suction friction head losses N Pump speed
hsp Head due to upstream surface n1 Constant for calculating tube
pressure bundle diameter
hd Total discharge head NOG Number of overall gas-phase
transfer units
hds Static discharge head NP Number of passes
hdf Discharge friction head losses Ns Dimensionless specific speed
hdp Head due to downstream pressure Ns Specific speed
Hv Height of cylindrical section of NT Number of tubes
column
hvap Vapour pressure head at suction Nu Nusselt number
J Joint factor (NPSH)A Available net positive suction
head
jH Friction factor P Pressure
K1 Constant for calculating tube Pr Prandtl number
bundle diameter
K3 Percentage flooding correction Pvap Vapour pressure
factor
K4 Generalised pressure drop Po Power output of pump
correlation constant
kf Fluid thermal conductivity Pi Power input to pump
kw Tube wall thermal conductivity Pf Pressure drop due to friction
L Pipe length; Tube length Pt Tube-side pressure drop
Lm Molar liquid flow rate per unit Ps Shell-side pressure drop
cross-sectional area
LW Liquid mass flow rate Pt Tube pitch
45
Q Volumetric flow rate; Heat VW* Gas mass flow rate per unit
transferred (heat duty of heat column cross-sectional area
exchanger)
r Radius v Velocity
R Dimensionless constant in vopt Optimum velocity
calculating temperature correction
factor
Rc Crown radius w Maximum liquid density
Re Reynolds number Wv Total weight of shell
Rk Knuckle radius Y Expansion factor
S Maximum allowable design stress; y1 Mole fraction of solute in the
Dimensionless constant in gas at the bottom of the column
calculating temperature correction
factor
SE Allowable stress y2 Mole fraction of solute in the
gas at the top of the column
(Sc)L Liquid Schmidt number Z Total height of packing
(Sc)V Gas Schmidt number Zguess Total height of packing guess
t Tube thickness; Shell thickness Pump efficiency
(absorber)
T1 Hot fluid temperature (inlet) Density
t1 Cold fluid temperature (inlet) L Liquid density
T2 Hot fluid temperature (outlet) V Vapour density
t2 Cold fluid temperature (outlet) Viscosity
Tm True mean temperature difference L Liquid viscosity
Tlm Log-mean temperature difference V Vapour viscosity
U Overall heat transfer coefficient h Factor for HG
ut Tube-side velocity h Factor for HL
V Volume
VW Gas mass flow rate
46
Appendix A Pump P-109 Design Calculations
Design Conditions
Design temperature = 1.1 Normal temperature
Design pressure = 1.2 Normal pressure
Design flow rate = 1.2 Normal flow rate
Outlet pressure assumed 0.5 atm above inlet pressure.
Design Conditions Inlet Outlet
Temperature (C) 5.5 5.5
Pressure (atm) 1.30 1.80
Mass flow rate (kg/s) 2.53
Volumetric flow (m3/s) 2.26 10-3
Pipe design
Two methods were used to calculate the required pipe diameter.
1. Calculating optimum pipe diameter.
Carbon steel is a suitable piping material, given that ethylene glycol is generally stable and non-
corrosive. For carbon steel,
d, optimum = 293 G0.53 -0.37 (Sinnott 2005)
47
d, optimum = 35.59 mm = 1.40 inch
2. Calculating required pipe diameter using optimum velocity method.
Q = 2.26 10-3 m3/s
Fluid density (kg/m3) Optimum velocity (ms-1)
1600 2.4
800 3
1125.32 2.76 (by linear interpolation)
From above, vopt = 2.76 ms-1
Areq = Q vopt
4
dreq = = 0.03229 m = 1.27 inch
The larger required diameter is d, optimum, and will be used for pipe selection. For a carbon steel
pipe of optimum diameter 1.40 inches, the next largest nominal steel pipe size is 1 inches.
Pipe selected: 1 inch Schedule 40 Carbon Steel (Green and Perry 2008)
48
Pipe data (Green and Perry 2008):
Outer diameter (inch) 1.9
Outer diameter (mm) 48.26
Internal diameter (inch) 1.61
Internal diameter (mm) 40.89
Wall thickness (inch) 0.145
Wall thickness (mm) 3.68
()
di (m) = 1000
2
A= 4

Actual fluid velocity, v = = 1.72 ms-1
Checking minimum thickness required.

