TABLE OF CONTENT MAJOR EQUIPMENT CHAPTER 1 GENERAL DESCRIPTION 1.1)

Process Description Selection Criteria for Distillation Column …………………

3

1.2)

Design Methodology ……………………………………………………………

7

1.3)

Reator Selection…………………………………………………………………

8

CHAPTER 2 PROCESS DESIGN 2.1) Reactor Volume……………………………………………………………………….

10

2.2) Space time……………………………………………………………………….

12

2.3)

Energy Balance………………………………………………………………..

13

2.4)

Reactor design Temperature ……………………………………………………

13

2.5)

Reactor design pressure………………………………………………………..

15

CHAPTER 3 MECHANICAL DESIGN…………………………………………………………..

16

CHAPTER 4 SPECIFICATION SHEET AND DRAWING(S) 4.1) Specification Sheet ……………………………………………………………. 4.2) Technical Engineering Drawing ……………………………………………… CHAPTER 5 COSTING………………………………………………………………………….. 46

CHAPTER 6 OPERATING MANUAL PROCEDURE……………………………………………..48

1

Minor Equipment (PUMP)…………………………………………………….. 50 Minor Equipment (Compressor) ………………………………………………..55

2

CHAPTER 1 1.1)

Process Description

The equation for the reactions taking place in reactor is: nBHET

PET + (n-1)EG

Figure 1: Process Description In the pre polymerization reactors, the main concern is the characteristics of the product that relate to the mechanical properties. The distribution of molar masses in the polymer product, orientation of groups along the chain, cross-linking of the polymer chains, copolymerization with a mixture of monomers, and so on are the main considerations. Monomer BHET from reactor R-2 is pre-heated by heat exchanger E-6 before entering another reactor, which is reactor labeled R-3 for pre-polymerization (low polymerization). Polymerization reaction takes place in vacuum condition and in very high temperature. Reactor R-3 operates at 300°C temperature and 4 kPa pressure. In this pre-polymerization reactor, the used degree of polymerization of 21. The vapors evolved from reactor R-3 which is mainly EG are drawn to the distillation column together with the vapor streams from reactor R-1 and reactor R-2 3

Stream Properties The following tables summarized the operating conditions of the input and output structure for reactor R-3. Criteria Reaction and conversion

Details nBHET

Conversion : 99% i.

Reaction condition

PET + (n-1)EG

Temperature: 270oC

ii. Pressure: 4kPa iii. Catalyst: Antimony Trioxide

4

Propeties Table From Icon

Energy Streams OutQ [W] OutQ [W]

VapFrac T [C] P [kPa] MoleFlow [kgmole/h] MassFlow [kg/h] VolumeFlow [m3/hr] StdLiqVolumeFlow [m3/hr] StdGasVolumeFlow [SCMD] Energy [W] H [kJ/kmol] S [kJ/kmol-K] MolecularWeight MassDensity [kg/m3] Cp [kJ/kmol-K] ThermalConductivity [W/m-K] Viscosity [Pa-s] molarV [m3/kmol] ZFactor Cv [kJ/kmol-K] MoleFlows [kgmole/h] ETHYLENE GLYCOL TEREPHTHALIC ACID WATER BHET* PET* PET1*

Connection Value ---9840055.0918 9840055.0918 Delta P [Kpa] 0.00 Rxn0_Conversion [Fraction] 1.00 In Out 0.1892 0.946 270.00 270.00 15.0 15.0 456.70 96382.13 26106.154

453.91 96382.01 129349.941

72.124

84.571

2.5966E+5 -248002.4532 -1954.92 697.295 211.042 3.6919 281.338

2.5808E+5 16745536.5699 132809.63 651.268 212.336 0.7451 458.748

0.1706 1.1667E-3 57.163 0.1899 273.024

0.1435 3.9997E-5 284.967 0.9465 450.434

0.64

353.19

0.15 82.95 372.96 0.00 0.00 5

0.15 82.95 0.00 0.00 17.63

PET125* MassFlows [kg/h] ETHYLENE GLYCOL TEREPHTHALIC ACID WATER BHET* PET* PET1* PET125* StdLiqVolumeFlows [m3/hr] ETHYLENE GLYCOL TEREPHTHALIC ACID WATER BHET* PET* PET1* PET125* Rxn Name Base Comp Rxn0_Conversion [Fraction] Solution Order ETHYLENE GLYCOL TEREPHTHALIC ACID WATER BHET* PET* PET1* PET125* Balance H Rx'n(25°C) [kJ/kmol]

0.00

0.00

39.60

21921.68

24.83 1494.28 94807.39 0.00 2.09 13.94

24.83 1494.28 0.00 0.00 72927.28 13.94

0.035

19.637

0.013 1.496 70.567 0.000 0.002 0.010

0.013 1.496 0.000 0.000 63.415 0.010

Rxn0 poly1 BHET* 1.00 0.00 20 0 0 -21.158 0 1 0 -0.0068 256233.96

6

1.2)

Design Methodology

During the Mechanical design for the Pre polycondensation Reactor, the reference used is British Standard 5500 r and the design values were referred in the Mechanical Design of Process Equipment Data Hand Book. The methodology of reactor design are stated as follows ; 1. Selection of major equipment 2. 2. Justification on the type of reactor which is suitable for the process 3. 3. Determination of the optimum operating condition 4. Volume determination base on the rate of reaction 5. Reactor sizing 6. Reactor mechanical design 7. Equipment cost analysis 8. Technical drawing for Prepolycondensation reactor 9. Start up and procedures description

7

1.3)

Reactor Selection

Reactor Selection: Series of Continuous Stirred Tank Reactor After considering all the important elements needed in choosing the best reactor for esterification and polycondensation, we strongly agree that Continuous Stirred Tank Reactor (CSTR) in series is the most suitable choice for both of processes.

Figure 4.3: Schematic diagram of CSTR in series The correct choices of reactors used are vital to produce the desired target for the production of PET. The choices of reactors are highly dependent on the details that have been discussed above. Below table shows the comparison for four types of common reactors which are Fixed Bed Reactor, Continuous Stirred Tank Reactor, Plug Flow Reactor and Fluidized Bed Reactor: Type of Reactor

Advantages

Disadvantages

Fixed Bed Reactor

- High conversion per unit mass of -Undesired thermal gradients may catalyst.

exist.

-Low operating cost

-Poor temperature control.