tm = 2( + ) + C (Green and Perry 2008)
SE = 19444000 Pa
Y = 0.4
tm = 0.085 inch = 2.16 mm
The selected pipe has a greater thickness than the minimum thickness. Hence, it can be used.
49
Total Suction Head
Total suction head, hs = hsh + hsp - hsf
From the layout, hsh = 1 m
Using suction pressure, hsp = = 11.96 m
For calculating friction head losses in the pipe, friction losses due to valves and fittings are
incorporated as equivalent lengths. These lengths are given by Sinnott (2005) in terms of
equivalent diameters.
Suction losses due to valves and fittings
Fitting or Valve Number Equivalent diameter
90 standard radius elbow 2 40
Fully open globe valve 1 300
Tank outlet connection 1 25
50
Total equivalent pipe diameters = 405
Total equivalent pipe length = 405 di = 16.56 m
Actual pipe length = 6 m
Pipe length for friction loss calculation, L = 22.56 m
Suction velocity, v = 1.72 ms-1
Absolute roughness for commercial steel pipe = 0.046 mm
Relative roughness, e/d = absolute roughness di = 1.12 10-3

Re = = 2808.54
From graph provided by Sinnott (2005), Fanning friction factor, f = 0.007
Pressure drop due to pipe friction, Pf:
2
Pf = 8 f ( ) ( 2) = 51492.15 Pa

hsf = = 4.66 m
Total suction head, hs = hsh + hsp - hsf = 8.29 m
Total Discharge Head
Total discharge head, hd = hds + hdf + hdp
From plant layout, hds = 4 m
Using discharge pressure, hdp = = 16.55 m
51
Discharge losses due to valves and fittings
Fitting or Valve Number Equivalent diameter
90 standard radius elbow 2 40
Fully open globe valve 1 300
Heat exchanger inlet connection 1 2
Total equivalent pipe diameters = 382
Total equivalent pipe length = 405 di = 15.62 m
Actual pipe length = 14 m
Pipe length for friction loss calculation, L = 29.62 m
Pressure drop due to friction within a heat exchanger is estimated as 70 kPa by Sinnott (2005).
Pressure drop due to pipe friction, Pf:
2
Pf = 8 f ( ) ( 2) + 70000 = 137603.52 Pa

hdf = = 12.46 m
Total discharge head, hd = hds + hdf + hdp = 33.01 m
Total System Head
Total system head, H = hd hs = 24.72 m
Available Net Positive Suction Head
Available net positive suction head, (NPSH)A = hs hvap
52
From the Aspen HYSYS stream simulation, vapour pressure = 46.95 Pa
Using this vapour pressure, hvap = = 4.25 10-03 m
(NPSH)A = hs hvap = 8.29 m
The (NPSH)A is significantly positive. This means that the inlet pressure is significantly higher
than the vapour pressure of the liquid at design temperature. Hence, cavitation will be avoided.
Pump Type
From the pump selection guide below, the pump is recognised as a single-stage, 3500 rpm
centrifugal pump.
Figure 15: Pump Selection Guide (Sinnott 2005)
53
Power Output of Pump
Power output of pump, Po = HQ 3.67 105 (Green and Perry 2008)
Po = 0.62 kW
Power Input to Pump
From the centrifugal pump efficiency graph below, pump efficiency () is estimated to be 66%.
Figure 16: Centrifugal Pump Efficiency Graph (Sinnott 2005)
Power input to pump, Pi = Po = 0.93 kW
From the value of power input, energy requirements can be found. Some are shown below.
54
(1 kWh = 3.6 MJ)
Period Pump Energy Requirement (kWh)
One day 22.43
One 28-day month 628.00
One 333-day year 7468.75
Centrifugal Pump Specific Speed
Sinnott (2005) states that centrifugal pumps are characterised by their specific speed. This can be
useful details for a pump manufacturer.
Specific speed in dimensionless form (Ns):
1
2
Ns = 3 = 4.51 10
-2
() 4
where N is in rps, Q is in m3/s, and H is in m.
Sinnott (2005) mentions that pump manufacturers generally define a form of specific speed in rpm,
Ns.
Ns = 1.73 104 = 780.81 rpm
Mechanical Design Specifications
The pump specific speed is in the range of 400-1000, indicating that a radial impeller will be
suitable (Sinnott 2005). According to the characteristic curve of a centrifugal pump below, this
should be a 4 1/2 inch impeller.
55
Figure 17: Centrifugal Pump Characteristic Curve (Green and Perry 2008)
The impeller will be housed in a volute casing, known for its efficiency. Other casing types
considered included the seldom-used circular casing, and guide vanes, which are mainly used in
turbine pumps. A mechanical seal should be used, due to its more effective performance when
compared with packing. Carbon steel is a suitable material for the pump seal and casing, given the
non-corrosive environment. (Green and Perry 2008)
56
Appendix B Tank V-117 Design Calculations
Calculations were done using Microsoft Excel 2013. Aspen HYSYS v8.6 was also employed.
Design Conditions
The operating pressure of 1 bar is respecified to 1 atm.
The tank operates at atmospheric pressure, and is henceforth classified as a non-pressure tank. The
tank will be designed for design pressure of 7.5 mbar and a vacuum of 2.5 mbar. (BSI 1989)
Design metal temperature will be 10 C above the minimum temperature of the contents (BSI
1989).
Design Conditions
Temperature (C) 45
Operating pressure (atm) 1
Design pressure (mbar) 7.5
Design vacuum (mbar) 2.5
Design Capacity
For a hold-up time of 10 days and a safety over-design factor of 10%,
Design capacity = Q Hold-up time 10% = 47.98 m3
Water load = Design capacity = 47678.4 kg
57
Tank Shell Dimensions
A vertical, cylindrical tank is selected. Using the available nominal capacities of standard vertical
cylindrical tanks, provided by BSI (1989), nominal volume, height and diameter for the shell were
selected.
Vessel volume = 50 m3
Vessel diameter = 4 m
Vessel height = 4 m
Liquid height = V r2 = 3.82 m
Height of shell above liquid (freeboard) = Vessel height Liquid height = 0.18 m
Material of Construction
The tank (shell, roof and base) will be constructed using high grade A-36 carbon steel plates, as
this is used by the Central Valley Tank of California, Inc. (CVT 2015)
Carbon steel typically has a minimum yield strength of 360 N/mm2 (Sinnott 2005).
For corrosion protection, the carbon steel plates will be galvanised, making use of the sacrificial
oxidation protection of zinc. This is a much more economical way of preventing corrosion, rather
than short-term methods such as painting, extreme methods such as cathodic protection, or use of
expensive alloys such as stainless steel (CST 2015).
58
Design of Shell Plates
Maximum allowable design stress (S) is to be 260 N/mm2 or two thirds of the minimum yield
strength of the material, whichever is lower (BSI 1989).
2/3 of 360 N/mm2 = 240 N/mm2
Hence, S is selected as 240 N/mm2.
Corrosion allowance under conditions where high levels of corrosion are not expected is
recommended to be 2 mm for carbon steel (Sinnott 2005).
c = 2 mm
w = 1 g/mL
Minimum shell plate thickness for a non-pressure tank,

= 20 (98( 0.3)) + = 2.30 mm
This thickness is less than the minimum permissible thickness of the shell plates of a 4-m diameter
tank, according to BSI (1989) a value of 5 mm. Hence, the actual shell plate thickness will be 5
mm. This includes corrosion allowance, as it is of a value greater than the minimum shell plate
thickness (permitted by BSI (1989)).
The shell will be designed to have all courses truly vertical, and the plates will be welded together.
Vertical and horizontal seams shall be butt joints. (BSI 1989)
Design of Base Plates
The bottom of the tank will be constructed from rectangular plates with sketch plates to the
perimeter. The thickness of the base plates is recommended to be 6 mm, excluding corrosion
59
allowance. Hence, with a corrosion allowance of 2 mm, the thickness of the base plates will be 8
mm. All joints shall be lapped and welded together, with a minimum lap of 60 mm. (BSI 1989)
Roof Design
A fixed self-supporting dome roof is selected.
Radius of curvature of roof is to be 1.5 times the diameter of the tank.
Radius of roof curvature = 1.5 D = 6 m
The thickness of the roof plates will be that of the shell plates, exclusive of corrosion allowance.
Hence, the actual roof plate thickness (with 2 mm corrosion allowance) will be 7 mm. The roof
plates will be lapped and welded together with a minimum lap of 25 mm. (BSI 1989)
Foundation
The tank will be supported on a square concrete slab, using concrete of minimum compressive
strength 3000 psi. The tank must rest on a sand cushion at least 1 inch in thickness. The edge of
the slab must be at least 3 inches from the bottom of the tank, and neatly rounded for drainage
away from the tank. The concrete foundation below the ground shall not be less than 12 inches in
depth. (FM Approvals 2011)
Accessories
Nozzles
Inlet and outlet pipes are designed identically.
Calculating optimum pipe diameter.
For carbon steel,
60
For a carbon steel pipe of optimum diameter 0.18 inches, the next largest nominal steel pipe size
is inches.
Pipe selected: inch Schedule 40 Carbon Steel (Green and Perry 2008)
Venting
Normal vacuum venting is required for the tank, considering the contents and design pressure and
temperature. An open valve will be used for venting, designed to accommodate a maximum air
flow rate of 1.0 m3/h. The opening of the vent shall be screened to prevent insects and birds from
entering. (BSI 1989)
Manhole
The roof will be built with a manhole of diameter 500 mm. This manhole will have a tight-gasket,
bolted cover. (BSI 1989)
Ladder
A fixed, vertical ladder will be welded to the side of the tank, close to the manhole, with a safety
cage beginning 4 m above the base. (BSI 1989)
61
Appendix C Heat Exchanger E-107 Design Calculations
All formulas, graphs and methods applied in these calculations and design considerations are taken
from those presented by Sinnott (2005), unless otherwise specified. The calculations use an
iterative method for thermal heat exchanger design. Calculations were done using Microsoft Excel
2013. Aspen HYSYS v8.6 was also employed.
Energy Balance and Design Conditions
A shell and tube heat exchanger is to be used, specifying counter-current flow. The exchanger is
to be designed with one shell and two tube passes, with a split-ring, floating head. The exchanger
will use segmental baffles with 25% cut. The process stream still has the potential to condense, so
the process stream will pass through the shell side since the shell side is best for condensing fluids
(Walas 1990). With the process stream assumed 100% methyl chloride, the energy balance was
done by simulating the heat exchanger in Aspen HYSYS v8.6. A screenshot of the flow sheet used
is shown below. The simulation file is included in the attached CD.
Figure 18: Heat exchanger simulation flow sheet on Aspen HYSYS v8.6
62
The following data were taken from the simulation. (The bolded data were specified.)
SHELL SIDE TUBE SIDE