- Continuous operation

-Channeling may occur Unit may be difficult to service and clean

CSTR

- Continuous operation

- Lowest conversion per unit volume

- Good temperature control

- By-passing and channeling possible

- Easily adapts to two phase runs

with poor agitation

8

PFR

- High Conversion per Unit Volume

- Undesired thermal gradients may

- Low operating (labor) cost)

exist

- Continuous Operation

- Poor temperature control

Fluidized-Bed

-

The

temperature

is

relatively - High cost of the reactor and catalyst

Reactor

uniform throughout the bed

regeneration equipment

- It doesn’t have hot spot - Good temperature control - Can handle large amounts of feed and solid - Ease in catalyst replacement

Polycondensation The design of pre-polycondensation reactor meets three special requirements: (i) A large surface area for mass transfer and respectively short diffusion length for low molecular weight by-products. (ii) A sufficient heat transfer area (iii)A design assuring low gas velocity

Besides, the design for polycondensation reactor is depends on its capacity. For high capacity plant design, a CSTR reactor is connected in series with a horizontal reactor operated with ring perforated disc to increase the specific surface area.

9

CHAPTER 2 PROCESS DESIGN 2.1) Reactor Volume The design equation for CSTR is given by:

VCSTR 

FA 0 X  ra

 ra  kCA Where, FA0

= inlet flow rate feed mixture to the first reactor (kgmol/hr)

X

= overall conversion

V

= total reactor volume (m3)

k

= experimental reaction rate constant

CA0

= concentration of feed mixture before entering the first reactor

Since the reaction in liquid phase and steady state, we can take volume initial is the same with final volume. V = Vo Thus, FAo = VoCAo FA = VCA = VoCA In liquid phase, since density is constant, we can simplify CA in term of conversion. CA = CAo (1 – X) 10

Substitute CA into rate of reaction, we get, -rj = k CAo (1 – X)

Substitute -rj = k CAo (1 – X) and FAo = VoCAo into the volume equation, we will get,

V 

C AoV oX kC Ao (1  X )

V 

V oX k (1  X )

Simplify, thus, we will get

Where, V = Volume reactor (L) Vo = Volumetric BHET flow rate (L/min) K = Rate constant (min-1) X = Conversion Taking

VL = 30.05 m3 For the Volume Liquid calculated it is just for volume in the reactor. Thus, assumed the volume in vapor in the reactor in 15% (or 15% allowance), the total actual volume of the reactor is

VT = V Liquid x (1.15) 11

VT = 34.5 m3

2.2)

Residence Time

The holding or space time in the reactor can be obtained by dividing the reactor volume by the volumetric flow rate entering the reactor. Total space time for all reactors,

 

Assuming constant volume for each reactor, Vtotal = 34.5 m3/min Therefore, The space time for each reactor = 25 minutes .

12

V Vo

2.3)

Energy Balance The method of heat load calculation is based (Silla, 2003) and is presented as follows.

Note: Standard conditions are referred to 25oC, 101.325kPa; 1 tonne = 1000kg n in

H in

n out

H out

(kmol/hr)

(kJ/hr)

(kmol/hr)

(kJ/hr)

TPA

0.1495

5.97E+03

0.1493

1.37E+03

EG

0.638

2.33E+04

6.0566

1.22E+04

BHET

372.9638

4.14E+07

0

1.27E+05

H20

82.9453

1.54E+06

0.6805

7.86E+02

17.626

2.17E+03

Component

PET (n=10) EG (vapor) H20 (vapor)

Hliq at BP (kJ/hr)

Hla at BP (kJ/hr)

H at

Hvapor

superheat

(kJ/hr)

(kJ/hr)

347.1325

4.57E+06 1.72E+07

1.90E+06

2.37E+07

82.2648

2.06E+05 3.35E+06

4.68E+05

4.02E+06

Table 2.5: Specifications from iCON for heat balance calculation Reactor Temperature = 270oC The equation for determining the enthalpy for each component is given by Enthalpy, ∆H = FCp ∆T Where; ∆T = Tout – Tin = temperature difference of stream temperatures with the reference temperature, at 25oC.

13

Sample calculation for enthalpy Feed in: Total Hin = 4.30E+07 kJ/hr

Feed out: To 2nd Polycondensation Reactor: Total Hout = 2.50E+05 kJ/hr

To Distillation Column: Total Hout = 2.77E+07 kJ/hr ΔĤo r = [(1 x -1.45E+05) + (372.66 x -389.58)] – (373.66 x -1115.22) = 126532 kJ/hr ΔĤo r = = 2.23E+09 kJ/hr (Endothermic Reaction) ΔH = ξΔĤo r + ∑noutΔĤout - ∑ninΔĤin = 2.23E+09 + (2.50E+05 + 2.77E+07) - 4.30E+07 = 2.22E+09 kJ/hr

14

2.4)

Reactor design temperature

The strength of metals decreases with increasing temperature so the maximum allowable design stress will depend on the material temperature. The design temperature at which the design stress is evaluated should be taken as the maximum working temperature of the material, with due allowance for any uncertainty involved in predicting vessel wall temperatures (Sinnort, Chemical Engineering Design, 1998). Since Austenitic stainless steel has been chosen for the fabrication of CSTR for which the design stress is evaluated at 300°C, thus the design temperature of the CSTR is 300°C. Operating Temperature = 270 °C. Design Temperature = 300°C. 2.5)

Reactor design pressure

A vessel must be designed to withstand the maximum pressure to which it is likely to be subjected in operation. Vessels subject to external pressure should be designed to resist the maximum differential pressure that is likely to occur in service. From Chemical Process Equipment by Stanley M. Walas, it is stated that for vacuum operation, design pressures are 15psig and full vacuum Operating Pressure = 15 kPa Design pressure = 4 kPa

15

CHAPTER 3 MECHANICAL DESIGN Dimensions of The Reactor The calculation of energy balance assists in finding the dimensions of the reactor. The following elaboration defines an initial estimate for the design of the reactor. Two methods of determining the basic dimensions for the design of the reactor are presented in this section. The first method will be used in the basic design of the reactor while the second method is utilized to assist in determining the dimensions for the jacket of reactor and to estimate the power requirement for the stirrer. Dimension for reactor vessel Volume of a CSTR, V=34.55 m3 Assume reactor is a cylindrical vessel,

Thus ; D = 3.09 m L = 4.635 Reactor outer diameter, Do Do = Di + 2e = 3.09 m + 2 (0.01) 16

= 3.11 m Reference: Chemical Process Engineering - Design and Economic (Silla, 2003) From Page 373, Table 7.3 - Standard Stirred Tank Reactor selection, Selected rated capacity = 10000 gal = 37.854 m3 Actual capacity (include headspace) = 10775 gal = 40.78m3 Jacket Area = 540 ft2 = 50.166 m2 Outside diameter, D = 3.09 m Straight Shell =135 in = 3.429 m Length (include headspace) = 5.919 m Jacket length = Jacket area / πD = 3.365 m Dimension for jacket of reactor From the Section 2.6.1, Total Heat for reactor, QR-3 = - 2.22E+09 kJ/hr From Page 376, Table 7.6 - Approximate Stirred Tank Reactor Overall Heat Transfer Coefficient, U, For Jacket/Agitated Liquid, Cooling water for aqueous solution, U = 110 Btu/h-oF-ft2 = 624.58 W/m2-K Inlet Jacket temperature, Tj1 = 30 oC Outlet Jacket temperature, Tj2 = 70 oC 17