Location
IN OUT IN OUT
Stream 49 50 51 52
Fluid Methyl Chloride Ethylene Glycol
kg/h 6342.28 7788.37
Flow rate kmol/h 125.62 125.48
m3/h 6.93 7.01
Temperature C 43.5 15.2 5.0 13.0
Pressure bar 1.4 1.1
Density kg/m3 2.68 2.74 1125.32 1119.54
Viscosity Pa.s 1.09E-05 9.92E-06 2.82E-02 2.08E-02
Specific heat kJ/kgK 0.87 0.84 2.39 2.47
Thermal conductivity W/mK 1.28E-02 1.12E-02 0.25 0.25
Latent heat of vaporisation kJ/kg 422.56 424.33 807.56 812.15
Heat transferred (Q) kJ/h 153038.05
Heat Transfer Area
Calculating log-mean temperature difference:
((12)(21))
Tlm = 12 = 18.53 C
ln( )
21
This value is corrected using a temperature correction factor (Ft), corrected as a function of
dimensionless temperature ratios, R and S.
12
R= = 3.54
21
63
21
S = 11 = 0.21
Temperature correction factor is read off the following graph.
Figure 19: Temperature correction factor for one shell pass, two tube passes (Sinnott 2005)
Ft = 0.875 approximately
Estimation of true mean temperature difference:
Tm = Ft Tlm = 16.22 C
For an initial estimate of the overall heat transfer coefficient (U), a value of 157.5 kJ/hm2K is
recommended by the Aspen HYSYS simulation between the two fluids.
U = 157.5 kJ/hm2K = 43.75 W/m2K
Heat transferred (Q) = 153038.05 kJ/h = 42510.57 W
Calculating heat transfer area (A):
64
Q = UA Tm
Therefore, A = 59.92 m2
Tube Design Specifications
Ethylene glycol is generally non-corrosive, so fouling is not regarded as a major issue. Stainless
steel tubes are selected. 5/8 to 1 inch diameter tubes are preferred for most duties. Larger tubes are
mainly desirable when heavy fouling is expected. A large tube wall thickness (gauge) is not
necessary, due to the small pressure difference between the tube-side and shell-side fluids.
Optimum tube lengths typically fall within the range of 5-10 m.
The tube pitch arrangement will be equilateral triangular, offering high heat transfer rate, with a
pitch/diameter ratio of 1.25. The following data is therefore specified each tube, based on standards
supplied by Sinnott (2005).
Do 16 mm
di 12.8 mm
t 1.6 mm
pt 20 mm
L 5 m
Number of Tubes
Single tube surface area:
As = doL = 0.251 m2
Number of tubes:
NT = A As = 238.4
65
Rounding up, NT = 239 tubes
Number of passes = 2
Number of tubes per pass = 120 tubes (rounded up)
Tube cross-sectional area:
Ax = di2 4 = 1.29 10-4 m2
Area per pass = Number of tubes per pass Ax = 1.54 10-2 m2
Tube Bundle and Shell Diameter
Tube bundle diameter (Db):
1/1
Db = ( )
1
For triangular pitch, 2 tube passes, constants K1 = 0.249 and n1 = 2.207.
Db = 359.22 mm = 0.36 m
Using a split-ring, floating heat exchanger, typical shell bundle clearance is read off the following
graph.
66
Figure 20: Shell bundle clearance (Sinnott 2005)
Shell bundle clearance is approximately 65 mm.
Shell diameter (Ds):
Ds = Db + Shell bundle clearance = 424.22 mm = 0.42 m
Tube-side Heat Transfer Coefficient
Tube-side velocity, ut = Volumetric flow Area per pass = 0.13 m/s
67

Re = = 6.37

Pr = = 270.10

L/di = 390.63
Tube-side heat transfer factor is read off the graph below.
Figure 21: Tube-side heat transfer factor (Sinnott 2005)
jH = 8 10-2
Nu = jHRePr1/3 = 33.29