Since Q in reactor is less than Q of jacket, then Jacket temperature, Tj = 45 oC Heat transfer to jacket, Q = UA∆T Q = 783 317.007Watt = 2 819 941 .23kJ/hr Cp water = 79.096 kJ/kmoloC To determine the mass flow rate of water to the jacket, use the heat transfer equation: Q = FCp ∆T F = 1426.085 kmol/hr Mass flow rate of water into jacket, m = 30053 kg/hr

18

Mixer Power Design P = pVR Where; P = approximate mixer power required VR = volume of reactor From Page 377, Table 7.7 - Approximate Mixer Power for Stirred Tank Reactors, For polymerization solution, p = 30 hp /1000 gal = 5910 W/m3 P = 203 895.00 W/m3 = 203.8951 kW/m3 From Page 229, Table 5.10 - Standard Electric- Motor Sizes (Silla, 2003) Standard electric motor selected for the design = 150 hp This is the next nearest standard electric motor size for the reactor.

19

Support of Reactor Vessel A reactor vessel is usually supported either in vertical or horizontal position, depending on the type of process requirement. For vertical vessels, the general supports normally used in industry are skirt support, bracket or lug support, leg support and ring support. For this reactor vessel support design, bracket support is selected as it is most commonly applied in industry. Among the advantages of using bracket as the vessel’s support are easily to construct and can be attached to the vessels with a minimum length of the weld stream. This support also can absorb diametrical expansions (provided they are equipped with a device for sliding) and are mobile. However, the disadvantages have to be accounted for; the eccentricity, the compressive, tensile and shear are induced in the vessel wall. Therefore, in the thin-walled vessel, this type of support requires reinforcement of the wall with backing plate. Figure 2.3 is the rough sketch of the arrangement for a bracket support.

Reactor Vessel Backing plate

Bracket support

Bracket support

Figure 2.1: Reactor vessel on bracket support

20

Pressure Drop Across Reactor There are bound to have pressure drops across any equipment with a pressure difference from the inlet and outlet stream of that equipment. The pressure drop across the reactor is calculated based on pressure drop equation in Coulson and Richardson’s Volume 6 book, given by

 L P  8 j f   de

 u2    2

Where; ∆P = pressure drop across the reactor jf = friction factor (obtain from Table 12.24 from Coulson & Richardson, Vol 6, 2004) de = equivalent diameter Specifications for the calculation of pressure drop For the specification of the calculation for pressure drop, some of the values are calculated in the design of reactors. Hence, the values calculated are utilized and listed in Table 2.8. Flowrate of into reactor, FAo

Density of inlet stream to reactor, ρ

Fao = 96 382kg/hr

ρ = 84.893 kg/m3

Diameter of channel into reactor, d

Fluid viscosity entering the reactor, μ

d = 0.04 m

μ = 0.0015868 Pa.s

Table 2.8: Inlet and outlet reactor properties Determination of Reynold’s number, Re To find the cross sectional area of inlet channel, A: 21

A = πd2/4 A = 0.0012m2 Re = 18129 (turbulent flow) Pressure drop calculation From Table 12.24, at Re = 18129, jf = 0.0041

 L  u2 Therefore, using P  8 j f     de  2 ∆P =2.2402 kPa The pressure drop across the reactor is 2.2402 kPa, which is lesser than 1 atm. From guidelines, pressure drop lesser than 1 atm is considered feasible in industry.

22

Materials of Construction In designing the process vessels, material constructions is to be specified first. Table 3.1 represents the material that has been selected for the key components of the reactor. The justifications on the selected material are presented here and are based on Coulson and Richardson Volume 6 and specification from British Standards. Equipment

Material Specification Stainless Steel type 316

Shell

(IS:1570-1961, 05 Cr 18, Ni 11, Mo 3) Stainless Steel type 316

Closure

(IS:1570-1961, 05 Cr 18, Ni 11, Mo 3)

Bolt

18-8 Cr-Ni Steel Stainless Steel type 316

Flange

(IS:1570-1961, 05 Cr 18, Ni 11, Mo 3,) Asbestos filled with corrugated metal jacket for S.Steel

Gasket

(Based on IS:2825-1969)

Brackets

Carbon Steel, IS : 2002-1962 Grade 2A Table 3.1: Material selection for Reactor

There are many factors to consider when selecting material of construction, but the overriding factor is usually the ability to resist corrosion, cost and mechanical strength. The factors that must be considered are: 

Nature of service conditions: Type of loading, service temperature, and specific nature of fluid handled.



Material characteristics: Strength and other mechanical properties such as elongation and reduction in area, notch toughness, hardness and resistance to wear, creep and fatigue strength, etc

23



Processing factors: Effects of fabrication techniques like forming, cutting, etc., heat treatment and weldability



Behavior in the medium: Resistance to corrosion or other damage in the environment; specific effects on material and identification of the specific material characteristic relevant to the failure contingency



Cost; Balance of cost considerations against service life and hazards of failure



Commercial availability

Briefly, the most economical material that satisfies the process and mechanical requirements are highly favored above all other criteria. This includes considering the cost of material over the entire life of the plant, since a more costly material would generally be more durable, thus require less maintenance and replacement. In terms of material costs, stainless steel lies in the mid of selected materials, as listed in Table 3.2.

Table 3.2: Listing of selected material costs Metal

Cost (UK Pound / tonne)

Carbon steel

300

Low allow steels (Cr-Mo)

400-700

Austenitic stainless steels 304

1600

321

1700

316

2400

310

3000

Nickel

3000

Monel

2600

Titanium

20000

Although it is sometimes possible to use a cheaper material with a higher corrosion rate, with frequent replacement, this is only limited to the following cases: 

Relatively simple equipment with low fabrication costs 24



Situations where premature failure will not a serious hazard The two constraints do not met the design criteria of the reactor and as such, carbon steel

and low allow steels cannot be considered as the material of construction vessel shell, heads and closure. However, as long as there is no contacting liquid present, material such as carbon steel can be used and is prioritized above other materials. For example, the design of bracket support favors the use of carbon steel to support the reactor, which saves a large fraction of the reactor fabrication cost. The selection of material for the shell construction, the closures, bolts and supports are less complicated to the less harsh operating conditions. However, it is important to specify the class of welding specification, the higher the class, the costly will be. According to the standard for the chemical process plant, the presence of toxic materials should implement a weld joint efficiency, J = 1.00 with the description of “Class I, Contain toxic or lethal material. Fully radiographed. Double welded butt joint fully penetrated”. EG is considered as a highly toxic substance that lies in this category. Hence, for all contacting surfaces with EG, the specified value of J mentioned should be placed on high importance in the design of process equipment. For less toxic and corrosive material such as cooling water used in the jacket side, specification that can be considered for use in the Class II, single welded butt joint with backing strip category is J = 0.80. For non-contacting surfaces, Class III can be employed in the design provided the safety aspects fulfill the design criteria. Over a long period, corrosion will tend to take place and thus reduce the vessel thickness. To ensure that during the life time of the vessels in spite of corrosion, additional thickness must be add on to the safety design value, as known as the corrosion allowance. From the standard, for the carbon and stainless steel in the environments where the low corrosion is expected, the corrosion allowance, c of 2.0 mm will add to design thickness. However, in the environment of high corrosion, the c = 4.0 mm will be added instead.

25

Shell and Jacket Design Pressure The design pressure (PD) is based on the maximum working pressure (MWP) with a 5% of safety factor. The reactor reacts totally in liquid phase; therefore, for a certain liquid level in the reactor vessel, hydrostatic pressure exerted by the liquid will contribute to the design pressure. Stringently, the hydrostatic pressure in the reactor cannot be neglected. Pressure design in the vessel Assume level of liquid in the reactor is 75% of the whole vessel, h = 0.75*(3.09) = 2.32 m = 5.40 m ρliquid = 84.893 kg/m3 and g = 9.81 m/s2 Hydrostatic pressure exerted by the liquid, Phydrostatic = h x ρliquid x g = 23.32 kPa Consider 5% noise in hydrostatic fluid due to agitation in the liquid Phydrostatic' = 22.154 kPa Internal/operating pressure, Pi1 = 60 kPa Consider 10% noise in supernatant fluid, Pi1' = 54 kPa Consider 10% overpressure for safety relief valve Pi1'' = 95.0 kPa MWP1 = 94.05 kPa

For cooling water jacket pressure design, Operating pressure, Pi2 =105.32 kPa Consider 5% noise in supernatant fluid. 26

Pi2' = 100.054 kPa Assume level of liquid in the jacket is 80% of the height of jacket, h = 0.8(3.09) = 5.562 m ρwater = 1000 kg/m3; g = 9.81 m/s2 Hydrostatic pressure exerted by cooling water, Phydrostatic = 54.788 kPa Consider 7% overshoot in cooling water level in the jacket Phydrostatic' = 50.22 kPa MWP2 = 118.703 kPa

Design Pressure for reactor vessel, PD1 = 1.05 (MWP1- MWP2) 118.703 kPa- 94.05 kPa (1.05) =25.89 kPa Design Pressure for cooling water jacket, PD2 = 1.05 (MWP2 - Patm) PD2 = 18.9 kPa

Shell and Jacket Design Temperature According to guideline, for the process with exothermic reaction, an additional of 10oC is added up to the maximum operating temperature for the body of the material to attain the course of operation. Thus, the material is selected with the design temperature as shown below; 27

TD  Tmax  10C For reactor shell

For reactor jacket

T operating = 270 oC

T operating = 50oC

Tmax

= 300 oC

T max

= 70 oC

T D1

= 300 oC

T D2

= 70 oC

Shell and Jacket Thickness, t The shell material used is Stainless Steel type 316(IS: 1570-1961, 05 Cr 18, Ni 11, Mo 3). The corresponding design stress, f at design temperature of 100oC is 142 000 kPa. With Class I of welding, the welding efficiency, J=1.00. A minimum corrosion allowance, c = 4 mm is specified as the shell material thickness of corrosion. PD1 = 25.89 kPa Shell internal diameter, Di = 2.00 m Shell thickness can be found from:

tS 

PD Di c 2 fJ  PD

t1 = 0.003823 m = 3.8 mm From Table 8 - Thickness of Standard Steel Sheets, choosing the next available plate thickness, t1 = 4.0 mm Validity check,

t ,  0.00200  0.1 , which is an acceptable value for the design of thin-walled vessel. Di

28

Shell and Jacket Closure Thickness, tC Determination of Shell Closure Thickness The ends of the reactor vessel have to be closed before putting into operation. For reactor design of Pi1 = 34.548 kPa and T operating = 270oC, Torispherical head (refer to Figure 3.1) is the type of head that is generally recommended and the for the vessel design to operate at pressure below 15 bar. The strength of this type of head is approximately equal to the strength of a seamless cylindrical shell having the corresponding inside and outside diameters.

ho tc

Sf Doc1

Figure 3.1: Torispherical head

The top closure material used is Stainless Steel type 316 (IS: 1570-1961, 05 Cr 18, Ni 11, Mo 3). The corresponding design stress, f at the design temperature of 100oC is 142000 kPa. A “Class I, Contain toxic or lethal material, Fully radiographed, Double welded butt joint fully penetrated” weld joint efficiency (welding factor, J= 1.00) is used. A corrosion allowance of 2 mm is specified as a standard. PD1 25.89 kPa Shell internal diameter, Di = 2.00 m The thickness of the head (tc) and the dished height (ho) are determined using the following equations while the flange thickness (Sf) is computed in the next section which gives the value S f = 0.068 m. 29

tc 

PRc C s c 2 fJ  PC s  0.2

 3   Cs  

Rc Rk

   

4

Do  Di  2t where Rc

= crown radius = internal diameter of shell

Rk

= knuckle radius

P

= design pressure

Cs

= stress concentration factor

t

= thickness of reactor shell

Di, Do = inner and outer diameter of vessel

The thickness of the head (tc) and the dished height (ho) are determined using the equations below. PD2 = 29.243 kPa Shell internal diameter, Di = 2.00 m

t

PDi c (2 fJ  0.2 P)

Doc  Di  2t c

30

ho 

Doc 4

Thus, tc2 = 0.001213 m = 1.213 mm From Table 8- Thickness of Standard Steel Sheets, choosing the next available plate thickness, tc2 = 1.213 mm Doc2 = 2.11 m hoc2 = 1.3323 m

Design of Ring Flange, Gasket and Bolts The main purpose of utilizing a flange is to connect removable closures and pipes to the vessel. As the internal pressure of the vessel is low, a Raised Face flange is chosen for this design since it is optimal for this type of operation. Asbestos filled with corrugated metal jacket for Stainless Steel is used as the gasket for the closure flanges to prevent leakage of the process fluid to the shell side of the reactor. Only one flange is required in the design, which is designed for the top closure as other closures are welded for permanent closure. The following information are used for designing the ring flange. 