Nu =
So, hi = 650.27 W/m2K
68
Shell-side Heat Transfer Coefficient
This calculation is done using Kerns method.
Baffle spacing, IB = 0.2Ds = 0.08 m
( )
Area for cross flow, As = = 7.20 10-3 m2

Shell-side linear velocity = Gs = 0.66 m/s
Shell-side equivalent diameter (hydraulic diameter) for equilateral triangular pitch arrangement:
1.1
de = (2 0.9172 ) = 1.14 10-2 m

Re = = 1832.06

Using segmental baffles with 25% cut, shell-side heat transfer factor is read off the graph below.
Figure 22: Shell-side heat transfer factor (Sinnott 2005)

69
jH = 1.2 10-2
Similarly, Pr = 0.74 and Nu = 19.87

Nu =
So, hs = 22.47 W/m2K
Overall Heat Transfer Coefficient

1 1 1 ln ( ) 1 1

= + + + ( + )
2
For the fluids, dirt coefficients (fouling factors) are both approximately 5000 W/m2K.
For stainless steel tubes, thermal conductivity, kw = 45 W/mK.
Uo = 21.32 W/m2K
When compared with the estimated value of Uo, this results in an error of 51.3%.
As mentioned, the method is an iterative procedure. If the error is greater than 30%, as is the case,
the calculations are repeated using the calculated value of Uo. The results are presented below.
Using Uo = 21.32 W/m2K:
A 122.98 m2
NT 490 tubes
Number of tubes per pass 245 tubes per pass
Db 497.33 (0.50) mm (m)
Shell bundle clearance 65 mm
70
Ds 562.33 (0.56) mm (m)
hi 318.50 W/m2K
hs 22.47 W/m2K
lB 0.11 m
Uo 20.44 W/m2K
Using the new estimate, calculating Uo = 20.44 W/m2K, the error is now 4.1%.
Data isn't widely available to attest the accuracy of this value. However, the overall heat transfer
coefficient between gases and cooling water is generally between 20 and 300 W/m2K, and that
between gases and cooling brine is typically between 15 and 250 W/m2K (Sinnott 2005). The value
calculated (between gases and ethylene glycol coolant), is appreciably within a similar range.
Hence, this value is taken as accurate.
71
Tube-side Pressure Drop
Tube-side friction factor is obtained from the graph below.
Figure 23: Tube-side friction factor (Sinnott 2005)
jf = 2.5 10-1
2
Pt = [8 ( ) + 2.5] ( )= 0.34 bar
2
Adding 0.1 bar for pressure drop across the tube inlet and outlet nozzles.
Pt = 0.44 bar
72
Shell-side Pressure Drop
Shell-side friction factor is obtained from the graph below.
Figure 24: Shell-side friction factor (Sinnott 2005)

jf = 1.1 10-1
2
Ps = [8 ( )] ( )= 0.11 bar
2
Adding 0.1 bar for pressure drop across the tube inlet and outlet nozzles.
Ps = 0.21 bar
73
Mechanical Design
Shell Design
Heat exchanger shells are generally made from standard steel pipes (Green and Perry 2008). The
shell will be designed using Schedule 40 Carbon Steel.
Calculated shell diameter is 22.14 inches. The next largest nominal steel pipe size is 24 inches.
Outer diameter (inch) 24 (0.61 m)
Internal diameter (inch) 22.624 (0.57 m)
Wall thickness (inch) 0.688 (17.48 mm)
Tube-side Nozzles
Inlet and outlet tube-side nozzles will be designed identically.
Calculating optimum pipe diameter.
For carbon steel,
74
For a carbon steel pipe of optimum diameter 1.29 inches, the next largest nominal steel pipe size
is 1 inches.
Shell-side Nozzles
Inlet and outlet shell-side nozzles will be designed identically.
For gases, optimum velocity is about 40 m/s to 9 m/s (Green and Perry 2008). Specifying optimum
velocity (vopt) of 20 m/s.
Areq = Q vopt
4
dreq = = 0.01107 m = 0.44 inch
For a carbon steel pipe of required diameter 0.44 inches, the next largest nominal steel pipe size is
inch.
Pipe selected: inch Schedule 40 Carbon Steel (Green and Perry 2008)
75
Design of Baffles
Number of baffles = Length of tube Baffle spacing = 45 (rounded up)
Baffle diameter = Ds 1.6 mm = 0.56 m
Insulation Specification
The heat exchanger will be insulated using cotton, with a metal foil finish. Metal finishes are more
durable, and require less maintenance. (Green and Perry 2008)
76
Appendix D Absorber T-100 Design Calculations
Stream Specifications
The specifications were developed based on the assumptions made. The composition of the most
important stream in this section (tops product) was left unchanged.
Streams
Lin Lout Gin Gout
Composition (mol %) 95 59 48 49
Methanol 0 2.93 1.5 0.1
Water 37.7 36.43 0 0
Methyl Chloride 0 0 97.8 99.5
Dimethyl Ether 0 0.42 0.6 0.4
Sulphuric Acid 62.3 60.22 0 0
Temperature (C) 85 37 50.4 43.5