Design pressure, PD1 = 25.89 kPa



Design pressure, T D1 = 300 oC



Bolting material = 18-8 Cu-Ni Steel



Gasket = Asbestos filled with corrugated metal jacket for Stainless Steel is; assume 16 mm thickness of the gasket 31



Gasket factor, m = 3.5



Min design seating stress, y = 45000 kPa



Min. actual gasket width = 0.01 m



Allowable stress of bolting material at bolt up conditions (Sg) = 109 MN/m2



Assume g1 = 1.145go = 0.005725 m

Gasket width computation

Min Design seating stress,y

45 MN/m2

Min Actual gasket width

10mm

Design Pressure

4kpa

Gasket Outer diameter

2.12 m

Gasket inside diameter

2.18 m

Gasket factor

3.5

Material og gasket

Asbestos, stainless steel

Gasket diameter ratio,

d o  y  Pd m   di  y  Pd ( m  1) 

0.5

Gasket width, Wo=0.03 Actual total width W, N = Wo x 2 = 0.06 m Corrected d0 = 2.18m + 0.03m 32

= 2.21m Outside diameter of gasket where gasket reaction acts, G=di + W0 = 2.18m + 0.02 = 2.2m

Bolt load estimation To estimate bolt loads, 

Under internal pressure, G = 2.2m



Allowable stress of bolting material, S0 = 144 MN/m2



Sg=212 MN/m2

W0= Force due to pressure + load to achieve minimum sealing = H+ Hp

= 0.0161 MN

33

Load to achieve gasket seating width = 0.18m Load to achieve minimum sealing = 0.002782 MN W0 = 0.002782 + 0.0161 MN = 0.01889MN Under bolting condition, Wg = πGby = 6.13 MN Since Wg > W0 choose the load that will be controlling Controlling load = Wg + 6.25 MN Minimum bolt area, A = 0.041 m2

34

A, dr, i

d, mm

mm

minimum, dr, m

Ar, m2

m2

n

6.36172E 1

M

12

1.5

9

0.009

-05

M

14

1.5

11

0.011

-05

0.0153

M

16

1.5

13

0.013

732

0.0153

M

18

2

14

0.014

938

0.0153

M

20

2

16

0.016

062

0.0153

M

22

2

18

0.018

469

0.0153

M

24

2

20

0.02

159

0.0153

M

27

2

23

0.023

475

0.0153

M

30

2

26

0.026

929

116

9072

2

0.075

5

0.075

0.02 100

9602

76

7

0.075

2525

0145

0.0153

253

64

35

1743

0.075

3

0.075

0.03 48

5

0.075

0.03 36

28.8 0.0153

0.03 0.03

36.8

0.000530 9

2697

0.075

0.02

48.7

0.000415 8

160

60.1

0.000314 7

9965

0.02

76.0

0.000254 6

Bs, m

0.02

99.3

0.000201 5

248

115.

0.000153 4

501 160.

0.000132 3

R, m

240.

9.50331E 2

nE

8

0.075

0.04 32

4

0.075

C1,m

C2,m

C,m

5.741

2.4514

5.74154

543

5

3

3.843

2.4554

3.84351

513

5

3

2.751

2.4614

2.75186

864

5

4

2.372

2.4654

2.37278

781

5

1

1.816

2.4714

66

5

1.435

2.4774

386

5

1.162

2.4814

663

5

0.879

2.4874

14

5

0.687

2.4994

966

5

2.47145

2.47745

2.48145

2.48745

2.49945

0.000660 10

M

33

2

29

0.029

519

23.1 0.0153

0.000706 11

M

36

3

30

0.03

858

M

39

3

33

0.033

298

0.0153

M

42

3

36

0.036

875

0.0153

M

45

3

39

0.039

59

0.0153

M

48

3

42

0.042

441

0.0153

M

52

3

46

0.046

901

0.0153

M

56

4

48

0.048

556

0.0153

M

60

4

52

0.052

715

0.0153

M

64

4

56

0.056

007

3131

16

0775

4341

6324

5113

0.0153

4357

0.05

0.08

2

0.086

5

0.091

0.05 12

7

0.096

0.06 12

1

0.102

0.06 8

5

0.11

0.06 8

7.20

0.002463 19

0.077

0.05

8.45

0.002123 18

16

9.20

0.001809 17

885

11.0

0.001661 16

7

0.05

12.8

0.001385 15

20

15.0

0.001194 14

4509 17.8

0.001017 13

24

21.6

0.000855 12

6359

0.04

9

0.118

0.07 8

5

0.126

6.21 0.0153

36

192

8

0.08

0.134

0.567

2.5054

737

5

0.551

2.5114

188

5

0.489

2.5154

692

5

0.435

2.5214

4

5

0.391

2.5254

376

5

0.358

2.5334

554

5

0.322

2.5414

351

5

0.317

2.5494

579

5

0.288

2.5614

946

5

0.264

2.5714

961

5

2.50545

2.51145

2.51545

2.52145

2.52545

2.53345

2.54145

2.54945

2.56145

2.57145

The chosen bolt diameter = 30 mm Number of bolt, n=88 Bolt spacing, B = 75mm Bolt circle diameter, C= 2306.3 mm Actual bolt area = 0.043 m2

37

REACTOR WEIGHT Pressure vessels are subjected to other loads in addition to pressure and must be design to withstand worst combination of loading without failure. It is not practical to give an explicit relationship relathip for the vessel thickness to resist combined loads. The main sources of load to consider are ; 1. Pressure 2. Dead weight of vessel and contents 3. Wind 4. Earthquake 5. External loads imposed by piping and attached equipment Weight of shell For steel cylindrical vessel with domed ends, and uniform wall thickness, the total weight of the shell is Reactor weight, WR = 7850t (RHR +0.5) Do2 Where : D0

= outer diameter

2.2m

RHR

= 1.5

1.5

t

Wall thickness

0.01m

WR = 7850(0.01) (1.5+0.5) (2.21)2 =

2401 kg

38

Weight of fluid in reactor Total weight of fluid in reactor comprises of the weight of fluid in the reactor and also weight of coolant in the jacket. Volume of fluid

34.5 m3

Density of cooling water

= 1.5

Wall thickness

=0.01m

Overall volume of shell = Overall volume of jacket = Overall volume of shell – volume of reactor

Volume of reactor = 34.5m3 – 30.05m3 = 4.44m3 Weight of cooling water = 4.44 x 1003 = 4453.32 kg Total weight of fluid in the reactor = 4453.32 kg + 16240 kg = 20 693.2 kg 39

Weight of Impeller Impeller diameter = 0.68 m Number of impeller=2 Impeller width = 0.11 m W1 = 7850 (0.2 + 0.09π) T1 Impeller Da2 =

7850 (0.2 + 0.09π) T1 Impeller Da2

= 182.29 kg Total weight of reactor = 182.29kg + 20 693.2 kg + 2401 kg = 23276.29 kg

Wind loading The stress due to wind load is generally determined by treating the vessel as uniformly loaded cantilever. The wind load is the function of wind velocity, air density, and shape of the vessel/tower and the arrangement of all such tall vessels. However, there is no need to employ this load into the loading analysis as the dimensions of the reactor are not critical for this analysis. It was decided that the wind loading analysis is discarded from the loading analysis. Combined Stress Analysis There are no eccentric loads on the reactor, nor earthquake loading or stress due to extreme temperature gradients. Thus the stresses considered are hoop stress, longitudinal stress and stress due to the weight of the vessel.

40

Pressure stresses The longitudinal σL and circumferential σh stresses due to pressure given by:

L 

PDi 4t

σL= 8240.07 kPa

h 

PDi 2t

σh = 16 480 kPa Dead weight stress

W 

Wv   ( Di  t )t

w = 3.141 kPa Bending stress There is no bending stress because the vessel is made in the proportion following the Golden Rule. For a dimension of 3.85m x 2.40m reactor vessel, wind loading is not critical; hence, it can be neglected in this case. Without wind loading, there would be no bending stress involved.

41

Pipe and Nozzle Estimation Five nozzles are design according to each stream specifications. All nozzles are constructed using stainless stel. Feed stream nozzle, liquid product outlet nozzle, vapor product outlet nozzle, cooling water inlet, and cooling water outlet.

Optimum duct diameter, d opt = 226 G 0.5 p -0.35 From iCON ,Flowrate of feed= 26.77 kg/s Density of feed = 3.69 kg/m3 = 0.74 m Nozzle thickness, Nozzle thickness, e = = 0.025 mm Cooling water outlet nozzle = 0.0013 mm As considered the corrosion allowance, the nozzle thickness available = 2mm

42

CHAPTER 4 SPECIFICATION SHEET AND DRAWING(S)

43

Reactor Data Sheet

Equipment No (Tag) Description

Pre-Polymerization

Sheet No

1/1

Operating Data Type Orientation

Continuous Stirred Tank Reactor Vertical SHELL

Jacketed

Organic Solvents

Cooling water

Diameter (Outer)

3.09m

1.53m

length

4.635 m

CONTENTS

3.365 m

Design Code Max Working Pressure

15kPa

15 kPa

Design Pressure

4kPa

4 kPa

Pressure Drop

-

2.2402 kPa

Max Working Temp

300 0C

30-70 0C

Design Temperature

2700C

45 0C

Mass flowrate

96 382 kg/hr

30053 kg/hr

Heat transfer cooficient

2.22E+09 kJ/hr

2 819 941 .23kJ/hr

Mechanical Design of vessel material

Stainless steel 304

Joint factor

0.9

Thickness

10 mm

44

Type of support

skirt

No of Bolts

88

Reactor Fluid Weightt

20 693.2 kg

Min Bolt Area

0.041 m2 Mechanical Design of Impeller Type

paddle

No of Agigator

2 0.68 m

Impeller diameter Impeller width

0.11 m

182.29 kg

Impeller weight

45

CHAPTER 5 REACTOR COST Fabrication and Costs of Reactor For bill of materials of the reactor, among the major costs that contribute to the expense of the reactor are the fabrication of the vessel body, head and jacket. This section presents the calculation for the fabrication of one reactor its relevant costs. Note that the workmanship costs are based on heuristics, updated as of August 2008. Values may vary with time. A. For vessel shell Diameter

3.09 m

Length

4.635

Thickness

0.005 m

circumference

9.707 m

Cross Sectional Area

44.90 m2

Density of Steel

7840 kg/m3

Mass of steel

1760.08 kg

46

As of July 2008, from MEPS (INTERNATIONAL) LTD, the cost of stainless steel (type 316), hot rolled coil = USD 6063 /tonne = RM 20.99/kg Material cost + Rolling cost (RM) = Cost of S.Steel x Mass of steel = RM 35 200 Cost of jacketed reactor Volume of reactor, m3

34.45 m3

Design pressure,kPa

4

Design temperature,0C

300

Material of construction

Stainless stell

Capital cost for material construction

2.4

Capital cost for design pressure

2.0

Capital cost for design temperature

1.6

Total capital cost

3.4

(2.4 x 2.0 x1.6 )= (11500) (14.20)^0.45 (3.4) $ 129 034.70 = RM 387 102.00 Total Cost RM 387 102 + RM 35 200 = RM 422 302

47

CHAPTER 6 OPERATING MANUAL PROCEDURES Start-up Procedure Start-up and commissioning are performed to check the operability of the equipment and to define the reactor’s performance. It is advisable to review the start-up procedure with licensor to ensure that the desired results are achieved. The start-up time required is very specific and will vary depending on numerous factors such as unit design and age, reactor operating conditions etc. However, a quick start up procedure is required to allow smooth downstream operation and separation processes. This is because the downstream separators will perform the first separation of the major product through the concept of settling. Thus, the initial start up procedure has to be performed as quickly as possible while meeting safety and law requirements. General start-up procedure specifically on the reactor (R-3) is listed as follow: 1.

Check inventory of each unit operation to ensure smooth start-up and operation of reactors.

2.

Start up and commission all unit operations except for the reactors.

3.

Confirm that all reactors are ready for start up. Firstly, go through reactor start up checklist.

4.

Swing blinds to de-isolate reactor from process stream.

5.

Perform hydrostatic test on reactor in order to detect leakage at the reactor vessel and jacket.

6.

Line up all transmitters, temperature, pressure, and level indicators and stroke all control valves.

7.

Increase the reactor pressure and perform leakage check on all flanges.

8.

Increase the pressure to twice as much in the reactor to twice the normal operating pressure of reactor and check for leakages.

9.

Line up the feed mixture to the reactor from E-2.

10.

Introduce feed mixture to the reactor.

48

11.

Start the stirrer to circulate the fluid through reactor shell side to obtain a constant reactor temperature at 270oC.

12.

Gradually increase the feed mixture into reactor.

13.

Adjust feed mixture flow rate to ensure maximum yield of PET(L) is achieved.

Basic checklist for reactor start-up: 

Plant area is clean; remove all hazardous materials from the area.



Safety equipment is always in position.



Emergency shutdown procedures are always in place to bring the reaction under control during contingency.



Reactor in proper start up conditions, i.e. gaskets have been replaced, seals in place, blinds removed, flanges connected etc.



Inventory line up to reactor in a proper order.

Shut Down Procedure Temporary shutdown Recommended procedure: Cut feed supply and purge the system with hydrogen (or highpurity nitrogen) for 1 h. Then close inlet and outlet valves of the reactor and maintain the temperature and pressure. Long-term shutdown For long-term shutdown without disassembly of the reactor, stop feed supply and purge the system with hydrogen or high-purity nitrogen for 1h. Close the inlet and outlet valves while maintaining at positive pressure and cool down the reactor naturally. For shutdown with disassembly for maintenance, purge and maintain at positive pressure with nitrogen and cool down to 35oC before disassembly. A proper procedure to prevent equipment damage and any unpleasant incidents that may cause injury or death is presented, as follows. 49

General shut down procedure for the reactor R-3: 1.

Reduce the production rate of PET steadily to avoid dramatically pressure drop across the reactor, while maintain the same ratio between the feed component and the product.

2.

When production rate is low enough (10%), shut down the last unit operation, the product purification column first and then shut down the byproduct purification column.

3.

Shut down the feed mixture to the reactor and confirm that the isolation valves and control valves are in position.

4.

Begin purging the reactor with compatible solvent to retard the reaction within the reactor.

5.