Pressure (bar) 1.1 1.1 1.1 1.1
Molar flow (kmol/h) 58.91 60.95 127.4 125.2
Mass flow (kg/h) 4000 4069 6391.8 6317.6
Density (kg/m3) 1667 1639 2.079 2.108
Viscosity (Ns/m2) 9.18 10-3 1.12 10-2 1.10 10-5 1.08 10-5
Values of density and viscosity were taken from a simulation of the respective streams using Aspen
HYSYS v8.6. Flow rate of the outlet liquid (shown in bold) was recalculated from the mass
balances, due to the change in sulphuric acid flow rate.
77
Absorber Type
The absorber is to be a packed bed column. A packed column is a vessel containing one or more
sections of packing. The liquid flows downwards on the surface of the packing, and the vapour
flows upwards through the packing, contacting the liquid. (Seader et al. 2010)
A packed column was selected because of the highly corrosive nature of sulphuric acid. Packed
columns are cheaper to maintain in corrosive systems (Sinnott 2005).
The column will be packed with 2" ceramic Intalox saddles.
Figure 25: Ceramic Intalox saddle (Sinnott 2005)

Compared with structured packing, random packing of saddles have a low relative cost, moderate
pressure drop, moderate efficiency, and fairly high vapour capacity (Seader et al. 2010). Ceramic
packing is also the first choice for corrosive fluids (Sinnott 2005).
Packing specifications (Sinnott 2005):
Type 2 ceramic Intalox saddles

2 in
Size
51 mm
Bulk density 609 kg/m3
Surface area, a 108 m2/m3
Packing factor, Fp 130 m-1
78
The optimum size of packing is dependent on the diameter of the column. For a column of diameter
greater than 0.9 m, 2-3 inch packing is suggested by Sinnott (2005). From the calculation of
column diameter (shown later on), the size of packing was shown to be an ideal choice.
Number of Transfer Units (NOG)

The term ( ) is used to find the number of stages. Optimally, this value is 0.7-0.8 (Sinnott

2005). Taking ( ) as 0.7.

y1 = 0.021
y2 = 0.005
1
= 4.2
2
From the graph below, NOG is read off approximately.
NOG = 2.2
79
Figure 26: Number of overall gas-phase transfer units as a function of y1/y2 (Sinnott 2005)
80
Diameter of Column
Calculating column liquid-vapour factor, FLV:
At this point, liquid flow rate was respecified to 4000 kg/h to give the lowest available value of
FLV, 0.02, for reading off the graph.

=
= 2.21 10 (Sinnott 2005)
-2

According to Sinnott (2005), pressure drop for absorbers should be 15-50 mm H2O/m of packing.
Designing for pressure drop of 21 mm H2O/m of packing a reasonable value which can be found
on the generalised pressure drop correlation graph (below).
From the generalised pressure drop correlation graph below, generalised pressure drop correlation
factor, K4 = 1.1.
At flooding, K4 = 6.
81
Figure 27: Generalised pressure drop correlation (Sinnott 2005)
1
2
Percentage flooding = [ 4 ] = 42.8% (Sinnott 2005)
4
Gas mass flow rate per unit column cross-sectional area, VW*, is found as follows.
0.1
)2
13.1( ( )

K4 = (Sinnott 2005)
( )

82
Rearranging and solving for VW*, VW* = 2.74 kg/m2s.
Column cross-sectional area required:

Areq = = 0.65 m2 (Sinnott 2005)

Column diameter:
4
d = = 0.91 m (Sinnott 2005)
Column diameter is 1.0 m rounded up.
Column cross-sectional area:
2
A= = 0.79 m2 (Sinnott 2005)
4
Areq
Percentage flooding at selected diameter = originally calculated percentage flooding ( )
A
(Sinnott 2005)
= 35.3 %
Height of Packing
Using Cornells method:
DL = 1.70 10-9 m2/s and DV = 1.45 10-5 m2/s

Gas Schmidt number, (Sc)V = = 0.37 (Sinnott 2005)

Liquid Schmidt number, (Sc)L = = 3238.44 (Sinnott 2005)