Continue with solvent purging to remove the feed and product from the reactor.

6.

Stop control valve on inlet to R-3 to stop the flow of fluid to the reactor once the reactor temperature drops to 35oC.

7.

Once the feed concentration in the reactor is less than 0.5%, stop the solvent purging and proceed to purge the reactor with nitrogen for cooling purposes. Nitrogen also forms a pressurized blanket that prevents air from entering the reactor, which will result in condensation of moisture in air as the reactor cools

8.

Once the reactor is brought to ambient temperature, continue nitrogen purge for a while and then quickly swing the blinds to isolate the reactor to prevent the entering of air after the reactor as been depressurized.

9.

Check the purge lines and vent lines to prevent air from entering after the reactor depressurization.

10.

Go through checklist for reactor shut down procedure before handing over the reactor to the maintenance department for inspection and maintenance tasks on the reactor if necessary.

50

Safety Precaution and Pollution Control

The safety and pollution control for the reactor has been discussed in the chapter on safety and loss prevention. Here, several additional points are discussed.

1.

An emergency block valve (EBV) should be placed on the feed stream and PET(L) product line. Thus, in the event of a contingency such a fire, the alarm trip will trigger and the EBVs will be shut, thus disallowing contact of these components with the surrounding. This effectively removes the fuel components from the fire triangle.

2.

The reactor temperature has to be monitored continuously to detect early indication of a runaway reaction. Provisions should be made to immediately halt normal operations of the reactor and to begin purging using compatible solvent in the event of a runaway reaction. If the temperature in the reactor exceeds the maximum permissible limit, the production of PET will either come to a halt, or the process slowed down.

3.

Controlling the reactor pressure is critical not only for optimum conversion, but also for safety reasons. The reactor pressure is controlled by regulating the reactor effluent flow rate. However, in the event of rapid pressure buildup, pressure safety relief valves (PSV) are installed to relief the overpressure in the reactor. The safety valves will be designed for either the contingency of fire or for blocked outlet, whichever requires a higher rating for the PSV. In the event of a PSV malfunctions, the pressure will be vented out manually through the PSV outlet to remove the excess pressure buildup within the reactor.

4.

Sufficient ventilation is provided to protect the operators against the high corrosive and hazardous chemicals entering and leaving the reactors. Also, all local instruments and indicators will be positioned in a safe location and preferably at ground level to allow safe and easy access to the operators and process engineers.

51

Handling and Maintenance 1.

The feed and the product of the reactor are hazardous and corrosive components. The material of construction of the reactor requires good protection against corrosion.

2.

The process fluids are very toxic to human health. Thus, the entire reaction system is designed as a closed system. Digital analyzers are specified for the indicators on the reactor to prevent excessive exposure to the operator of the process fluid especially during sampling processes. Where possible, online composition analyzers are specified.

3.

Proper personnel protective equipment (PPE) will be provided to operators and other personnel who will come into contact with the process fluid. Proper instructions and signage will also be put up to ensure complete compliance with government regulations on the use of PPE.

4.

EG is flammable substance, hence for safety precaution; ensure that the system is allocated far away from the heat source.

5.

Handling of the all chemicals can be performed only with the use of proper PPE. The instructions on handling and emergency procedures due to exposure to the chemicals can be obtained from the material and safety data sheet (MSDS) from the suppliers and subsequently imparted upon the operators and other personnel that are likely to be exposed to these chemicals.

52

MNOR EQUIPMENT PUMP

53

Introduction For any utility plant, pumps are important. They are used to convey fluid from one place to another by mechanical means. They can be classified into two main groups, namely, centrifugal and positive displacement pumps. Principle of Operation Centrifugal Pump Centrifugal pumps make use of centrifugal force to work. The liquid to be pumped is usually water. The construction of the housing is such that water is piped in at the centre of the impeller. The impeller is then rotated at a high speed so that the water is thrown outwards with high velocity. The housing of the impeller is usually constructed in the shape of a volute such that the volume is gradually expanded until the placed the water is led out as the discharge. The gradual expansion of the volume has the effect of converting the velocity of the water into pressure. Some centrifugal pumps make use of diffuser fins at the housing to achieve the same change of state. Positive Displacement Pump Positive displacement pumps make use of a mechanical object to displace the liquid. The liquid to be pumped can be water, oil, or other thick liquid. The mechanical object can move in a reciprocating manner or a rotary manner. Examples of the mechanical object are: pistons, gears, screws, lobe, vanes. The liquid is literally pushed aside by the object. Some pumps need to have inlet and outlet non-return valves fitted to work. Examples of this are piston pumps. Others like gears, screws, lobe, and vanes rotating at high speed need not employ valves to work. One characteristic of these pumps is the fact that the pressure can build up in time if it is not released. Usually a pressure relief valve is fitted at the discharge side of the pump to prevent over pressure.

Pumps are usually used to move liquid from a low pressure to a higher pressure. Pump is used to increase the pressure of the liquid (Ethylene Glycol and Terephthalic Acid) before it enters the last reactor. Centrifugal pump is chosen for this application because it simple to operate. The cost is also quite low compared to the other type of pump. Centrifugal pump also requires small floor place and it operates quietly. Centrifugal pump is also known due to its adaptability to be used with a motor or a turbine. 54

Pump Calculations

All the detail needed for the pump calculation was gathered from the simulation iCON and represented in the table below;

Parameter

In

Out

Mass Flow (kg/hr)

109 775.70

109 775.70

Volume Flow (m3/hr)

76.364

76.367

Viscosity

0.314

0.314

Temperature

30.827

30.174

Pressure

101.325

360.0

Density

1126.91

1126.9

Efficiency

95%

PARAMETER OF PIPING (ASSUMPTION) Length (m)

10

Diameter (m)

0.1 55

Head calculation

H

P γ

where H = head (m)

 P = differential pressure (Pa) between the suction and discharge line γ = specific weight of liquid (kg/m2s2), given by density × gravity

134360 Pa 1126.91 kg m 3  9.81 m s 2  12.15 m

H

Theoretical Hydraulic power, W The theoretical hydraulic power, W, gained by the fluid is given by the equation: ead Calculation, H

Thus ;

= 11 054.99 kg / m2.s2 e Head Pressure ; 56

H = 23.4m

Theoretical Hydraulic Power, W

W = 0.163 (Specific Gravity) x (pump capacity) x Head Pressure

W = 0.887 KW

Net Positive Suction Head

The pressure at the inlet to a pump must be high enough to prevent cavitation occurring in the pump. Cavitation is a phenomena when bubbles of vapor, or gas, form in the pump casing. Vapour bubbles will form if the pressure falls below the vapor pressure of the liquid. The net positive suction head available (NPSHavail) is the pressure at the pump suction, above the vapor pressure of the liquid, expressed as head of liquid. The net positive suction head required (NPSHreqd) is a function of the design parameters of the pump and will be specified by the pump manufacturer. The net positive head available is given by the following equation:

NPSH avail 

P



H 

Pf





57

Pv



where NPSHavail = net positive suction head available at the pump suction, m P = the pressure above the liquid in the feed vessel, N/m2 H = the height of liquid above the pump suction,m = 25m Pf = the pressure loss in the suction piping, N/m2 Pv = the vapor pressure of the liquid at the pump suction, N/m2

 = the density of the liquid at the pump suction temperature, kg/m3

Pump efficiency The shaft power must be greater than hydraulic power = 0.15 kw

S = 0.094 KW Brake Horse Power:

Velocity

58

= 2.675 m/s Reynolds number,

= 1289

= 1.26 x 1011 = 3.35 x NPSH available

NPSH avail  26.303m

59

PUMP DATA SHEET Equipment No Centrifugal Pump data sheet

Function

Feed Pump

Sheet No

1 of 2

Operating Data NUMBER OF MACHINES (unit)

Installed

TYPE

Single stage, pedestal mounted with single suction overhung impeller

LIQUID

Mixture of Glycerol and FAME

AVAILABLE NPSH (m)

26.303

CAPACITY (m3/h)

Max

76.364

Min

76.364

Normal

76.364

PRESSURE (kPa)

Suction

101.325

Discharge

360.00

Differential

258.68

ELECTRICAL SUPPLY

Volts

Phase

Single

Cycles(Hz)

VISCOSITY (cP) SG

1

Working

1

WORKING TEMP. (oC)

0.104234 1.3872

Standby

-

123

pH

VAPOR PRESSURE (kPa) Technical Data PUMP DRAWING NO

TYPE OF DRIVE

SPEED (rpm)

ABSORBED POWER REQD 60

Turbine

INSTALLED KW OF DRIVER

SAFE MINIMUM FLOW PUMP EFFICIENCY

70 %

SPEED OF DRIVER

PERFORMANVE CURVE

SPEED RATIO

DIRECTION OF ROTATION

POWER FACTOR

TYPE OF GLAND OR SEAL

MOTOR EFFICIENCY

BALANCE ARRANGEMENT

DETAIL OF LUBRICATOR

COOLING WATER REQD

TYPE OF BASEPLATE

DETAILED OF CONNECTIONS

SUPPLIER OF DRIVER

SUCTION

Single

COUPLING

SUCTION STAGE

Single

TYPE OF COUPLING

TYPE OF COUPLING GUARD

DRIVER HALF COUPLING FITTED BY

TYPE OF THRUST BEARING

FOUNDATION BOLT SUPPLIER

TYPE OF JOURNAL BEARING

MOTOR DESIGN CODE

TYPE OF GEAR AND MAKER

MOTOR TEMP CLASS

FULL LOAD TORQUE

MOTOR PROTECTION TYPE

STARTING TORQUE

IMPELLER TYPE

61

CASING TYPE

IMPELLER SIZE

MNOR EQUIPMENT COMPRESSOR

62

Compressor is used to compress gases from one point to another point. Each compressor is generally a function of the gas capacity, action and discharge head. There are three type of compressor widely used in industries namely; 

Centrifugal compressor



Reciprocating compressor



•Axial flow compressor

 Centrifugal and axial-flow units are continuous flow compressors. Centrifugal compressors are generally used for higher pressure ratios and lower flow rates. On the other hand, axial-flow compressors are used for lower-stage pressure ratios and higher flow rates. Axial-flow compressors are mainly used as compressors for turbines. The pressure ratio in a single-stage centrifugal compressor is about 1.2:1, while axial is 1.05:1and 1.15:1. Reciprocating compressors are generally used when a high-pressure head is requested at 63

a low flow rate. However, because of difficulty in preventing gas leakage and lubricating oil contamination, reciprocating compressors are seldom used forcompression of gases requiring high purity.

64

Shaft work,WS= Ws = ( 658.02) (1.087/(1.087-1)(8.314)[ (101.3/15)^ ( 1.087-1/1.087) -1 = 318.142 kW For Actual Work n=0.7 Ws= 482.11 hp

65

References:

1. Douglas J.M., 1988, “Conceptual Design of Chemical Processes”, McGraw-Hill International Editions, Chemical Engineering Series 2. Geankoplis Christie J., 2003, “Transport Process and Unit Operations”, Fourth Edition, New Jersey, Prentice Hall International, Inc. 3. Max S. Peters, Klaus D. Timmerhaus and Ronald E. West, 2004 “Plant Design And Economics for Chemical Engineers”,Fifth Edition, Mc-Graw Hill 4. Sinnott R.K, 1999, “Coulson’s & Richardson: Chemical Engineering”, Volume 6, Third Edition, Butterworth-Heinemann 5. Smith R., 2005, “Chemical Process: Design and Integration”, England, John Wiley & Sons. 6. http://www.bloomberg.com/markets/currencies/asiapac_currencies.html

66

67

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pleasant daily practice of responsible, purposeful decisions for developing ..... has sat out a minimum of one full semester. He may not return ..... Lunches, homework, books and other items may be left in the school ..... Updated: August 2018. 49.

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Hate coding your emails for Outlook? Too bad! Outlook ... Outlook 2007-13 do not support the margin or padding CSS properties when placed within an image.

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113.1 Discipline Of Students With Disabilities. 113.2 Behavior Support. 113.3 Screening And Evaluations For Students With Disabilities. 114 Gifted Education.

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Insert Information Protection Policy Classification from Slide 12. 23. Replication Monitoring. ▫ Auto-discovers replication topology. ▫ Master/Slave performance monitoring. ▫ Replication advisor. ▫ Best practice replication advice. "I use the

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Does Orika automatically map fields with the same property name? ..... In this example our converter was anonymous, and Orika use the converter's canConvert .... For example, suppose you have the following domain (getters/setters omitted):.

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numerous notes providing additional information on the use of each material. 2. A tabulation of ...... API RP-520. 2.4.1. Determining Reaction Forces In An Open-Discharge System. The following formula is based on a condition of critical steady-state

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GPS. Global Positioning System. GSM. Global Standard for Mobile ..... Two major tracking techniques are used for positioning: Kalman Filter (KF) and ...... [Wan00] E.A. Wan, R. Van Der Merwe, “The unscented Kalman filter for nonlinear.

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Oct 26, 2007 - In a study of 52 Japanese patients with chronic urticaria without other ..... chronic urticaria patients, more than 50% responded to an elimination diet (48). • Another large series showed improvement in only about one third of patie

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the actors in the problematic system to make theory a reality. .... example, associating Osama bin Laden's terrorist organization with Islam has proven to ...... 1992, Ramzi Yousef traveled from Peshawar to New York under a false name and Ali.

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APPENDIX E. Diagram of Room Worksheet for Radon Measurements .... or batteries to operate, such as charcoal detectors or alpha track detectors. "Perimeter ..... A description of all measurement devices the applicant or licensee plans to use ...