83
The following graphs are used to find percentage flooding correction factor (K3), factor for HG for
1 inch Berl saddles (h), and factor for HL for 1 inch Berl saddles (h). These factors for Berl
Saddles can be used to make conservative estimates for Intalox saddles, as explained in the
Difficulties Encountered (Sinnott 2005).
Figure 28: Percentage flooding correction factor graph (Sinnott 2005)
84
Figure 29: Factor for HG for 1 1/2 inch Berl saddles (Sinnott 2005)
Figure 30: Factor for HL for 1 1/2 inch Berl saddles (Sinnott 2005)
From the above graphs, K3 = 1, h = 75, and h = 0.04.
85
The total height of packing (Z) is now guessed. This value is then calculated, and an iterative
procedure is used to get Zguess appreciable close to the calculated value of Z. This sample
calculation uses the final values obtained.
Zguess = 5 m
Cornells equations (Sinnott 2005):
Neglecting viscosity, density and surface tension correction:
1.11 0.33
= 0.011 ()0.5
(0.305) (3.05) /( )0.5 = 1.85 m
0.15
= 0.305 ()0.5
3 (3.05) = 0.75 m
The height of an overall gas-phase transfer unit (HOG) is now found.

= + ( ) = 2.37 m (Sinnott 2005)

Here, total height of packing is calculated. The guess value is repeated until it is approximately
equal to the calculated value.
= = 5.21 m (Sinnott 2005)
The total height of packing (Z) is 6 m rounded up.
86
Mechanical Design
The column will be cylindrical in shape, with a torispherical head.
Design Conditions
Maximum operating pressure is 1 atm. Design pressure should be 5-10% above operating pressure
(Sinnott 2005). Using 10% over-design, design pressure is 1.1 atm.
Maximum operating temperature is 85 C. Using a 10% over-design temperature, design
temperature is 93.5 C.
Material of Construction
The column shell, head, and fittings shall be constructed with Type 304 Stainless Steel. Type 304
Stainless Steel exhibits excellent corrosion resistance to a wide range of atmospheric and chemical
industry exposures, and can be exposed continuously to temperatures up to 899 C without
scalding. Type 304 Stainless Steel is weldable by common fusion and resistance techniques. (AK
Steel 2007)
Shell Thickness
Design stress (f) = 145 N/mm2 at 100 C (Sinnott 2005)
Joint factor (J) = 1 (Sinnott 2005)
Minimum shell thickness (e):

= 2 = 0.4 mm
87
Using a corrosion allowance of 4 mm, recommended by Sinnott (2005) for severe corrosive
conditions, e becomes 4.4 mm.
For vessels of diameter 1 m, with a corrosion allowance of 2 mm, Sinnott (2005) recommends a
minimum shell thickness of 5 mm. Hence, with 4 mm corrosion allowance, minimum shell
thickness should be 7 mm. Since this is the larger value, shell thickness (t) is taken to be 7 mm.
Column Head Design
Standard torispherical heads are most common for operation up to 15 bar (Sinnott 2005). Hence,
one is deal for the column. Using crown radius (Rc) as column diameter, and knuckle radius (Rk)
as 6% Rc (Sinnott 2005).
Rc = 1000 mm
Rk = 60 mm
1
Stress concentration factor, Cs = 4 (3 + ) = 1.77 (Sinnott 2005)

A joint factor (J) of 1.0 is used (Sinnott 2005).

Head thickness, e = 2+ ( 0.2) = 0.7 mm

Using a corrosion allowance of 4 mm, head thickness = 4.7 mm.
Weight Loads
Weight of Shell
Factor to account for weight of fittings, Cv = 1.15 for columns (Sinnott 2005)
88
Mean vessel diameter = d + t = 1.007 m
Taking height of cylindrical section (Hv) as height of packing.
For a steel vessel,
Total weight of shell, Wv = 240 ( + 0.8 ) = 13240.46 N = 13.24 kN (Sinnott 2005)
Weight of Packing
Volume of packing = Cross-sectional area of column Height of packing = 4.71 m3
Weight of packing = Volume of packing Bulk density 9.81 = 28153 N = 28.15 kN
Weight of Accessories
The only significant accessory is a caged ladder of height 6 m. Other accessories (fittings) were
accounted for in calculating shell weight.
Weight of steel caged ladder = 360 N per m length (Sinnott 2005)
Weight of ladder = 360 Hv = 2160 N = 2.15 kN
Total Weight of Column
Total weight of column = Weight of Shell + Weight of packing + Weight of accessories
= 43.55 kN
Total weight of column is 44 kN rounded up.
89
Internal Accessories
Wide-spaced grids will be used as packing support. Unlike simple grid and perforated plates, these
do not result in a high pressure drop. A layer of larger packing might be required to support the
smaller packing. (Sinnott 2005)
For a small column such as this, a central pipe fitted with a spray nozzle is adequate for liquid
distribution (Sinnott 2005).
As far as liquid redistribution is concerned, beds of height less than 8-10 column diameters (for
saddles) do not require liquid redistributors (Sinnott 2005).
A hold-down plate should be used at the top of the packing to prevent fluidisation. Under normal
operation, or in the event of a gas surge, the packing may become fluidised. This can damage
ceramic packing, causing small pieces to filter down the column and plug the packing. (Sinnott
2005)
Column Support
The column will be supported by a skirt support. Skirt supports are typically cylindrical and
conical, and are welded to the base of the tower to transmit the load of the tower to the foundation.
Reinforced openings should be present for access for connecting pipes. (Sinnott 2005)
The skirt will be a straight cylinder. It is preferred to weld the skirt flush with the shell, as shown
below. The minimum thickness of the skirt should be 6 mm. (Sinnott 2005)
90
Figure 31: Skirt support welded flush with the shell (Sinnott 2005)
The loads on the skirt are transmitted to the foundation by the skirt base ring (or bearing plate).
The type to be used is a flange ring design, specifically a double ring stiffened with gussets, as
shown below. When compared with simple designs, this design is preferable for larger columns.
(Sinnott 2005)
Figure 32: Base ring: Double plate with gusset (Sinnott 2005)
91
Anchor bolts connect the base ring to the foundation. The following specifications are made using
guide rules for the anchor bolts.
1. Minimum bolt diameter 25 mm (1 in.);
2. No less than 8 bolts;
3. Use bolts in multiples of 4;
4. Bolt pitch should not be less than 600 mm (2 feet) (Scheiman 1963).
92

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The University of the West Indies

Department of Chemical Engineering

CHNG 3012: Chemical Engineering Design Project

Design of a Methyl Chloride Plant

Student: Brian Jr Brandon Geoffroy 812000719

Project Supervisor: Dr Sydney Thomas

Date Submitted: 17th April, 2015

The equipment designed are:

stream. This was designed as an absorber with only physical absorption.

3) Pump P-109 Ethylene glycol pump to heat exchanger E-107.

considerations for each piece of equipment are appended.

2. Design of Pump P-109 ............................................................................................................ 4

2.1 Design Criteria ...................................................................................................................... 4

2.2 Modifications to the Original Design ................................................................................... 5

2.4 Layout ................................................................................................................................... 6

2.5 Methodology ......................................................................................................................... 7

2.6 Pump P-109 Specification Sheet ........................................................................................... 9

2.7 Difficulties Encountered ..................................................................................................... 10

2.8 Control System and Instrumentation .................................................................................. 10

2.9 Recommendations ............................................................................................................... 11

3. Design of Tank V-117 .............................................................................................................. 12

3.1 Design Criteria .................................................................................................................... 13

3.2 Modifications to the Original Design ................................................................................. 13

3.4 Methodology ....................................................................................................................... 14

3.5 Tank V-117 Specification Sheet ......................................................................................... 16

3.6 Difficulties Encountered ..................................................................................................... 17

3.8 Control System and Instrumentation .................................................................................. 19

3.9 Recommendations ............................................................................................................... 19

4. Design of Heat Exchanger E-107 ............................................................................................. 20

4.1 Design Criteria .................................................................................................................... 21

4.2 Modifications to the Original Design ................................................................................. 21

4.4 Methodology ....................................................................................................................... 22

4.5 Heat Exchanger E-107 Specification Sheet ........................................................................ 24

4.6 Difficulties Encountered ..................................................................................................... 25

4.7 Heat Exchanger E-107 Schematic Diagram ....................................................................... 27

4.8 Control System and Instrumentation .................................................................................. 29

4.9 Recommendations ............................................................................................................... 30

5. Design of Absorber T-100 ........................................................................................................ 30

5.1 Design Criteria .................................................................................................................... 33

5.2 Modifications to the Original Design ................................................................................. 33

5.4 Methodology ....................................................................................................................... 34

5.5 Absorber T-100 Specification Sheet ................................................................................... 37

5.6 Difficulties Encountered ..................................................................................................... 39

5.8 Control System and Instrumentation .................................................................................. 41

5.9 Recommendations ............................................................................................................... 42

Appendix A Pump P-109 Design Calculations .......................................................................... 47

Design Conditions ..................................................................................................................... 47

Pipe design ................................................................................................................................ 47

Total Suction Head ................................................................................................................... 50

Total Discharge Head ............................................................................................................... 51

Total System Head .................................................................................................................... 52

Available Net Positive Suction Head ........................................................................................ 52

Pump Type ................................................................................................................................ 53

Power Output of Pump.............................................................................................................. 54

Power Input to Pump ................................................................................................................ 54

Centrifugal Pump Specific Speed ............................................................................................. 55

Mechanical Design Specifications ............................................................................................ 55

Appendix B Tank V-117 Design Calculations .......................................................................... 57

Design Conditions ..................................................................................................................... 57

Design Capacity ........................................................................................................................ 57

Material of Construction ........................................................................................................... 58

Design of Shell Plates ............................................................................................................... 59